The effect of third bodies on wear and friction at the wheel-rail interface

The friction forces between the wheel and rail depend on a number of variables including the third body layer at the wheel–rail interface, the wheel and rail profiles, and the train dynamics. The third body layer significantly influences the damage mechanisms at the wheel-rail interface, especially wear, rolling contact fatigue (RCF), corrugations and other surface defects that then require maintenance. The introduction of additional constituents at the wheel–rail interface in the form of an additive with anti-wear and anti-crack properties can reduce the wear and RCF. In general, such an additive also reduces the friction. However, it is important to avoid the friction coefficient between the wheel tread and the top of the rail falling below 0.3 because the result would be wheel slip and long braking distances. Measuring friction coefficients accurately is still a challenge, as most existing tribometers are unable to replicate the wheel-rail contact conditions, specifically the contact pressure and sliding speed. The present study used a newly designed handheld tribometer that is able to match the typical contact pressure. Results obtained with the handheld tribometer have been compared with values extracted from the traction-force measurement system of a locomotive. The tribometer field measurements have shown that by using a top-of-rail friction modifier (TOR-FM), both the wear and the friction coefficients can be reduced, but also that heavy TOR-FM films may cause unacceptably low friction. Comparing the results of field and laboratory tests confirms that weather and realistic third bodies present on the track have a significant effect on friction and wear.