Numerical simulation and experimental verification of interrupted quenching (IRQ) for heavy-haul railway wheels
YAO Sancheng1,2, ZHANG Jian1,2, LIU Xuehua1,2, ZHAO Hai1,2, SHI Na1,2, XU Jun3
1. Key Parts of Rail Transit Technology Innovation Center of Anhui Province, Maanshan 243003, Anhui, China; 2. Technology Center, Maanshan Iron and Steel Co., Ltd., Maanshan 243003, Anhui, China; 3. School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Abstract：The non-pearlite mixed microstructure layer containing martensite (M) and bainite (B),which is generated during the heat treatment cooling process of railway wheels,is a potential source of driving faults and hazards. For heavy-haul railway wheels with prominent non-pearlite layer,the finite element numerical model of interrupted quenching (IRQ) was established based on software MSC. Marc and Thermal Prophet,and the influence of IRQ process on temperature field,microstructure and mechanical properties of the wheel was analyzed,and the physical verification was carried out. The simulation results show that during the short quenching interruption period,due to the influence of heat conduction inside the deeper rim,a small temperature platform or temperature return phenomenon occurs near the surface of the wheel tread. The return temperature is lower than the critical point Ac1,which can avoid secondary austenitization,but the tread sub-surface and inside of the rim are slightly affected. IRQ process slow down the temperature drop near the tread surface,and avoid most of the M and B transformation areas. The non-pearlitic layer is inhibited,and its thickness is controlled within 6 mm,so the microstructure near the tread is significantly improved. The interior of the rim has a relatively uniform microstructure with fine pearlite and a small amount of ferrite (P-F),but within a depth range of 10-15 mm from the tread surface,the composition of the microstructure may fluctuate locally,and a small amount of B microstructure may be regenerated in the P-F microstructure. The gradient of strength and hardness distribution from the tread surface of the wheel is reasonable and gradually decreased,and the strength and hardness level of most areas inside the rim is not significantly affected. Due to the pre-cooling effect,the IRQ process improves the average effective cooling rate within the depth range of 15-30 mm from the tread surface,forming a local maximum area of strength and hardness,slightly improving the strength and hardness compared with the traditional process wheel. The physical verification results are basically consistent with the simulation results. After comprehensive evaluation,it is basically feasible to apply IRQ process to control the non-pearlitic microstructure layer of heavy-haul railway wheels.
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