ER9车轮材料激光熔覆层微观组织及性能研究 
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Wheels and rails of high-speed trains are prone to severe damage, fatigue, and fracture damage on the wheel surface owing to wear, corrosion, strength reduction, fatigue cracking, and other reasons, thus affecting the stability and safety of train operation. The commonly used repair process to eliminate wheel surface defects causes material wastage and economic losses. To improve the service life of a wheel, laser cladding technology is used to prepare a cladding layer on the surface of a wheel and rail to enhance their damage resistance. Therefore, in this study, Fe-, Ni-, and Co-based alloy coatings, widely used in the field of laser cladding, are prepared on the surface of the ER9 wheel material using laser cladding technology. The mechanical properties, damage mechanism, and corrosion behavior of the substrates and coatings are investigated.
The base material of the laser cladding experiment was taken from the ER9 wheel steel tread, and three types of self-fluxing alloy powders—Fe-, Ni-, and Co-based—were used as cladding materials. Laser cladding technology was used to prepare the powder coating with thickness of 15 mm on sample surface by coaxial powder feeding. All samples was cut using the wire-cutting method. First, after the prepared metallographic samples were corroded, a SU8010 scanning electron microscope (SEM) and X-ray diffractometer (XRD) were used to study the microstructure and phase of the cladding layer. The microhardness of the samples was measured with a Vickers hardness tester (Qness-Q60). The prepared tensile and impact specimens were then tested for mechanical properties using an MTS universal testing machine and a Charpy pendulum impact testing machine, respectively. Furthermore, the fracture morphologies of the tensile and impact specimens were observed by SEM. Next, the prepared friction and wear samples were characterized by an MFT-EC4000 tester, and the wear surface, wear debris morphology, and element content of the samples were characterized and analyzed using SEM and its accompanying EDS. An electronic balance scale with an accuracy of 0.1 mg was used to measure the average wear. Finally, potentiodynamic polarization curves (Tafel) and electrochemical impedance spectroscopy (EIS) of the samples were obtained using an electrochemical workstation in a 3.5% NaCl solution at room temperature.
As shown in Fig. 2, the coating surface is uniform and dense, without noticeable cracks, pores, and other defects. Furthermore, the microstructure is mainly composed of dendrites and eutectic structures. XRD spectrum analysis (Fig. 3) shows that the Fe-based coating is mainly composed of α-Fe, (Fe, Ni), Cr7C3, and other solid solutions. The Ni-based coating is mainly composed of solid solution γ-Ni, intermetallic compound FeNi3 and hard Cr23C6 phase. The crystal phases of the Co-based coating are mainly the FeNi3, γ-Co, and Cr23C6 phases. The investigation of mechanical properties indicates that the surface hardness after laser cladding treatment improves significantly (Fig. 4), and the Fe- and Ni-based alloy coatings have the highest microhardness (approximately 716.5 HV). The average hardness of the Ni-based alloy coating and Co-based alloy coating is approximately 384.2 HV and 456.1 HV, which are an increment 45.6% and 72.8%, respectively. The hardness of the coating structure is enhanced to achieve a strengthening effect. Figures 5 and 6 show that the elongation of the Fe-based tensile specimen is the lowest (1.34%), and the tensile fracture has cleavage steps. The tensile strength of the Co-based alloy coating is the highest (approximately 976.41 MPa), and the tensile fracture exhibits a river pattern feature. The tensile strength of the Ni-based alloy coating tensile specimen (approximately 813.95 MPa) decreases compared with the substrate, but the elongation reaches 34.5%, and the tensile fracture exhibits a dimple-like morphology. Figure 7 shows that the impact fractures of Fe- and Co-based coatings are brittle, while the Ni-based coating exhibits good ductility and an impact toughness considerably higher than that of the former two. In terms of friction and wear research (Figs. 9 and 11), the wear amount and wear rate of the coatings are significantly reduced, while those of the Co-based alloy coating are the lowest [4 mg and 0.4×10-4 g/(N·m), respectively], which is 78.9% lower than that of the base material. Only furrows appeared on the wear surface. The wear mechanism is mainly abrasive wear. The wear rate of the Fe-based alloy coating was reduced by approximately 52.6% compared with the substrate, and the wear surface is slightly damaged. The wear mechanism is characterized by abrasive and adhesive wear. The Ni-based alloy coating has a rough grinding surface and a large amount of wear debris accumulation because of the coupling effect of abrasive and adhesive wear. In the electrochemical corrosion study, the Nyquist curves of the substrate and cladding layer in a 3.5% NaCl solution showed capacitive arc characteristics (Fig. 12). The maximum impedance of the cladding layer is two orders of magnitude higher than that of the substrate. According to the test parameters of the polarization curve (Table 4), the self-corrosion potentials of the Fe-, Ni-, and Co-based coatings are -0.475, -0.415, and -0.408 V, respectively, and the self-corrosion densities are 2.980, 0.249, and 0.172 μA/cm2, respectively.
The microstructure of the laser cladding coating on the surface of the wheel material is mainly composed of dendritic and eutectic structures. The hardness of the coating is significantly improved. The Ni-based alloy coating has good tensile strength and impact toughness, and the fracture is characterized by toughness, whereas the Co- and Fe-based alloy coatings have a brittle fracture; however, the difference is marginal. Compared with the matrix, the cladding coatings have a lower friction factor, wear rate, and better corrosion resistance, and the Co-based alloy coating has higher hardness (the microhardness was increased by 72.8%). The wear resistance of the Co-based alloy coating is the best (the friction factor is 0.31, the wear amount is approximately 4 mg, and the wear scar depth is 10.70 μm). The corrosion resistance of the Co-based alloy coating is the best (the impedance value is two orders of magnitude higher than that of the substrate). A comparative analysis of the three coatings shows that the Ni-based coating has a rough surface, high wear rate, poor wear reduction effect, and weak hardness and strength. The wear and corrosion resistance of the Co-based coating is higher than that of the Fe-based coating, but the latter has lower engineering costs and also provides overall wheel protection.
1 引言
随着我国列车速度的提高以及轴重、运量的增大，轮轨间运行环境变得更加复杂，车轮表面常常会因磨损、腐蚀、强度下降以及疲劳开裂等出现严重损伤、疲劳和断裂破坏等，极大地影响了行车的安全性和旅客的舒适度［1］。为了消除车轮表面缺陷，目前常用镟修工艺进行修型，这将造成材料浪费与经济损失。据统计，我国每年投入多达80亿元用于轮轨的维护与更新［2］。为了提高车轮的服役寿命，亟须开展提高车轮表面强度和耐蚀性、耐磨性的研究。
目前，主要的金属表面处理技术有超声冲击［3］、激光冲击［4］、激光淬火［5］、层流等离子淬火［6］、激光熔覆［7］等。与其他表面强化技术相比，激光熔覆技术制备的涂层可与基材形成良好的冶金结合，而且涂层厚度和稀释率可控，涂层组织均匀细小。选择不同的材料进行激光熔覆可以实现高强度以及耐磨、耐蚀等性能优良的涂层。目前，已有很多学者通过在轮轨表面制备激光熔覆层来提高其抗损伤能力，并在此方面进行了大量研究［8-9］。慕鑫鹏等［10-11］在车轮钢基材上激光熔覆了铁基和钴基合金涂层，对滚试验后发现两种涂层均呈现出了良好的耐磨效果，磨损率相较于基材降低了80%以上。丁阳喜等［12-13］在轮轨表面熔覆了铁基涂层和铁、钴复合基涂层，这两种涂层表现出了比车轮钢基体材料更加优异的摩擦磨损性能和滚动接触疲劳性能。Guo等［14］在CL60车轮钢表面熔覆了钴基合金涂层并通过滚动试验机来测试其耐磨性，结果发现强化后的表面磨损率相比车轮钢基体下降了42.2%~69.4%。这一结果表明激光熔覆技术可用于车轮损伤修复，有效提高了车轮材料的耐磨性。Ding等［15］通过滚动摩擦磨损试验考察了铁基合金涂层的性能，结果显示，该涂层对降低熔覆层的摩擦因数具有积极作用。Wang等［16］在轮轨材料表面熔覆了铁基合金涂层，该涂层提高了轮轨材料的耐磨性及耐滚动接触疲劳性能。Ringsberg等［17］采用数值分析方法和相关试验研究了Co-Cr合金熔覆层的耐磨性，结果显示，涂层表面不易产生棘轮效应而且能够避免出现滚动接触疲劳损伤。Lewis等［18］采用激光熔覆技术在钢轨材料表面制备了高性能马氏体不锈钢涂层（MSS），测试后发现激光熔覆处理的钢轨试样的疲劳性能显著提高，同时车轮材料的磨损也得以减轻。Zhu等［19］通过滚动接触试验研究了受损车轮表面不锈钢涂层的疲劳性能和耐磨性，结果显示，不锈钢涂层表现出了比车轮基体材料更优异的疲劳强度和耐磨性。这一结果说明激光熔覆技术可用于损伤车轮的强化。分析后可以发现，以上研究主要集中于车轮表面激光熔覆层的滚动接触疲劳性能，而针对熔覆后车轮钢力学性能、耐磨性及耐蚀性能的研究较为欠缺。
自熔性合金粉末具有良好的自脱氧造渣功能［20］以及制备简单、成形性能优异等特征，鉴于此，本团队采用激光熔覆技术在ER9车轮材料表面分别制备出激光熔覆领域应用广泛的铁基合金熔覆层、镍基合金熔覆层和钴基合金熔覆层，并对熔覆层的显微组织、力学性能、耐磨性以及耐蚀性等展开研究，以揭示基体和熔覆层的力学性能、损伤机制和腐蚀行为。本研究成果可为激光熔覆技术在轨道车轮表面强化领域的应用提供重要的理论支持。
2 试验
2.1 材料
激光熔覆试验的基体材料取自列车车轮（ER9车轮钢）踏面，其化学成分如
表 1. ER9的化学成分
Table 1. Chemical composition of ER9
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表 2. 粉末材料的化学成分
Table 2. Chemical composition of powder materials
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2.2 熔覆工艺及制样
采用LaserlineLDF6000-100激光柔性增材制造系统在试样表面以同轴送粉方式制备厚度约为15 mm的熔覆层。设计并优化的激光工艺参数如下：激光功率1.6 kW，扫描速度7.5 mm/s，光斑直径4 mm，搭接率50%。整个熔覆过程在氩气（纯度大于99.9%）保护下按纵向“弓”形路径进行。最后，利用线切割方法取样，熔覆过程示意图、取样方式及试样尺寸如
图 1. 试样熔覆过程、取样方式及试样尺寸示意图
Fig. 1. Schematic of sample cladding process, sampling and sample size
2.3 测试与分析
沿垂直于扫描速度方向的熔覆层横截面切割出尺寸为10 mm×8 mm×10 mm的样品，制备金相试样，对金相试样进行打磨、抛光后用王水（HCl与HNO3按体积比为3∶1混合配制而成）进行腐蚀，采用SU8010扫描电子显微镜（SEM）对试样的微观组织进行观察。采用X射线衍射（XRD）技术对熔覆层进行物相分析。利用维氏硬度仪（Qness-Q60）测量试样的显微硬度。
采用MTS万能试验机，根据GB/T 228.1—2010《金属材料 拉伸试验 第1部分：室温试验方法》的要求进行拉伸测试；冲击试验参考GB/T 229—2007《金属材料 夏比摆锤冲击试验方法》制备标准U形缺口夏比摆锤冲击试样，拉伸与冲击试验的取样部位以及试样规格如
摩擦磨损试样的尺寸为20 mm×15 mm×10 mm。对激光熔覆样品表面进行磨削、抛光，使熔覆层表面平整，表面粗糙度为0.05~0.1 μm。摩擦磨损试验采用MFT-EC4000试验仪进行，对磨件为Φ6 mm的Si3N4陶瓷球（硬度为1700 HV，表面粗糙度Ra≤0.2 μm），固定载荷为20 N，往复频率为2 Hz，摩擦距离为5 mm，摩擦时间为60 min。试验后，用乙醇对所有样品进行15 min的超声波清洗。借助SEM及其附带的能谱仪（EDS）对试样进行表征分析。使用精度为0.1 mg的电子天平对磨损前后的试样进行称重，取6次称重的平均值计算磨损量。
在室温3.5%NaCl溶液中，利用电化学工作站测试样品的动电位极化曲线（Tafel）与电化学阻抗谱（EIS）。采用标准的三电极体系，其中熔覆层和基体试样为工作电极，饱和甘汞（内充饱和KCl溶液）为参比电极，Pt作为辅助电极，暴露面积为1 cm2。电化学阻抗谱测试频率范围为0.01~105 Hz，振幅为10 mV，随后以1 mV/s的扫描速率完成动电位极化测试。特别地，在阻抗谱和动电位极化测试前，需测试20 min的开路电位（OCP），直至腐蚀电位稳定。
3 结果与讨论
3.1 微观组织
图 2. 激光熔覆层的微观组织与能谱分析
Fig. 2. Microstructures and energy spectra analysis results of laser cladding coating
从熔覆层表面的元素分析及元素定量能谱分析结果可以看出：铁基熔覆层中主要存在Fe、Cr、Ni、C元素，其中Cr、C元素在枝晶间富集，该现象是凝固时晶型转变控制的结果［26］；镍基熔覆层主要以Ni和Cr元素为主，并且溶解了Fe和C等元素，涂层内元素分布均匀，未发现明显的富集现象；钴基熔覆层中的主要元素为Co、Cr、Fe和C等，枝晶上和枝晶内的元素分布不一，枝晶上有Cr、C元素富集，Fe元素主要分布在枝晶内。
3.2 熔覆层的力学性能
熔覆层试样的拉伸性能是评价熔覆层成形质量的一个重要指标，
图 5. 熔覆层试样的拉伸性能。（a）应力-应变曲线图；（b）抗拉强度与伸长率
Fig. 5. Tensile properties of laser cladding coating samples. (a) Stress-strain curve graph; (b) tensile strength and elongation
为了明晰各熔覆层试样在室温下的断裂机制，用乙醇对断口进行超声清洗，然后进行SEM观察，各试样的断口形貌如
图 6. 试样的拉伸断口形貌。（a）铁基熔覆层试样；（b）镍基熔覆层试样；（c）钴基熔覆层试样
Fig. 6. Tensile fracture morphologies of samples. (a) Fe-based laser cladding coating sample; (b) Ni-based laser cladding coating sample; (c) Co-based laser cladding coating sample
图 8. 试样的冲击断口形貌。（a）铁基熔覆层试样；（b）镍基熔覆层试样；（c）钴基熔覆层试样
Fig. 8. Impact fracture morphologies of samples. (a) Fe-based laser cladding coating sample; (b) Ni-based laser cladding coating sample; (c) Co-based laser cladding coating sample
3.3 熔覆层的耐磨性
式中：Wr为磨损率，单位为g/（N·m）；
图 9. 基体和熔覆层的摩擦磨损测试。（a）摩擦因数；（b）磨损量及磨损率
Fig. 9. Friction and wear experiments of substrate and laser cladding coatings. (a) Friction coefficient; (b) mass loss and wear rate
图 10. 试样的三维磨损轨迹与最大磨损深度。（a）铁基熔覆层；（b）镍基熔覆层；（c）钴基熔覆层；（d）基体
Fig. 10. Three-dimensional wear trajectory and maximum wear depth of samples. (a) Fe-based laser cladding coating; (b) Ni-based laser cladding coating; (c) Co-based laser cladding coating; (d) substrate
图 11. 试样磨损区域的表面形貌。（a）铁基熔覆层；（b）镍基熔覆层；（c）钴基熔覆层；（d）基材
Fig. 11. Surface images of worn area of each sample. (a) Fe-based laser cladding coating; (b) Ni-based laser cladding coating; (c) Co-based laser cladding coating; (d) substrate
图 12. 表面氧化物的EDS结果。（a）点1；（b）点2；（c）点3；（d）点4
Fig. 12. EDS results of surface oxides. (a) Spot 1; (b) spot 2; (c) spot 3; (d) spot 4
3.4 熔覆层的耐蚀性
图 13. 试样在3.5%NaCl溶液中的电化学阻抗谱。（a）Nyquist图；（b）Bode图
Fig. 13. Electrochemical impedance spectra of samples in 3.5% NaCl solution. (a) Nyquist diagram; (b) Bode diagram
图 14. 等效电路。（a）基体；（b）熔覆层
Fig. 14. Equivalent circuit. (a) Substrate; (b) laser cladding coatings
表 3. 熔覆层与基体的电化学阻抗拟合结果
Table 3. Electrochemical impedance fitting results of cladding layers and substrate
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为了进一步研究试样的耐蚀性，进行了动电位极化试验，试验结果如
表 4. 熔覆层与基体的极化参数
Table 4. Polarization parameters of cladding layers and substrate
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4 结论
在ER9车轮材料表面制备了铁基、镍基和钴基合金熔覆层，研究了熔覆层的微观组织及性能，得到如下结论：
1）车轮材料表面激光熔覆层的微观组织主要由枝晶组织和共晶组织构成；铁基熔覆层主要由α-Fe、（Fe，Ni）、Cr7C3等固溶体组成，镍基熔覆层主要由固溶体γ-Ni、金属间化合物FeNi3和硬质相Cr23C6组成，钴基涂层的结晶相主要是FeNi3相、γ-Co相和Cr23C6相。
2）激光熔覆处理后，铁基熔覆层的显微硬度显著提升至716.5 HV左右，镍基和钴基合金熔覆层的硬度相比基体分别提高了45.6%和72.8%。铁基熔覆层的伸长率和冲击韧度最低，塑性较差；钴基涂层的抗拉强度最大，约为976.41 MPa；镍基涂层的伸长率约为34.5%，冲击韧度高达163.56 J/cm2，说明镍基涂层获得了良好的延展性。
3）激光熔覆钴基合金涂层的摩擦因数（约0.31）和磨损率［约0.4×10-4 g/（N·m）］均最低，损伤最轻，磨损机制主要为磨粒磨损；铁基熔覆层的磨损率相比基体降低了52.6%，其磨损机制以磨粒磨损为主，并伴有少量的黏着磨损特征；镍基熔覆层的磨损表面较为粗糙且存在磨屑堆积，其磨损机制为磨粒磨损与黏着磨损。
4）铁基、镍基和钴基合金熔覆层在3.5%NaCl溶液中的电荷转移电阻分别为135.55、288.14、535.89 kΩ·cm2，均显著高于基体的电荷转移电阻，且钴基熔覆层具有最优的耐蚀性。
5）对3种熔覆层进行比较及综合评价后可知，镍基熔覆层具有良好的塑韧性，但其耐磨性效果不佳，钴基熔覆层相对于铁基熔覆层具有更优异的耐磨和耐蚀性。在实际工程应用中，考虑到成本效益，铁基合金粉末仍为优选。
本文可为激光熔覆技术在车轮表面强化方面的工程应用提供一定的技术指导。
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Article Outline
杨文斌, 李仕宇, 肖乾, 杨春辉, 陈道云, 廖晓咏. ER9车轮材料激光熔覆层微观组织及性能研究[J]. 中国激光, 2023, 50(8): 0802202. Wenbin Yang, Shiyu Li, Qian Xiao, Chunhui Yang, Daoyun Chen, Xiaoyong Liao. Microstructure and Properties of Laser Cladding Coatings for ER9 Wheel Materials[J]. Chinese Journal of Lasers, 2023, 50(8): 0802202.
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