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Extensive field experiments (the ‘Silinge wheel flat experiments’) with a moving train have been designed, performed (at Silinge) and evaluated. More than 200 wheel flats were formed under controlled conditions involving different wheel loads, train speeds and sliding durations, and the friction coefficient between the wheel and the rail was also varied (and indirectly measured). Samples extracted from flats of the tested wheels have been metallographically examined with respect to phase transformations and cracks. A numerical model for wheel flat prediction has been qualitatively verified and quantitatively calibrated. In the experiments, martensite was found beneath all flats and cracks were observed in most cases. It is concluded that the risk for future spalling should be considered for all wheelsets with flats. A damaged wheelset should be taken out of service as quickly as possible. When reprofiling the wheels, all martensite and an additional layer of several millimetres should be machined off.

Liquid phase sintering of M3/2 grade high speed steel (HSS) was carried out at 1270uC in high vacuum reaching near full density starting from loose packed powder. Focus is placed on the study of the effects of the addition of Si, Ni and V as elemental powder and cooling rates on the as sintered microstructure, the main objective being improving M 6 C characteristics and control of pearlite appearance. Slow cooling from the sintering temperature and Si addition in wt-% resulted in a completely fine pearlitic matrix with less elongated and more uniformly distributed M 6 C precipitates. Adding V or Ni in wt-% quantities decreased the amount of pearlite owing to MC formation and delayed pearlite formation. The study involved the use of thermodynamic modelling and sintering cycle optimisation as well as the evaluation of sintered material by means of optical and scanning electron microscopy, X-ray diffraction and hardness testing.PM/1115

Coated low alloyed steel tubes were exposed in two combustion power plants of the type Circulating Fluidised Bed (CFB) and Pressurised Fluidised Bed Combustion (PFBC). The power plants were fired with wood chips and coal with a small addition of olive seeds, respectively. In addition to laser coating two thermal spray techniques were used; arc-spray (air as carrier gas) and High Velocity Oxy Fuel (HVOF). The sample locations in the PFBC plant were at the highest and lowest loops of a platen immersed in the fluidising bed. The material temperatures in each loop were 450 C and 400 C, respectively. The exposure lasted over two firing seasons for a total time of 8089 h. In the CFB plant a probe was located at the cyclone entrance where the material temperature was 630 C for an exposure time of about 2100 h before being reduced to 480 C for a further 920 h. The material wastage was determined from metallographic studies on cross-sections of rings cut from the exposed tubes. The nature and chemical composition of the corrosion products and deposits formed were determined by SEM/EDX, Auger spectroscopy, XPS and XRD. Cobalt based coatings show the best performance in both the PFBC plant and the CFB plant, while nickel based coatings are resistant to a corrosive atmosphere but very sensitive to erosion. The degree of corrosion is much larger in the CFB plant as is clearly seen from the chromium carbide containing coating, which totally degraded in this environment. Contrary the performance of the same coating was excellent in the fluidised bed due to its high erosion resistance. The material wastage of a coating with a specific composition is independent of the deposition method. No significant differences in spallation behaviour occurred among coatings deposited with the different techniques.

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