Abstract
In this study, the effects of thermal cracks on the friction and wear properties of forged steel used in railway brake discs were investigated. First, friction tests were conducted on forged steel obtained from a serviced brake disc with and without thermal cracks against powder metallurgy alloys obtained from brake pads. The occurrence of thermal cracks reduced the coefficients of friction (COF) to one-third of that of the specimen without thermal cracks and sharply increased the fluctuation of the COF. The observation of the third-body film (TBF) indicated that its integrity was destroyed by thermal cracks; the TBF on the thermal crack was discontinuous and island-like, surrounded by adhesion pits. The poor quality of the TBF was responsible for the low and fluctuating COF of the specimen with thermal cracks. The debris tended to fill the interspaces of the thermal cracks instead of forming a TBF owing to the occurrence of thermal cracks, while the compressional force was not large enough to cause the accumulation and compaction of the debris to form an integrated TBF.
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