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<p>The crevice between heavy-haul rail-foot and insulated gauge block suffers from fretting-induced mechanically assisted crevice corrosion (MACC), threatening rail service safety. Using a fretting-crevice corrosion simulator, electrochemical measurements, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS) and laser confocal scanning microscopy (CLSM), U75V-Zn samples prepared by Zn-diffusion treatment were evaluated for protective performance, failure mechanism and corrosion-wear trade-off. U75V-Zn exhibits a more negative stable open circuit potential (OCP, 0.9 to − 1.0&#xa0;V versus − 0.6 to − 0.7&#xa0;V for U75V), providing effective sacrificial anode protection. However, its lower hardness (346.3&#xa0;HL versus 366.3&#xa0;HL) causes fretting-induced deformation, cracking and ~ 50&#xa0;μm undulation, accelerating wear. Early electrochemical evolution differs oppositely between coated and uncoated steel, and coal media exacerbates corrosion-wear synergy. This work clarifies Zn-diffusion coating application boundaries and supports rail-foot protection optimization.</p>

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Performance and Degradation of Zn-Diffusion Coating Under Synergistic Fretting and Crevice Corrosion Conditions: Implications for Rail Foot Protection

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • ZhenPing Shi

摘要

The crevice between heavy-haul rail-foot and insulated gauge block suffers from fretting-induced mechanically assisted crevice corrosion (MACC), threatening rail service safety. Using a fretting-crevice corrosion simulator, electrochemical measurements, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS) and laser confocal scanning microscopy (CLSM), U75V-Zn samples prepared by Zn-diffusion treatment were evaluated for protective performance, failure mechanism and corrosion-wear trade-off. U75V-Zn exhibits a more negative stable open circuit potential (OCP, 0.9 to − 1.0 V versus − 0.6 to − 0.7 V for U75V), providing effective sacrificial anode protection. However, its lower hardness (346.3 HL versus 366.3 HL) causes fretting-induced deformation, cracking and ~ 50 μm undulation, accelerating wear. Early electrochemical evolution differs oppositely between coated and uncoated steel, and coal media exacerbates corrosion-wear synergy. This work clarifies Zn-diffusion coating application boundaries and supports rail-foot protection optimization.