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<p><b>Abstract</b>—A significant challenge in railway track maintenance is the degradation of switch frogs caused by substantial railhead wear. Worn zones are gradually renewed, which extends the service life of railroad switch frogs and significantly enhances their operational lifespan. This work investigates the potential for extending the service life of high-stress zones through the application of a protective Al–Ti–Zr–V–Nb powder coating. Coating deposition and subsequent laser melting are performed using a laser processing system comprising an LS-5 laser source and a KUKA KR-60 HA robotic arm with argon shielding gas protection. Gas blowing is carried out in two stages: before and after the deposition and melting processes. It takes for 0.3 s before and 1 s after these processes. The phase composition of the coating is analyzed using X-ray diffraction (XRD) in the range 2θ = 20°–80°. Phase and structural analysis data (EBSD) are obtained at a resolution of 100 μm. A combined XRD and SEM analysis reveals the following optimum melting parameters for a deposited Al–Ti–Zr–V–Nb powder: 325 W laser power, 0.2 m/s scan speed, and 0.6 mm coating thickness.</p>

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Effect of Melting Conditions on the Phase and Structural Composition of an Al–Ti–Zr–V–Nb–Fe Coating

  • 期刊论文

  • 发表日期：

    2025年2月1日

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  • M. V. Kiselev,
  • A. A. Terekhova,
  • I. S. Bakhteev,
  • A. A. Krylov,
  • T. V. Osinkina,
  • A. S. Russkikh,
  • K. I. Oleinik

摘要

Abstract—A significant challenge in railway track maintenance is the degradation of switch frogs caused by substantial railhead wear. Worn zones are gradually renewed, which extends the service life of railroad switch frogs and significantly enhances their operational lifespan. This work investigates the potential for extending the service life of high-stress zones through the application of a protective Al–Ti–Zr–V–Nb powder coating. Coating deposition and subsequent laser melting are performed using a laser processing system comprising an LS-5 laser source and a KUKA KR-60 HA robotic arm with argon shielding gas protection. Gas blowing is carried out in two stages: before and after the deposition and melting processes. It takes for 0.3 s before and 1 s after these processes. The phase composition of the coating is analyzed using X-ray diffraction (XRD) in the range 2θ = 20°–80°. Phase and structural analysis data (EBSD) are obtained at a resolution of 100 μm. A combined XRD and SEM analysis reveals the following optimum melting parameters for a deposited Al–Ti–Zr–V–Nb powder: 325 W laser power, 0.2 m/s scan speed, and 0.6 mm coating thickness.