Surface Damages Regeneration of Railway Wheels

This study investigates the application of Plasma Transferred Arc (PTA) surface treatment as an advanced method for the regeneration of railway wheels. Traditional wheel reprofiling, performed using semi-automatic lathes, involves the removal of at least 6 mm of metal from the running surface, leading to progressive rim thinning and eventual wheel replacement. Furthermore, the reprofiled surfaces lack any subsequent treatment to extend their operational lifespan. To address these limitations, PTA cladding was selected for its capability to produce enhanced surface layers with improved mechanical properties. Unlike commonly used diode laser treatments, PTA enables the deposition of alloying materials in wire form, providing a robust and controlled cladding process. The resulting surface structure comprises a heat-affected zone, a transition zone, and a remelted zone, all exhibiting significantly increased hardness compared to the untreated base metal. The cladding process allows for the incorporation of metal particles into the surface layer, facilitating the formation of a high-quality, wear-resistant top layer. These findings demonstrate the potential of PTA surface treatment to extend the service life of railway wheels by providing a durable and hard-wearing surface, thereby reducing maintenance frequency and costs [1–3].