(a) 浸金属碳滑板外观图
Published:10 July 2022,
Received:22 February 2022,
Revised:11 May 2022
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In order to explore the wear mechanism of pantograph carbon slide surface, taking the pantograph copper to impregnate carbon slide material before and after the wear of a domestic subway line as the object, the surface microstructure and chemical composition of the carbon slide were tested and analyzed by electron microscope, laser confocal microscopy, scanning electron microscope and energy dispersive spectrometer. The results showed that the surface color of carbon slide changed obviously after wear, and the surface morphology changed from machining gully to wear scar, few cracks and arc ablation holes; the results of SEM and EDS showed that the distribution of C and Cu phases on the surface of unwearied pantograph carbon slide was relatively clear, while the distribution of C and Cu elements on the surface after wear was relatively uniform and there was no obvious boundary, indicating that the oxide film was formed during the wear process; arc ablation gathered in the relatively concentrated area of Cu distribution. The main wear forms of the surface were arc ablation, mechanical wear, abrasive wear and material transfer. Among them, arc ablation had the greatest impact on wear, inducing arc ablation pits, the material surface presents a typical rough and rugged morphology, and the friction condition deteriorated significantly, which aggravated the vibration of pantograph and catenary, further affected the friction surface, and led to the increase of temperature rise of contact pair and arc ablation. The resulting high temperature induced material transfer. Under the combined action of various wear forms, the surface cracks of the pantograph carbon slide plate continuously initiated and expanded, and finally, the surface material fell off, resulting in the surface wear of carbon slide plate.
受电弓是地铁列车集电装置的重要组成部分,在运行过程中,通过其顶端碳滑板表面与接触网的滑动接触为地铁列车提供电能。根据材料不同,碳滑板可分为纯碳素滑板、浸金属碳滑板和粉末冶金碳滑板。相关研究表明,浸金属碳滑板具有机械强度高、自润滑及耐磨性能好等特点,现已在地铁列车上被大量使用[
在受电弓受流过程中,碳滑板不可避免将产生滑动磨损,该过程不仅包括常见的机械磨损,还伴随着大电流、高速度的载流磨损。随着城市的快速发展,地铁列车的运载量逐渐增大,需要更高的牵引功率和运行速度,碳滑板所受电流和弓网相对滑动速度也随之提升,其表面载流摩擦磨损情况将关系到受流稳定和列车运行安全。国内外学者针对不同材料摩擦副的载流磨损开展了大量研究,文献[
试验材料来源于
(a) 浸金属碳滑板外观图
(b) 取样示意图(单位:mm)
图1 碳滑板试样制备
Fig. 1 Sample preparation of carbon slide
利用纽荷尔DZ-Y500L型电子显微镜获取试样表面宏观图。
(a) 未磨耗碳滑板表面宏观图
(b) 磨耗碳滑板表面宏观图
图2 碳滑板表面宏观形貌分析
Fig. 2 Analysis of the carbon slide surface macroscopic topography
此外,在电弧烧蚀和振动冲击的共同作用下,碳滑板表面出现了大面积的裂纹。在后续使用过程中,裂纹将会继续扩展,同时会有更多的裂纹萌生,最终形成块状剥落,进而导致滑板的磨损。
摩擦副之间的接触状态直接关系到碳滑板受流和磨损情况,为深入探究磨耗表面形貌微观特征,采用日本OLYMPUS OLS4100激光共聚焦显微测试分析系统对不同类别试样表面进行微观图采集。采用20倍物镜采集试样表面形貌特征,分别获取碳滑板未磨耗试样和磨耗后试样表面微观图,大小约为2 390 μm×2 390 μm。
(a) 未磨耗表面微观图
(b) 未磨耗表面三维云图
(c) 磨耗后表面微观图
(d) 磨耗后表面三维云图
图3 碳滑板表面微观形貌分析
Fig. 3 Analysis of the carbon slide surface micro topography
为进一步获取碳滑板表面微观信息,探究表面摩擦磨损机理,利用日本电子JSM-IT500LV扫描电镜及其所搭载的能谱仪,对磨耗试样的表面进行SEM(Scanning electronic microscope)和EDS(Energy dispersive spectrum)分析,
(a) 区域1
(b) 区域2
图4 磨耗表面SEM形貌分析
Fig. 4 SEM topography analysis of the wear surface
(a) 未磨耗表面微观图
(b) C能谱
(c) Cu能谱
(d) O能谱
图5 未磨耗表面EDS结果
Fig. 5 EDS results of the unworn surface
(a) 磨耗表面微观图
(b) C能谱
(c) Cu能谱
(d) O能谱
图6 磨耗后表面EDS结果
Fig. 6 EDS results of the worn surface
(a) 电弧烧蚀区域
(b) Cu能谱
(c) C能谱
(d) 电弧烧蚀孔洞
(e) 材料剥落区域
图7 电弧烧蚀区域形貌及EDS结果
Fig. 7 Appearance of the arc ablation area and the
EDS results
从
从
(1) |
(2) |
这表明在载流磨损的过程中,碳滑板表面生成了包含Cu氧化物组成的氧化膜,除了前述其具备一定的润滑作用外,由于表面CuO和Cu2O的存在使得弓网之间的电阻升高,摩擦磨损表面温度受到影响,反而会导致磨耗率上升。
(a) 未磨耗
(b) 磨耗后
图8 碳滑板表面EDS谱
Fig. 8 The EDS spectrum of the carbon slide surface
本文通过多种方式获取了碳滑板磨耗前后表面的宏观图、微观图、SEM图和EDS结果,并针对碳滑板表面磨耗前后微观组织、三维形貌、化学成分上的差异进行了分析,得出如下结论:
①浸铜碳滑板在磨耗过后,表面出现大量裂纹,将表面划分为多个块状区域,在弓网摩擦过程中,块状区域易发生脱落,致使磨耗发生。
②电弧烧蚀是导致浸铜碳滑板表面磨耗的主要因素之一。磨耗后的碳滑板表面出现大量电弧烧蚀痕迹,裂纹往往分布在电弧烧蚀孔洞周围,这主要是由于电弧烧蚀产生的热应力持续对表面材料造成疲劳破坏。
③碳滑板磨耗的主要形式包括机械磨损、磨粒磨损、电弧烧蚀、材料转移等,其中电弧烧蚀是影响磨耗的主要因素,通过适当地降低电弧烧蚀率将有利于提高碳滑板的耐磨性。
需要指出的是,尽管本文从微观角度对碳滑板磨耗机理进行了分析,但对磨损过程的跟踪及量化表征,还有待结合线路与台架试验,开展进一步研究。
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