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Control of the bainitic structure for a wear-resisting hard-faced rail track

Abstract Carbide-free bainite with filmlike retained austenite structure has been reported for its higher wear resistance and toughness compared with conventional bainite and pearlite structure. In order to take advantage from such beneficial structure, this study employs the surface welding method with self-shielded wire electrode containing low carbon (0.15 mass%), high silicon, and nickel on two pearlitic rail steels, R260 and R350HT. The preheating temperature and other welding parameters were carefully selected to avoid too high dilution, which leads to martensite formation. The weld metal, heat-affected zone, and base material were investigated by scanning electron microscopy. Microhardness and wear tests were carried out to ensure improved properties after the surface repair. The results show significant improvements in hardness and wear rate in weld metal compared with the base material.