Estudio de la fabricación aditiva para su aplicación en el reperfilado de ruedas de ferrocarril desgastadas por su uso
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La operación de reperfilado de ruedas ferroviarias consiste en un proceso de torneado que devuelve a la rueda desgastada su perfil original. Esto implica que, cuando el desgaste se produce principalmente en la pestaña de la rueda o provoca daños locales en la banda de rodadura, es necesario eliminar una cantidad considerable de material, reduciendo por tanto la vida útil y aumentando los costes de mantenimiento.
Para hacer frente a este problema, recientemente se ha propuesto la fabricación aditiva como una solución ideal. Concretamente, la tecnología de Deposición de Energía Dirigida o DED (Direct Energy Deposition) es conocida por su viabilidad a la hora de reparar daños locales con gran precisión, y ya ha sido utilizada para soldar y reparar carriles ferroviarios. Sin embargo, su aplicación a las ruedas de ferrocarril aún está siendo objeto de estudio, debido a los exigentes requisitos mecánicos y al adecuado comportamiento frente a desgaste que el material de la rueda debe alcanzar.
El objetivo de este estudio es investigar materiales de polvo metálico adecuados para el reperfilado de las ruedas de ferrocarril y comprobar que el resultado obtenido es adecuado para la rodadura ferroviaria atendiendo a las propiedades mecánicas alcanzadas. Los materiales comerciales empleados han sido AISI 4140, Stellite 6, 100Cr6, y AISI H13, los cuales han sido depositados sobre probetas extraídas de la banda de rodadura de una rueda utilizada hasta su servicio final. Por tanto, el material utilizado como sustrato es material endurecido, tratando de reproducir de esta manera las condiciones reales lo más fielmente posible.
La calidad de los recubrimientos se ha comprobado examinando la geometría de las uniones mediante un Microscopio Óptico, y la microestructura y tensiones residuales mediante técnicas de Fluorescencia de Rayos X y Difracción de Rayos X, respectivamente La consistencia de la unión también ha sido estudiada analizando la dureza del recubrimiento y su variación a lo largo de la profundidad. Se han realizado ensayos tribológicos para caracterizar el comportamiento de fricción y evaluar la resistencia al desgaste de las probetas con revestimiento frente al material de rueda no revestido.
Los resultados indican que el uso de la fabricación aditiva en ruedas ferroviarias resulta de especial interés para su uso en aplicaciones de reperfilado. Es posible conseguir una resistencia al desgaste adecuada y excelentes propiedades mecánicas en términos de dureza y tensiones residuales compresivas, y por consiguiente, apropiadas para una mayor resistencia a fatiga.
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