Doctoral Thesis

The effect of contamination on friction modification in the wheel-rail contact

Final Thesis 5.81 MB Appendix 18.48 MB

Author of thesis: Ing. Šimon Skurka, Ph.D.

Acad. year: 2025/2026

Supervisor: prof. Ing. Martin Hartl, Ph.D.

Reviewers: Dr. Martin Evans, Assoc. Prof. Angelo Mazzù, PhD

Abstract:

Top-of-rail products are used for friction modification on the railhead. Over the past three decades, intensive research has shown that they can reduce operational costs and extend the service life of wheels and rails by mitigating wear and rolling contact fatigue. Most of this research, however, has been performed under clean laboratory conditions. In reality, the wheel–rail interface is an open system in which various contaminants are always present, and conditions may change even between passing axles of the same vehicle. It is therefore reasonable to expect that these contaminants also affect the performance of top-of-rail products. For this reason, this PhD thesis investigates how contamination influences friction modification in the wheel–rail contact.

The experimental work combines friction measurements performed on a laboratory tribometer with rolling contact fatigue tests on a twin-disc machine. A climate chamber was used to simulate humid environments and to form oxide layers, while a humidifier unit and a peristaltic pump reproduced contamination modes such as dew or precipitation. Specimens were prepared as metallographic cross-sections, and scanning electron microscopy was used to evaluate crack morphology under the different test conditions.

The results showed that contamination has a strong effect on top-of-rail products. For waterbased products, light moisture prolonged their effect, whereas larger amounts of water washed them away and ended their effect on friction, wear and rolling contact fatigue. Oil-based products behaved differently: water greatly amplified their lubricating effect, causing extremely low friction, suppressed wear and caused rapid liquid-assisted crack growth. Oxides had only a small influence on friction, but oxidation contributed to material weakening and had an unexpected effect on cracks, as it caused oxygen-assisted propagation.

These findings underline the importance of considering environmental conditions when optimising friction-modification strategies and provide insights into the mechanisms governing product behaviour under real operating conditions. In addition, a new benchmarking methodology for assessing the performance of top-of-rail products was proposed, offering a standardised and reliable approach for laboratory testing.

Keywords:

Top-of-Rail Products, Wheel–Rail Adhesion, Rolling Contact Fatigue, Water, Contamination, Iron Oxides

Date of defence

18.06.2026

Result of the defence

Defended (thesis was successfully defended)

znamkaPznamka

Process of defence

The dissertation meets the requirements arising from Section 47 of Act No. 111/1998 Coll., on Higher Educations Institutions and on Amendments and Supplements to Other Acts, and from Article 40 of the Study and Examination Regulations of BUT. It contains original results published, among others, in four articles in an impact-factor journal.

Language of thesis

English

Faculty

Department

Study programme

Design and Process Engineering (D-KPI-P)

Composition of Committee

doc. Ing. Daniel Koutný, Ph.D. (předseda)
doc. Ing. David Nečas, Ph.D. (místopředseda)
doc. Ing. Milan Klapka, Ph.D. (člen)
Dr. Martin Evans (člen)
Assoc. Prof. Angelo Mazzù, PhD (člen)

Supervisor’s report
prof. Ing. Martin Hartl, Ph.D.

The candidate started his PhD studies in 2021 and from the beginning showed a clear interest in defining a structured study plan covering individual research steps, expected publication outputs and an international internship. The plan was followed successfully throughout the study and most modifications represented positive developments, such as completing additional research stays beyond the original plan. The candidate approached his work actively and responsibly. Communication was frequent and productive. He regularly proposed his own ideas, interpretations and directions for further work. Overall, the candidate demonstrated a high level of commitment and responsibility throughout the PhD study.

The candidate demonstrated a high level of independence throughout the PhD study. He proposed experimental approaches, prepared testing procedures and performed experiments independently. The evaluation of results and preparation of scientific manuscripts required only limited supervision. His very good English skills significantly accelerated manuscript preparation and simplified both internal and external review processes. He was also able to present the obtained results at leading international conferences and discuss them with experts from academia and industry. Besides activities directly related to the dissertation, the candidate actively participated in several research projects. Some of these projects were closely related to the thesis topic, while others addressed different tribological problems. The candidate was also significantly involved in the development of a testing methodology for top-of-rail products. This methodology is currently routinely used within the research group, not only for internal research activities but also in cooperation with industrial partners. Through these activities, the candidate demonstrated a high level of responsibility, technical competence and the ability to work independently.

The thesis addresses an important knowledge gap related to the performance of top-of-rail products under contaminated conditions. Although these products have been used in railway practice for many years, their interaction with environmental contaminants has not been systematically studied. The candidate focused on the influence of contamination, particularly water, on the frictional performance of top-of-rail products, as well as the effects of contamination on wear and rolling contact fatigue. The research activities at Brno University of Technology focused on frictional performance, while wear and rolling contact fatigue were studied during his stays at Southwest Jiaotong University, where he broadened his expertise in wheel-rail tribology. Based on the results of the thesis, general recommendations for the application and operation of top-of-rail products under different contamination conditions were proposed. The candidate also contributed to the development of testing methodologies that are currently used for the evaluation of top-of-rail products. The results of the thesis were published in three first-author journal papers and one co-authored paper. The papers were published in leading tribology journals, including Wear, Tribology International and Tribology Letters. My only comment regarding the presented work is that part of the results could have been further validated under field conditions or using a full-scale testing approach. Nevertheless, the overall scientific contribution of the thesis is significant and the obtained findings have both scientific and practical relevance.

PhD thesis is an independent scientific work that presents a novel solution to a significant problem in the research area and demonstrates the candidate’s ability to conduct independent research.

Reviewer’s report
Dr. Martin Evans

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Responsibility: Mgr. et Mgr. Hana Odstrčilová