Development of a Base Material–Barrier Coating System Using Affordable Raw Materials for the Sustainable Production of Critical Railway Components

The promising potential of porous metallic materials for railway applications (e.g., conductive materials, materials for braking systems) is due to their unique combination of low density, high specific surface area, and high energy absorption capabilities. Porous multi-phase silicide coatings (FeSi, Si2CN4) provide a synergistic effect, doubling surface hardness and establishing a stable diffusion barrier. The article proposes a comprehensive approach to replacing materials for critical railway transport components, involving the development of a base material and a barrier coating. The use of widely available induction-melting components to produce a base material with superior mechanical properties is demonstrated. The material exhibits high static strength and hardness while maintaining acceptable impact toughness and ductility. To enhance wear, corrosion, and scale resistance, technology for forming a barrier layer via silicide coatings is proposed. The coating formation technology enables the regulation of porosity through the formation of nitrogen-containing phases. It is shown that pores can serve as “containers” for fillers that impart functional properties to the coatings (e.g., adjusting the friction coefficient or electrical conductivity). The new base material–barrier coating system can serve as a foundation for the sustainable production of critical rolling stock parts and other devices for railway transportation systems.