System and method of forming a wear surface for a wheel of a rail vehicle

1. A method of forming a wear surface of a wheel of a rail vehicle, the method comprising:

depositing a first alloy powder having a first composition onto a main body of the wheel, wherein the first alloy powder includes 0.19% Carbon (C), 3.1% Chromium (Cr), 0.19% Manganese (Mn), 0.15% Silicon (Si), 0.6% Molybdenum (Mo), and 2.1% Nickel (Ni);

plasma transfer arc welding the first alloy powder onto the main body of the wheel to form a first alloy layer secured to the main body of the wheel;

depositing a second alloy powder having a second composition over the first alloy layer, wherein the second composition differs from the first composition, wherein the second alloy powder includes 0.25% C, 3.0% Cr, 0.21% Mn, 0.18% Si, 4.9% Mo, and 3.2% Ni; and

plasma arc welding the second alloy powder onto the first alloy layer to form a second alloy layer.

2. The method of claim 1 , further comprising:

depositing a third alloy powder having a third composition over the second alloy layer, wherein the third composition differs from the first composition and the second composition; and

plasma transfer arc welding the third alloy powder onto the second alloy layer to form a third alloy layer.

3. The method of claim 2 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder has a different composition than the main body.

4. The method of claim 1 , wherein the main body is formed of carbon steel.

5. The method of claim 2 , wherein each of the first alloy powder and the second alloy powder further includes one or more additional materials, and wherein the third alloy powder includes 0.42% C, 11.6% Cr, 0.4% Mn, 0.4% Si, 1.2% Mo, 4.6% Ni, and one or more additional materials.

6. The method of claim 1 , wherein the wheel includes an inner rim, an outer rim, and a support rim between the inner rim and the outer rim.

7. A method of forming a surface of a component, the method comprising:

depositing a first alloy powder having a first composition onto a base structure of the component, wherein the first alloy powder includes 0.19% Carbon (C), 3.1% Chromium (Cr), 0.19% Manganese (Mn), 0.15% Silicon (Si), 0.6% Molybdenum (Mo), and 2.1% Nickel (Ni);

plasma transfer arc welding the first alloy powder onto the base structure of the component to form a first alloy layer secured to the base structure of the component;

depositing a second alloy powder having a second composition over the first alloy layer, wherein the first composition differs from the second composition, wherein the second alloy powder includes 0.25% C, 3.0% Cr, 0.21% Mn, 0.18% Si, 4.9% Mo, and 3.2% Ni; and

plasma arc welding the second alloy powder onto the first alloy layer to form a second alloy layer.

8. The method of claim 7 , further comprising:

depositing a third alloy powder having a third composition over the second alloy layer, wherein the third composition differs from the first composition and the second composition; and

plasma transfer arc welding the third alloy powder onto the second alloy layer to form a third alloy layer.

9. The method of claim 8 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder has a different composition than the base structure.

10. The method of claim 7 , wherein the base structure is formed of carbon steel.

11. The method of claim 8 , wherein each of the first alloy powder and the second alloy powder includes one or more additional materials, and wherein the third alloy powder includes 0.42% C, 11.6% Cr, 0.4% Mn, 0.4% Si, 1.2% Mo, 4.6% Ni, and one or more additional materials.

12. A method of forming a wear surface of a wheel of a rail vehicle, the method comprising:

depositing alloy powders onto a main body of the wheel, wherein the alloy powders comprise:

a first alloy powder including 0.19% Carbon (C), 3.1% Chromium (Cr), 0.19% Manganese (Mn), 0.15% Silicon (Si), 0.6% Molybdenum (Mo), and 2.1% Nickel (Ni);

a second alloy powder including 0.25% C, 3.0% Cr, 0.21% Mn, 0.18% Si, 4.9% Mo, and 3.2% Ni; and

a third alloy powder including 0.42% C, 11.6% Cr, 0.4% Mn, 0.4% Si, 1.2% Mo, and 4.6% Ni; and

plasma transfer arc welding the alloy powders to form one or more alloy layers secured to the main body.

13. The method of claim 12 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder further comprises one or more additional materials.

14. The method of claim 12 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder has a different composition than the main body.

15. The method of claim 12 , wherein the main body of the wheel is formed of carbon steel.

16. The method of claim 12 , wherein the wheel includes an inner rim, an outer rim, and a support rim between the inner rim and the outer rim, wherein the first alloy powder is deposited onto the support rim.

17. A method of forming a surface of a component, the method comprising:

depositing alloy powders onto a base structure of the component, wherein the alloy powders comprise:

a first alloy powder including 0.19% Carbon (C), 3.1% Chromium (Cr), 0.19% Manganese (Mn), 0.15% Silicon (Si), 0.6% Molybdenum (Mo), 2.1% and Nickel (Ni);

a second alloy powder including 0.25% C, 3.0% Cr, 0.21% Mn, 0.18% Si, 4.9% Mo, and 3.2% Ni; and

a third alloy powder including 0.42% C, 11.6% Cr, 0.4% Mn, 0.4% Si, 1.2% Mo, and 4.6% Ni; and

plasma transfer arc welding the one or more alloy powders to form one or more alloy layers secured to the base structure.

18. The method of claim 17 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder further comprises one or more additional materials.

19. The method of claim 17 , wherein each of the first alloy powder, the second alloy powder, and the third alloy powder has a different composition than the base structure.

20. The method of claim 17 , wherein the base structure is formed of carbon steel.