Fecha de publicación: -- Fuente: Journal of applied polymer Lugar: RESEARCH ARTICLE To address the challenge of simultaneously improving load-bearing performance and wear resistance for CFRP-steel hybrid load wheels fabricated via fixed low-pressure hot compression molding, this work conducts synergistic optimization of molding process parameters and fiber lay-up configurations. Ply orientation acts as the core determinant governing component flexural performance, while phosphating surface modification significantly strengthens steel-composite interfacial bonding. The optimized hybrid wheel achieves a 15.33% mass reduction relative to its aluminum alloy counterpart while fully retaining the wear resistance of the steel ring, providing a viable technical route for manufacturing high-performance lightweight load-bearing wheels under heavy-duty conditions.

ABSTRACT
Thermoplastic CFRP composites offer great potential for lightweight rail vehicle wheels due to high specific strength and fatigue resistance. However, poor molding parameters and stacking designs cause resin defects, while PEEK matrices lack wear resistance. This work fabricated CFRP-steel hybrid wheels via precision hot molding with three laminate configurations. Single-factor experiments evaluated how curing temperature, dwell time, and ply orientation affect flexural behavior. Results show ply orientation impacts performance most significantly: the [0°]20s lay-up reached 1225 MPa flexural strength, 28.3% higher than the 90° configuration. The 45° lay-up provided optimal dimensional stability and fracture toughness, with minimal degradation in complex flange regions. Optimal processing parameters were heating to 370°C at 3°C/min, holding for 30 min, and demolding below 60°C, balancing performance and efficiency. Integrating steel wear rings combined high load capacity with enhanced wear resistance, achieving a 15.33% mass reduction versus aluminum alloy wheels. This study provides a viable manufacturing pathway for high-performance lightweight composite wheels in demanding industrial applications.