Microstructural Evolution of Pearlitic Wheel Steel Under Thermal–Mechanical Fatigue

Pearlitic wheel steel subjected to thermal–mechanical fatigue (TMF) during braking can undergo catastrophic fracture. This study clarifies the microstructural evolution governing the macroscopic cyclic hardening/softening behavior of pearlitic wheel steel under thermal–mechanical fatigue (TMF) with a constant mechanical strain range of −0.4% to +0.2%. At lower temperature amplitudes (200–500 °C), the geometrically necessary dislocation (GND) density reaches 20.4 × 1014/m2 during initial cycles, corresponding to cyclic hardening due to dislocation pile-ups at cementite lamellae interfaces. With increasing cycles, the GND density decreases to 12.3 × 1014/m2, concurrent with softening arising from lamellar bending/fracture, partial spheroidization, and dynamic recrystallization of ferrite. At higher temperature amplitudes (200–730 °C), the GND density decreases from 8.8 × 1014/m2 to 3.5 × 1014/m2, reflecting sustained cyclic softening dominated by thermally activated mechanisms, including cementite spheroidization and dislocation annihilation. The resulting softened microstructure consists of ferrite grains, intragranular dispersed cementite, and chain-like coarse cementite at boundaries. Unlike previous studies that focused on single loading conditions (e.g., thermal fatigue, rolling contact fatigue, or wear), the present work addresses the more complex TMF scenario and quantitatively elucidates the interplay between mechanical response and microstructural evolution in pearlitic steel. This work provides theoretical guidance for the development of a fatigue life prediction model for pearlitic wheels under braking.