The interaction layer on the rail surface resulting from friction, adhesion, and melting of CuCrZr/AlMgSi friction pairs during ultra-high speed sliding electrical contact, such as in electromagnetic rail launch systems, plays a critical role in determining the lifespan and performance of the copper rail. This study investigates the evolution of the interaction layer microstructure, elemental diffusion behavior, and the formation mechanism of intermetallic compounds (IMCs) and mechanical properties after 45 launches. Results show that copper diffuses into aluminum, forming a diffusion layer in...
