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The next generation of lightweight structural materials for railway carbodies


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The transportation industry has for a long time been engaged in the application of new lightweight materials for primary structural design. The use of such materials is vital to achieving reductions in energy consumption and consequently to achieving reductions in greenhouse gas emissions. For instance, in aeronautics, where the weight of an aircraft is a critical factor for fuel consumption, composite materials are replacing metallic materials both structural and non-structural parts.
The railway industry could also benefit from the use of lightweight structural materials. The weight savings associated with the use of these new materials would result in reduced power consumption, lower inertia, less track wear and the ability to carry greater pay-loads.

Published in: Automotive
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The next generation of lightweight structural materials for railway carbodies

  1. 1. The next generation of lightweight structural materials for railway carbodies Eduardo de la Guerra (Talgo) WP3 Leader Roll2Rail Compositi 4.0-3rd of May Torino
  2. 2. • Introduction • Roll2Rail Project • Roll2Rail: WP3 Carbodies • Studies • Conclusions • Shift2Rail • Open challenges Index vs
  3. 3. Introduction • Current railway carbody structures close to the limit in lightweight terms – Steel or aluminium • New concept lightweight structure Aircraft and automotive industry (completely valid models for railway application?)
  4. 4. Introduction • Reduce mass of the structure • Possibilities: – High strength alloys – Composites – Combinations – … Weight reduction
  5. 5. IntroductionAlstom BT TTX Voith
  6. 6. Introduction
  7. 7. Roll2Rail Project Increase capacity and bring flexibility to adapt capacity to demand Increase operational reliability and therefore punctuality Reduce the LCC of vehicles and track Increase the energy efficiency of the system Improve passenger comfort and thus increase attractiveness of rail transport The Roll2Rail project aims to develop key technologies and to remove already identified blocking points for radical innovation in the field of railway vehicles, as part of a longer term strategy to revolutionise the rolling stock for the future. WP3 devoted to carbody shells
  8. 8. Roll2Rail: WP3 Carbodies • WP3 aims – Define the technical specification for the new lightweight carbodies (HS and Urban application) – Feasibilities/conceptual studies regarding structural and adhesive joints taking into account weight-saving potential – Strategies for the acceptance of the new lightweight carbodies
  9. 9. Studies Baseline models defined for the studies
  10. 10. Studies • Topology optimization (Optistruct) – Geometric variations and derivatives Reference model: 282mm door , 162mm window pillars widths Modified model: 305mm door and window pillars ↓14% weight↓6% weight
  11. 11. Studies • Design proposal for Urban Embedded Stiffener Shear panel Extruded profile and AFS Sandwich and Stiffeners
  12. 12. Studies
  13. 13. Studies • Optimization regarding fibre orientation
  14. 14. Studies Roof Main frame
  15. 15. Studies • Joints Analysis of the junction between main frame and lateral panel Load cases - LC1: Maximum vertical load - LC2: Overpressure(+6000Pa) - LC3: Underpressure(-6000Pa) - LC4: 1500kN compresion and vertical load - LC5: 1000kN traction and vertical load
  16. 16. Studies• Joints – Different concepts – Adhesive bonding LC2 UR LC2 DR LC3 DR dominant component maximum principal dominant component maximum principal dominant component maximum principal Butt Joint 14.1 16.7 23.9 24.8 98.4 104 Lap Joint 15.3 17.1 25.6 26.7 95.8 103
  17. 17. Studies • Detail design of subassemblies Current solution Proposal
  18. 18. Studies • Static assessment and stiffness calculation 1st mode frequency 10.3 Hz Riveting Load Case Safety Factor Exceptional 3.45 Fatigue 1.05 Laminate Most critical Load Case 3gz Maximum Failure Index 0.11 31% of weight saved
  19. 19. Conclusions • Deliverables: – D3.1 Technical Specification (PU) – D3.2 Material assessment (CO) – D3.3 Joining technologies (CO) – D3.4 Final report (PU) • Reduction around 20% in weight • Optimization methodologies powerful tool during design phase.
  20. 20. Conclusions • Hybrid structures mixing material: high strength alloys, aluminium, composites (carbon fibre). Depending on location and functionality. • Multifunctional materials are desired • Necessary to develop joints and resins adapted to railway applications. • Out of autoclave technologies (↓cost).
  21. 21. Shift2Rail • The WP3 of Roll2Rail are aligned with the expected achievements of the TD1.3 Carbodyshell of Shift2Rail: – Weight reduction between 15 and 30%. – Energy savings in operation, resulting from the weight reduction. – Improvement of maintainability, coming from new concepts. • Demonstrator up to TRL7 in High Speed will be developed to test the concepts (2022)
  22. 22. Open challenges • Existing gaps regarding standandization usiTowards a REgulatory FRamework for the usE of Structural new materials in railway passenger and freight CarbOdyshells ( • Fire, smoke and toxicity (EN 45545). Few composite available complying 100% FST requirements (mainly resins). • Electromagnetic compatibility. Changing the materials of the structure modifies the response of the EM field. • Structural an crashworthiness requirements (EN 12663 and EN 15227). Only metals is considered until now for fatigue and crash assessment. • Joints. Standard gap in railway industry regarding design, manufacture and acceptance criteria regarding joints (multi-material or composites joints). • Reparability and maintainability. Define new strategies. • KPI at railway level
  23. 23. Eduardo de la Guerra Patentes Talgo Paseo del tren Talgo, 2 28290 Las Matas – Madrid (Spain) @