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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 2 - Mat4Rail (Designing the railway of the future: Fire resistant composite materials and smart modular design)

Teaser

Europe’s rail vehicles require a step change in technologies and design to remain competitive. Innovative materials and modular design for rolling stock are considered to become a key to success. Composite materials have demonstrated a high potential for lighter, more...

Summary

Europe’s rail vehicles require a step change in technologies and design to remain competitive. Innovative materials and modular design for rolling stock are considered to become a key to success. Composite materials have demonstrated a high potential for lighter, more energy- and cost-efficient structural components. However, currently available structural composites do not meet Fire, Smoke & Toxicity (FST) requirements of the railway sector, and cannot be used for the manufacturing of carbody shell parts. In this context, the overall aim of the Mat4Rail project has been to lay the foundation for:

• Reducing train weight by developing novel Fibre Reinforced Polymers which can replace structural metal parts of the carbody.
• Increasing capacity and passenger comfort via built-in modularity of train interior design.

Work performed

The Materials work stream in Mat4Rail covered the development of fibre reinforced polymers (FRP) and joints with suitable requirements for railway regarding FST, mechanical performance and cost, together with novel concepts for access door systems. Regarding FRPs, novel formulations of epoxy, benzoxazine and hybrid chemistry based resins were prepared and tested regarding FST properties. From these, 6 novel composites based on glass, basalt and carbon fibre reinforcements resulted compliant to EN45545-2 and a very detail testing campaign was performed on them, including fatigue testing. Cost analysis data was also compiled and presented. Regarding joints, a novel methodology was performed for static strength and fatigue assessment of joints and polymeric materials on the basis of structural bonding. A commercial elastic and a structural adhesive were selected as exemplary polymeric materials to validate the methodology for certification on track load cases. A numerical Finite Element simulation of a train was also performed to calculate the local stresses caused by global forces and moments. Permanent joint concepts were developed both for dissimilar and/or polymeric materials and also the development of repair methods for bonded composites was covered. In addition, 3D models were prepared to simulate the demonstration case and compare the results. Different repair technologies were proposed and two of them were fully developed and characterised.

Regarding innovation in access door systems, requirements and design specifications were gathered. Then, different design concepts for the door leaves were generated, focusing on innovative material systems, manufacturing processes and joining technologies by means of robust design methodologies. Three different concepts emerged as having the highest potential: one based in aluminium, another in the composite materials developed in Mat4Rail and a last one by additive manufacturing. While it was found to be not feasible within the scope of the project to develop a demonstrator with additive manufacturing, two large demonstrators were prepared for the other concepts.

In the Interior Design work stream, the identification of requirements was focused on traveller, operator and train producer needs. This was combined with the results of an assessment of emerging technologies to identify innovation potential. Based on a first evaluation of potential benefits and impact, different novel concepts were developed for plug & play systems (a flexible approach for the wall structure addressing structural and energetic issues for flexibility for ancillaries’ products, e.g., sockets, displays), seating situation and the driver’s cabin. For selected concepts 3D virtual and physical prototypes have been produced.

Mat4Rail website, newsletters and multiple presentations at conferences and fairs have been realised. Lastly, close interaction with standardisation groups were performed to ensure that Mat4Rail innovative materials and concepts will be included or will give rise to appropriate standards.

Final results

Mat4Rail will have an impact on: (1) The rail supply industry: It will allow the generation of new materials and design concepts to be implemented in this sector, increase its competitiveness and thus help create/save jobs in Europe. It will enable the introduction of new composites in the market for carbody shell parts based on novel resins that meet all railway requirements. Structural adhesive joints combined with riveting/bolting will allow joining of polymeric materials to metals and thus will allow primary multi-material structures of carbodies. This is expected to allow a weight reduction of carbody shell sections by up to 30% and a weight reduction of access door systems by 10-20%, depending on the train family. (2) Rail operators: Mat4Rail results will increase rail operators’ competitiveness by reducing costs for maintenance and refurbishment, while increasing passenger comfort, increasing passenger numbers and profitability of rail operators. The new interior design concepts are expected to allow an increase in capacity by up to 30%, reduced maintenance costs and reduced energy consumption due to the weight reduction. (3) Passengers: Mat4Rail will increase passenger comfort and satisfaction by adaptive seating concepts, more personal space, increasing number of seats during peak periods and better thermal insulation/acoustic attenuation of vehicles.

The main achievements at the end of the project in the Materials work stream were the following:
• Novel epoxy, benzoxazine and hybrid chemistry based resins have been developed that meet FST requirements.
• Six novel composites compliant with EN45545-2, based on glass, basalt and carbon fibre reinforcements have been successfully developed and validated. Their thermal and mechanical characterisation has also demonstrated the great potential of these composites for railway applications, while they have demonstrated to be cost-efficient candidates for their future introduction into the market.
• Certification procedure for polymeric materials for operational loads, damage accumulation validated for structural adhesive
• In addition, three novel concepts for access door systems were also presented, one of them based on composite materials developed within the project.

In the Interior Design work stream, Mat4Rail has developed a new seating concept: a hyper flexible and intelligent new ultra-lightweight seat system that can be arranged and fitted in a super dense and rapid way. It consists of a small frame structure which is holding an intelligent woven inlay structure, that generates all the ergonomic and comfort needed. The lightweight frame system is cantilever suspended or floor based fixed. This tangible, producible vision will have an impact to significantly reduce the number of parts and the total weight as well as the production costs and CO2 emissions during production and use.
Additionally, Mat4Rail has developed a plug & play system up to the stage of a fully functional mock-up. The system addresses all the needs with an intelligent multi layered energy & communication grid and a flexible mounting structure, including quick and easy refurbishment, installation on side wall of the train and different suppliers for lighting and crane systems.
Lastly, a virtual prototype of the whole train, showcasing the driver’s cabin as well as the plug & play system and a modular seating concept, has been built.

Overall, Mat4Rail has made a significant contribution to the trains of the future.

Website & more info

More info: http://www.mat4rail.eu/.