Mat4Rail Newsletter 04 | November 2019
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The search for new materials for access door systems (i.e. composites, metallic alloys) and their integration techniques (“one-shot” injection, welding & adhesive processes etc.) were addressed as part of the WP5 Innovative Access Door Systems, through innovative approaches considering relevant criteria, such as production costs, manufacturing aspects and railway constraints. The Mat4Rail project partners’ expertise from relevant industrial sectors (e.g. aeronautical) was also implemented to integrate innovative materials and processes for the railway sector.
Three concepts of door leaves were proposed and developed by the Mat4Rail partners, COEXPAIR, ITAINNOVA, ASAS and UNI-HB: a composite concept, a metallic one using a new aluminium alloy and a concept made by additive manufacturing. These solutions must meet very stringent requirements and specification provided by PIVOT partners (low cost, FSE behaviour, mechanical strength and vibration behaviour).
Three concepts of door leaves were proposed and developed by the Mat4Rail partners, COEXPAIR, ITAINNOVA, ASAS and UNI-HB: a composite concept, a metallic one using a new aluminium alloy and a concept made by additive manufacturing. These solutions must meet very stringent requirements and specification provided by PIVOT partners (low cost, FSE behaviour, mechanical strength and vibration behaviour).
Composite door manufacturing at COEXPAIR
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RTM composite process: the injection and cure of the full structure is done in only
one operation
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Standard methods were used for the design phase while mitigating the main risks linked to manufacturing. For the composite and the aluminium concepts, several tests were successfully conducted, with a sub-scale demonstrator manufactured at the end of the project and presented during the final joint event. The fabrication of a component by additive manufacturing (i.e. with defined high grade of functional specialisation using different natural materials and constructive principles) was not possible in a realistic cost-effective way vs. current state-of-the-art machines.
Overall, collaboration within Mat4Rail on doors, partnership was fruitful, and the resulting train door concepts are highly promising. For the composite door leave, the technology seems a promising candidate for upcoming projects if the target cost can be confirmed in the future. However, specific developments would still be required, to strengthen preliminary outputs such as thermal or acoustic attenuation requirements. For the aluminium door leaves, the technology and proposed material are already offering a solution for future doors in the short-term. Regarding the additive manufacturing, the technology is still at an early stage of development (i.e. size and cost competitiveness) but could become a longer-term candidate. |
Metallic door using a new aluminium
alloy made by ASAS
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