Mat4Rail Newsletter 04 | November 2019
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Novel EN-45545 compliant composites validated in Mat4Rail project
The composites are based on novel epoxy, benzoxazine and hybrid chemistry resins with improved fire resistance developed in the framework of the project
The composites are based on novel epoxy, benzoxazine and hybrid chemistry resins with improved fire resistance developed in the framework of the project
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One of the main objectives of Mat4Rail’s materials work stream was to develop novel resins that are suitable for the manufacturing of fibre reinforced composites (FRPs) for railway applications fulfilling all the railway environment requirements regarding Fire, Smoke and Toxicity (FST), mechanical performance and cost effective manufacturing.
Due to the intrinsic flammability of most of the polymers, it is mandatory to improve first the flame retardant behaviour of the polymeric matrix before composites with good fire retardant performance can be manufactured. Since the resin constitutes between 40 and 60% of the composite volume, it will contribute proportionally to the flame retardant, thermal and mechanical properties of the final composite material. The novel resin formulations developed in the framework of Mat4Rail project are aimed to be used in fibre reinforced polymer composites in the railway industry as an innovative replacement of metallic structural parts of the carbody shell. In this sense, one of the main achievements of Mat4Rail project is the development of three novel resin formulations based on three different chemistries (epoxy, benzoxazine and a novel hybrid chemistry) with improved fire resistance. Combining these three novel resins with three different types of fibre reinforcements (carbon, glass and basalt) and after an intense prevalidation phase with the testing of more than 24 different types of composites, six composites where manufactured in the validation phase and fully characterised regarding FST performance and mechanical properties by Mat4Rail partners CIDETEC, AIMPLAS, UNI-HB, HUNTSMAN, CENTEXBEL, COEXPAIR and RISE. |
Alaitz Rekondo (CIDETEC) presenting the six composite samples at the final joint event with the Shift2Rail Joint Undertaking projects PIVOT, Mat4Rail, RUN2Rail and FAIR Stations
Samples of the carbon, glass and basalt fibres
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Specifications of the carbon, glass and basalt fibres used in Mat4Rail
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Composition of the 6 composites developed and validated in Mat4Rail project
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Five composites achieved HL2 classification for R7, R8 and R17 carbody external applications according to the EN45545-2 standard. The mechanical characterisation of the composites also demonstrated the great potential of these materials for their application in carbody shell parts.
Three of these composites were manufactured by Dynamic Fluid Compression Moulding (DFCM) process which is an improved compression moulding process which allows the manufacturing of high-quality parts (similar to High Pressure RTM) efficiently and robust. The process allows the use of higher fibre volume content as it is processable with RTM. |
Schematic representation of the Dynamic Fluid Compression Moulding (DFCM) process
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