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Faiveley Transport Birkenhead Ltd 1
Research & Development
MOTTO:- The Future Belongs To Those
Who See Beyond Today!
Faiveley Transport Birkenhead Ltd 2
The Milestones
<145km/h
160km/h
200km/h
300 – 360 km/h
400km/h +
515km/h record
250km/h
Faiveley Transport Birkenhead Ltd 4
200km/h and above. Small wheel > high power/ swept area > steel discs.
Wheel mounted discs
Bogie mounted caliper
Faiveley Transport Birkenhead Ltd 5
Development of disc materials.
Higher crack resistance.Lower wear resistance
Sensitive tribologyCost x 2
Steel (15CDV 04)
Grey Cast irons.
Good tribology.
Good conductivity.
Low distortion
Low cost
Compacted graphite.
High strength
Good tribology.
Good conductivity.
Low distortion
Low cost + 10%
UK
Europe
Spheroidal Graphite
High strength
Reasonable tribology.
Good conductivity.
High distortion
Low cost +10%
Carbon % 0,15 - 0,20
Silicon % 0,60 max
Manganese % 0,40 - 0,80 Phosphorus %
0,040 max Sulphur %
0,040 max Chromium %
0,80 - 1,20 Molybdenum % 0,85 - 1,15 Vanadium %
0,15 - 0,30 Nickel % 0,50 max
Faiveley Transport Birkenhead Ltd 8
Not so crazy ideas.
Aluminium Brake Disc Advantages
• High thermal conductivity and low Young‘s modulus.
• Therefore low tendency to thermal cracking.
• Low wear of pad and disc material.
• Light
• No squealing
• Low emission of odours as the friction contact remains cooler than with iron Brake Discs.
Faiveley Transport Birkenhead Ltd 9
Aluminium Brake Disc
Material Properties Comparison
Grey Cast Iron
GG D
GJL 250
Aluminium
DURALCAN
F3S20S
Comparison Factor
[Al / GG]
Density [kg/dm³]
Specific Heat 150°C [J/(kg*K)]
Heat Conductivity [W/(m*K)]
Heat Expansion (50 – 300 °C) [10-6K]
Tensile Strength Rm [MPa]
Modulus of Elasticity [GPa]
Hardness [HB]
Maximum Operating Temperature [°C]
Melting Temperature [°C]
7,20
460
47,5
12,3
200
103
197
450 (500)
1250
2,77
955,32
185,2 (T6)
21,1
165
98,6
75
350 (400)
700
0,385
2,1
3,9
1,7
0,83
0,96
0,38
0,78
0,56
Faiveley Transport Birkenhead Ltd 10
Aluminium Brake Disc
Thermography of a SG iron and an Al MMC Brake Disc
SG Brake Disc Al MMC Brake Disc
Faiveley Transport Birkenhead Ltd 11
Aluminium Brake Disc
Wear of Al MMC und SG Brake Discs
-1.50
-1.40
-1.30
-1.20
-1.10
-1.00
-0.90
-0.80
-0.70
-0.60
-0.50
-0.40
-0.30
-0.20
-0.10
0.00
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Meßstellen (mm Abstand vom Außendurchmesser)
Ver
sch
leiß
der
Bre
mss
chei
ben
dic
ken
in m
m
Al1
Al1
GGG-FP / Becorit 918
Laufleistung: 934369 km
Faiveley Transport Birkenhead Ltd 12
Aluminium Brake Disc
Pad Wear on Al MMC and SG Brake Discs
Belagverschleiß von Al- -Bremsscheiben im Vergleich zu Standard-Bremsscheibe ICE-Mittelwagen
0
2
4
6
8
10
12
14
16
18
20
22
24
26
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
Laufleistung der Bremsscheiben [Tkm]
Be
lag
ve
rsc
hle
iß [
mm
]
Al 1 / Flertex 664 HD
Al 2 / Flertex 664 HD
GGG / J urid 877
GGG / Becorit 918
Faiveley Transport Birkenhead Ltd 13
Axle Mounted Disc
Axle Mounted Disc Development
WKS
R z 200 R z 6,3R z 16A3
A1A1-A3
Aus gewuc hte t au f 16 gm .
3 Ku l is s ens te ine P o s .7 in
120░ Te ilung m o ntie rt
Anziehdreh-
moment
M A =36Nm
Grenz e des
Aus wuc htbe re ic hes
8
7
2
5
6
4
3
1
°193
H6
0,5
Rz
63
150 ▒0 ,5
( 75 )
R z 6,3
A2
°350
+1
°640
+1
12
Rz
16
Range of
balancing
area
,, )( R z 63
R z 63Grenze des
Auswucht-
bereiches
1,5
110+0 ,5
70
22+2
7
1
A
B
C
D
E
F
G
H
23456789101112
123456789101112
A
B
C
D
E
F
H
G
M a s s e o h n e
To le ra n z -
a n g a b e
n a c h
D IN IS O 2 7 6 8
m itte l H
Bergi sche
Stahl - I ndustri e
Remscheid
Ma s s s ta b We rk s to ff
B u c h -
s ta b e
k o m m t
x v o r Aenderung Tagk o m m t
x v o r
U rs p ru n g :
Z e ic h n u n g s -N r. :
K la s s ifi z ie ru n g s -N r.:
B la tt:
B la e tte r:
W e ite rg a b e s o w ie V e rv ie lfa e ltig u n g d ie s e r U n te rla g e , V e rw e rtu n g
u n d M itte ilu n g ih re s In h a lte s n ic h t g e s ta tte t, s o w e it n ic h t a u s -
d ru e c k lic h z u g e s ta n d e n . Z u w id e rh a n d lu n g e n v e rp fl ic h te n z u
S c h a d e n e rs a tz . A lle R e c h te fu e r d e n Fa ll d e r P a te n te rte ilu n g o d e r
G e b ra u c h s m u s te r-E in tra g u n g v o rb e h a lte n . (S c h u tz v e rm e rk D IN 3 4 )
Name
E rs e tz t d u rc h :
E rs a tz fu e r:
NameB u c h -
s ta b e Aenderung Tag Name
N o rm g e p ru e ft
G e p ru e ft
S tu e c k g e w ic h t
in k g
R o h te il-N r.:
M o d e ll-N r.:P a s s m a s s : A b m a s s :
B e n e n n u n g :
B e a rb e ite t
Datum
128335/ 128331
+0 ,0 2 9
0
H6
193
128336E11-Wellen b remssch eib e
WK 6 4 0 G-N
131640
10. 11 Rakows ki
1999
1:1
Faiveley Transport Birkenhead Ltd 15
Aluminium Brake Disc
Performance of Al MMC Brake Discs
Aluminium Brake Disc ICEPerformance
Maximum Dissipated Energy 13 MJ
Maximum Short Time Brake Power at vmax 365 kW
Maximum Continuous Brake Power at 400°C ~30 kW
Faiveley Transport Birkenhead Ltd 16
Pad Material
Pad Material Development.
Partnership with innovative Lining Manufacturers.
Pad Construction
Faiveley Transport Birkenhead Ltd 18
Research & Development
Thermal stress
Low speed effect High speed effect
Hard lining Material
Faiveley Transport Birkenhead Ltd 19
Pad Material
Pad Conformability
0
200
400
600
CarConventional
RailConformable
Rail
MODULUS COMPARISON -
Faiveley Transport Birkenhead Ltd 20
Pad Material
High Temperature, Soft Underlayer Pad. In conjunction with Ferodo
3204 underlayer
High temperature friction material
Faiveley Transport Birkenhead Ltd 21
Pad Material
Improving Conformability for VHST NT Sinter pad construction for use on steel discs.
Faiveley Transport Birkenhead Ltd 24
Research & Development
Componentweight/per bogie
Steel Fibre re-inforcedCeramic (today)
FRC(target)
Discs 840 kg 380kg 280 kgCalipers 480 kg 250 kg 160 kgActuators 240 kg 130 kg 130 kgTotals 1560 kg 760 kg 570 kg
THE PROBLEM
Faiveley Transport Birkenhead Ltd 25
Research & Development
Development Programme (High speed Trains)
Targets• 100 MJ/ axle (88 MJ on TGV)• 2 x 640 mm discs ( To replace 4 steel discs on TGV).• 10 year disc life • Economical pad life - 1 year. • 50% weight reduction, both unsprung and total.
Faiveley Transport Birkenhead Ltd 26
Research & Development
Solution?
Fibre Reinforced Ceramic Discs / Ceramic Pads
Carbon fibre reinforced Silicon carbide:-
• Tough
• Good thermal performance
• Good wear resistance
Faiveley Transport Birkenhead Ltd 27
Research & Development
Research Route Ceramic coated steel.
1987
Monolithic ceramic 1988
Fibre re-inforced ceramic 1990 - 2003
Faiveley Transport Birkenhead Ltd 28
Research & Development
Ceramic DiscWeight:- 60kg Weight:- 96kg
Energy Capacity:- 30-50 MJ Energy Capacity:- >50 MJ
Faiveley Transport Birkenhead Ltd 31
Research & Development
Friction Pair
Fibre reinforced ceramic disc / Ceramic pads
• >1200oC peak temperature, >800oC average • > 55 MJ capability at 1,3m/s2 from 370 km/h.• 0,27 coefficient of friction.
Faiveley Transport Birkenhead Ltd 33
Research & Development
Surrounding Temperature Distribution @ 52 MJ
Bogie Frame 35 deg C
Actuator 90 deg C
Brake gear 100 deg CPad holder 200 deg C
Disc 900 deg C
Ambient 35 deg C
Faiveley Transport Birkenhead Ltd 34
Research & Development
Results > 55 MJ capability.
>10 year disc life. - 20+ years being tested today.
5 month pad life. - 12 month life being tested today.
Potential for greater performance.
Target price within reach.
Life Cycle Cost looking attractive against sinter/ steel combination
Faiveley Transport Birkenhead Ltd 35
Research & Development
Cost of operating 1 Axle over 30 years.
Operating Costs
020000400006000080000
100000120000140000160000
£ /
30 y
ears Pad Replacement
Disc Replacement
Cost of Weight
Initial System Cost
Faiveley Transport Birkenhead Ltd 36
Research & Development
Initial cost of purchase if new actuation is required for ceramic.
First Costs
0
5000
10000
15000
20000
25000
Steel 2x2 disc CI/Tenmat 3dpa SGL 2dpa SGL 3dpa
£
OE Cost for Actuators
OE Cost for Calipers
OE Cost for Pads
OE Cost for Discs
Faiveley Transport Birkenhead Ltd 37
Research & Development
Effect on TGV fleet costs.
Euro 5342 / axle/30years.
18 axles/train.
450 train sets.
Saving at today’s state of the art = Euro 1,4 million/year.
Faiveley Transport Birkenhead Ltd 38
Research & Development
Bottom Line
Low weight of brake installation
Low rotating inertia
Compact installation• smaller wheels.• less brakes.
Brakes are much less of a restriction in vehicle design.
Potential for significantly reduced brake running costs
Faiveley Transport Birkenhead Ltd 39
Research & Development
Market Potential Project Date Volume
TGV proto ¾ - 2001 8 brakes
TGV new trains 2003 - 2004 1300
Overhaul TGV fleet Start 2004 - 2005 14000
Japan Not known 31 - 61 000
Faiveley Transport Birkenhead Ltd 40
Research & Development
A Predicted Financial Effect on the ICE Fleet
Faiveley Transport Birkenhead Ltd 41
Research & Development
ICE 1&2
Route Friction pairMaterials
Wear Rate cm3/kWh
HH-Stuttg Becorit/GGG 4dpa 3,019
HH-Stuttg Ceramic/Ceramic 4dpa 0,245
HH-Stuttg Ceramic/Ceramic 2dpa 0,85
Faiveley Transport Birkenhead Ltd 42
Research & Development
Financial Effect on total ICE 2 fleet
48 axles/ train.
40 train sets.
Saving / axle/ 20 years = 38 000 Euro.
Total saving/ fleet/20 years = 76 000 000 Euro.
Faiveley Transport Birkenhead Ltd 44
Research & Development
DISC DEVELOPMENTS
Fibre A rchitectureF ibre Type & C oating
2D w eave3D w eave
M atrix TypeC arbon precursor type(s)
P repreg m ethodPre-treatm ents
S ilicon isation m ethodT im e
Tem peratureA lloying
M ATER IAL IM PR O VEM EN TSBY
M IC R O STR U C TU R AL D ESIG N
Faiveley Transport Birkenhead Ltd 45
Research & Development
Pad Im provem ents
D evelop current com m ercia l sourceFedera l M ogu l new form ula tions
O ptim isa tion and pad chem istry tria ls
A lte rna tive com m ercia l sourcesH oneyw ell re fractory com position
N eed design to in te rface m ateria l w itha brake shoe for use
R e-vis it re fractory m ateria ls as asource o f a generic m aterial
D eve lop and optim ise fo r use asa brake pad, externa lly
Sources o f pad life im provem ent
Faiveley Transport Birkenhead Ltd 46
Research & Development
We have just begun.
We are here in 2000
This is the potentialof Ceramics
Industry is behind us - now.
We were down there in 1988
Here in 1997
4 year life
10 year life
2002
20 year life
2003-5
30 year life