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Research & Development

Research & Development. MOTTO:- The Future Belongs To Those Who See Beyond Today!. 400km/h +. The Milestones. 300 – 360 km/h. 515km/h record. 250km/h. 200km/h. 160km/h. <145km/h. Tread Braking. 200km/h and above. Small wheel > high power/ swept area > steel discs.

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Research & Development

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  1. Research & Development MOTTO:- The Future Belongs To Those Who See Beyond Today! Faiveley Transport Birkenhead Ltd

  2. 400km/h + • The Milestones 300 – 360 km/h 515km/h record 250km/h 200km/h 160km/h <145km/h Faiveley Transport Birkenhead Ltd

  3. Tread Braking 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 tribology • Cost x 2 UK Steel (15CDV 04) Compacted graphite. High strength Good tribology. Good conductivity. Low 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 Europe Spheroidal Graphite High strength Reasonable tribology. Good conductivity. High distortion Low cost +10% Grey Cast irons. Good tribology. Good conductivity. Low distortion Low cost Faiveley Transport Birkenhead Ltd

  6. Material Development Ceramic particle reinforced steel Faiveley Transport Birkenhead Ltd

  7. Crazy Ideas 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 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 Faiveley Transport Birkenhead Ltd

  12. Aluminium Brake Disc Pad Wear on Al MMC and SG Brake Discs Faiveley Transport Birkenhead Ltd

  13. Axle Mounted Disc Axle Mounted Disc Development WKS Faiveley Transport Birkenhead Ltd

  14. Axle Mounted Disc • Analysis of Air flow and Heating and Cooling 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

  17. Research & Development • Temperature variations 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 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

  22. Why lighter discs? Faiveley Transport Birkenhead Ltd

  23. Research & Development CERAMICS - THE FUTURE. Faiveley Transport Birkenhead Ltd

  24. Research & Development 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 Disc Weight:- 60kg Weight:- 96kg Energy Capacity:- 30-50 MJ Energy Capacity:- >50 MJ Faiveley Transport Birkenhead Ltd

  29. Research & Development • Weight 75kg Faiveley Transport Birkenhead Ltd

  30. Research & Development • Ceramic and low loss steel disc 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

  32. Research & Development • Stable Friction . Faiveley Transport Birkenhead Ltd

  33. Research & Development • Surrounding Temperature Distribution @ 52 MJ Actuator 90 deg C Brake gear 100 deg C Pad holder 200 deg C Disc 900 deg C Ambient 35 deg C Bogie Frame 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. Faiveley Transport Birkenhead Ltd

  36. Research & Development • Initial cost of purchase if new actuation is required for ceramic. 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 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

  43. Research & Development Next Steps In Technology Development Faiveley Transport Birkenhead Ltd

  44. Research & Development Faiveley Transport Birkenhead Ltd

  45. Research & Development Faiveley Transport Birkenhead Ltd

  46. Research & Development We have just begun. This is the potential of Ceramics 2003-5 2002 We are here in 2000 30 year life Here in 1997 20 year life 10 year life 4 year life Industry is behind us - now. We were down there in 1988 Faiveley Transport Birkenhead Ltd

  47. SAB WABCO UK Faiveley Transport Birkenhead Ltd

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