Ligthweigth (Talgo) high speed rodal frame. Composites in high responsability rail components

Abstract

Nowadays, the railway sector demands new lighter designs in the structural components of rolling stock that compensate for its increase due to the incorporation of new technologies, to improve passenger comfort and experience, as well as to face new environmental challenges (reduction emissions, energy consumption, increased capacity, etc.). With this objective, Talgo introduces a frame in high-performance composite material (CFRP) in its rolling elements (wheels) for high-speed trains, traditionally made of metal (steel), which allows weight saving of over 45%. However, the introduction of new materials is subject to overcoming certain challenges: compliance with fire requirements, adaptation of existing regulations, ballast impact behavior, direct cost increase, etc. This project consists of different phases: a) design, in accordance with the requirements demanded by current standards, b) manufacture of prototypes, c) process of characterization and verification of properties of non-standard materials, d) testing of component validation equivalent to what is required of a conventional frame (static resistance and fatigue test up to 10 million cycles in accordance with existing regulations), and, finally, e) track tests.