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

Faiveley Transport Birkenhead Ltd 1

Research & Development

MOTTO:- The Future Belongs To Those

Who See Beyond Today!


The Milestones

<145km/h

160km/h

200km/h

300 – 360 km/h

400km/h +

515km/h record

250km/h


Tread Braking


200km/h and above. Small wheel > high power/ swept area > steel discs.

Wheel mounted discs

Bogie mounted caliper


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


Material Development

Ceramic particle reinforced steel


Crazy Ideas


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.


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



Thermography of a SG iron and an Al MMC Brake Disc

SG Brake Disc Al MMC 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



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


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


Axle Mounted Disc

Analysis of Air flow and Heating and Cooling



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


Pad Material

Pad Material Development.

Partnership with innovative Lining Manufacturers.

Pad Construction



Temperature variations



Thermal stress

Low speed effect High speed effect

Hard lining Material


Pad Material

Pad Conformability

0

200

400

600

CarConventional

RailConformable

Rail

MODULUS COMPARISON -


Pad Material

High Temperature, Soft Underlayer Pad. In conjunction with Ferodo

3204 underlayer

High temperature friction material


Pad Material

Improving Conformability for VHST NT Sinter pad construction for use on steel discs.


Why lighter discs?



CERAMICS - THE FUTURE.



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



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.



Solution?

Fibre Reinforced Ceramic Discs / Ceramic Pads

Carbon fibre reinforced Silicon carbide:-

• Tough

• Good thermal performance

• Good wear resistance



Research Route Ceramic coated steel.

1987

Monolithic ceramic 1988

Fibre re-inforced ceramic 1990 - 2003



Ceramic DiscWeight:- 60kg Weight:- 96kg

Energy Capacity:- 30-50 MJ Energy Capacity:- >50 MJ



Weight 75kg



Ceramic and low loss steel disc



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.



Stable Friction .



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



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



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



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



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.



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



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



A Predicted Financial Effect on the ICE Fleet



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



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.



Next Steps In Technology 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



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



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


SAB WABCO UK

Documents

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