February 2007
Angel Trains has begun in-service trials of the first rolling stock to be refurbished using carbon fibre composites in place of traditional welded steel repairs.
Using technology developed by systems and engineering technology company Frazer-Nash Consultancy and sister company DML Composites, repair methods have been developed for cost-effective rectification of common types of structural corrosion in mid-life rolling stock.
These composite repair methods restore the vehicle integrity by bonding high performance carbon fibre laminates in place to join together the corroded or damaged sections. The repairs are designed using comprehensive finite element analysis in order to closely replicate the original stiffness of the structure and thereby transfer load in a manner consistent with the original design intent.
By eliminating the need for damaged or corroded sections to be removed, significant savings in vehicle down time are generated, which has a very positive effect on both rolling stock availability and the planning of heavy maintenance activities. In some circumstances the repair procedures are even suitable for implementation within the depot environment, rather than at a heavy maintenance facility.
Steve Allen at Angel Trains commented:
“The transfer of composite repair technology from other industries is a huge step forward not only in the economics of rail vehicle repair, but also in the increase in availability from the significant downtime improvements.
“There is still much work to do in exploring all the suitable applications but all work to date is very positive”.
Dr Julian Austin, Group Leader at Frazer-Nash Consultancy added:
“There’s nothing particularly new about using composite technology for rectification of structural corrosion – it’s a tried and tested method with many years of experience behind it. Composite materials are used routinely in the oil and gas industry for safety critical on-load pipe repairs, and also within the Naval Marine sector for refurbishment of corroded deck structures and bulkheads where traditional welded repairs can often introduce more integrity problems than they solve.”
“Rail vehicles, particularly mid-life fleets, are a prime candidate for composite repairs, with a diverse range of potential applications including vehicle bodysides, floors, roofs and underframe structures.”
In-service trials are underway for Class 314 rolling stock, and will be complete early in 2007.
Notes to Editors
Frazer-Nash Consultancy has its roots firmly in Mechanical Engineering, providing systems and engineering technology expertise to its clients across a range of industries from defence, to rail and offshore.