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

2. The Milestones 400km/h + 300 – 360 km/h 515km/h record 250km/h 200km/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. Higher crack resistance.
Development of disc materials. UK
Higher crack resistance.
Lower wear resistance
Sensitive tribology
Cost x 2
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 % ,40 - 0,80
Phosphorus % ,040 max
Sulphur % 0,040 max
Chromium % ,80 - 1,20
Molybdenum % ,85 - 1,15
Vanadium % ,15 - 0,30
Nickel % ,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. Aluminium Brake Disc Advantages
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. Material Properties Comparison
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. Thermography of a SG iron and an Al MMC Brake Disc
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. Wear of Al MMC und SG Brake Discs
Aluminium Brake Disc
Wear of Al MMC und SG Brake Discs
Faiveley Transport Birkenhead Ltd

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

13. 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. Performance of Al MMC Brake Discs
Aluminium Brake Disc
Performance of Al MMC Brake Discs
Aluminium Brake Disc ICE Performance
Maximum Dissipated Energy MJ
Maximum Short Time Brake Power at vmax 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. High temperature friction material
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
Faiveley Transport Birkenhead Ltd

28. Research & Development
Ceramic Disc
Weight:- 60kg Weight:- 96kg
Energy Capacity: 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 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 years being tested today.
5 month pad life 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 brakes
TGV new trains
Overhaul TGV fleet Start
Japan Not known
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 = Euro.
Total saving/ fleet/20 years = 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