(23/05/2022) 
By using carbon fibre reinforced polymer composites (CFRP), the rolling assembly mass can be reduced by 50%, thus improving the energy consumption of the train and passenger capacity.

Current running gear frames are constructed using welded steel plates. Both the geometry of those frames and the welding properties do constrain the possibility of weight improvement in the running gear, which is the second heaviest structural component of the train, and the first one in terms of structural resistance requirements.

Thus, the substitution of steel with new generation composites can result in strong weight reductions with no impact for the rest of operating requirements.

Validation

Talgo has finished the full-scale validation of structural requirements according to the current standards, including both static and fatigue tests exceeding 10 million of cycles. The technology used to manufacture the running gear with composites is additionally based on hand lay-up CFRP prepreg, making it fully compliant with the most stringent Fire-Smoke-Toxicity standards in rail transport.

Next development steps will see the composite-made rodal running on track, operating under real conditions for final acceptance. In parallel, the development will also be used to gain valuable knowledge for the implementation of a new set of standards regarding the acceptance process of new materials like CFRP in rail transport.

Modular solution

The new rolling assembly has been developed using the Avril platform as a reference, but it could be adapted to other Talgo vehicles, with positive impacts on capacity of the train, simplified assembly processes, a reduction on energy consumption and of track wear and tear. In addition, the experience could be exported for other primary structural components of the train.

The CFRP running gear frame was formally presented at the JEC fair, held in Paris on 3-5 May 2022. This project has been supported by the European Commission through the Shift2Rail initiative.