Rail Coach Factory-Kapurthala Armacell products for train applications

Transcription

Armacell products for train applications
Development of durable train floor system compliant
with the new EN 45545 FST standard
Stefan Reuterlöv
Rail Coach Factory-Kapurthala
12/2014
© Armacell Enterprise GmbH & Co. KG
1. 
2. 
3. 
4. 
Armacell introduction
ArmaFORM PET core
Manufacturing of train floor panels
Testing of train floor panels
5.  Impact
6.  4-Point bending
7.  EN 45545 FST
8.  Rail SD
9.  Summing up and Conclusions
10. Questions
Development of
durable train floor
system compliant
with the new EN
45545 FST standard
3
Armacell – a reliable partner for the composite industry
Long Expertise
Armacell is one of the leading
manufacturers of Technical
Foams and Technical Insulation.
Founded in 2000 as a successor
to the former insulation division of
Armstrong World Industries.
Leading Innovation
Armacell was the first manufacturer
to succeed in qualifying PET foam
cores for industrial applications.
Reliable Partner
The strict quality control and
traceability has made Armacell
already a reliable partner in the
wind mill industry. Today more
than 20.000 blades are using
ArmaFORM PET!
Global Capacity
20 production plants
4 R&D centres
on 4 continents
4
Global manufacturing – 20 production plants in 14 countries
Spencer, USA
Oldham, UK
Thimister-Clermont, Belgium
(PET Headquarter)
Münster, Germany
Friesenhofen,
Germany
South Holland, USA
Mebane, USA
(PET Converting)
Souzhou,
China
Atlanta, USA
Panyu, China
Bangkok,
Thailand
Conover, USA
Damman, KSA
Sao Paolo, Brazil
Begur, Spain
Sroda Slaska, Poland
Melbourne,
Australia
Pune, India
5
ArmaFORM PET - strong in many areas!
Structural PET foam core material
transportation (rail & road)
wind energy
body • floor • roof • cabs
in trains, buses, trucks
rotor blades •
nacelles • spinners
marine
industrial & others
hulls • decks • cabin
interior • superstructures
containers • display panels •
lightweight construction
building & construction
facade and roof structures • bridge
construction • panel walling
The Sandwich Concept
In principle a sandwich consists of two skins or facings with a core material
in between. The skins take up normal stresses and give the structure a
hard-wearing surface. The core material absorbs the shear forces
generated by loads, distributing them over a larger area.
S-1
Sandwich – the definition
A composite is a combination of two materials (reinforcing elements,
fillers and matrix binder) differing in form and constitution. The
constituent materials retain their characteristics, that is they do not
dissolve or merge into another although they act as in concert.
A sandwich consists of three main parts. Two thin, stiff, and strong
faces are separated by a thick, light, and weaker core. The faces are
bonded to the core by an adhesive to obtain load transfer between the
components
Foam
Core
Honeycomb
Balsa
Skins
Laminates
Solids skins
The Sandwich Concept
Compared to single skin laminates, the
sandwich concept offers substantial
improvements in both flexural rigidity and
flexural strength. By doubling the
thickness of the core, the improvements
are even greater yet the weight increase
is negligible.
S-2
9
ArmaFORM PET foam cores– huge development potential
1940
Long-grain
Balsa used
in the
Mosquito
aircraft.
1960
End-grain
Balsa used
in the first
GRP
yachts.
1970
PVC foam
used for
GRP boats:
MSV
Viksten.
1980
SAN foam
introduced
as the new
foam core
for marine.
1990
PVC foam
used in first
volume
blades and
trains.
2000
2007: PET grade
introduced to wind
energy.
2010: AC grade
2012: FR and GR
grade
2013: full light
weight range of 60
kg/m³
10
ArmaFORM PET – the production process
ArmaFORM PET/E
(extruded)
ArmaFORM PET/W
(welded)
Extrusion direction
High quality and consistency
Constant raw material
inspection using enhanced
tools such as DSC
(Differential Scanning
Calorimeter) and Intrinsic
Viscosity.
100% Inline Density
Inspection on extruded
boards. The information
is automatically feed back
into the process creating
very low density variation
and excellent quality control.
Inspection of compression,
shear, tensile and flexion
on welded boards.
Full traceability to each raw
material and extruder
settings through imprinted
block number and barcode.
Unique Barcode per board !
inline
density
Comparison with original
approved material. Visual
inspection of the material
and packaging. Every board
is digitalized! Sample storage
of min. 24 months.
control
board thickness
optical inspection
12
ArmaFORM PET - product family
PET/W AC *
PET/W FR *
PET/W GR *
Light weight, strong an durable! Fire retardant!
The ‘Green’!
Meets the requirements of modern
composite materials: light weight
and high mechanical strength in
conjunction with residual flexibility.
Is designed for the stringent fire,
smoke and toxicity requirements in
the transportation sector and
combines superior FST performance
with excellent mechanical properties
and outstanding fatigue resistance.
Is manufactured from millions of
beverage bottles, which are in
circulation all over the world.
A fully recyclable product truly from
‘cradle-to-cradle’.
» 80 – 200 kg/m3
» 60 - 150 kg/m3
» 60 - 200 kg/m3
• 
• 
• 
• 
M1/F1 (NF F16-101)
S4/SR2/ST2 (DIN 5510-2)
FMVSS 302
UL94
Tailor-made: with scrim - grid scored - grooved - double contoured - perforated
* In extruded version (PET/E) available: size and thickness to be discussed.
13
Outstanding product properties!
Whether shear strength, compression strength or even the shear elongation at break.
ArmaFORM PET already meets all values of PET materials, currently on the market.
All the characteristics of ArmaFORM PET foams at a glance:
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
Excellent damage tolerance
Outstanding fatigue resistance (high threshold > 60%)
Excellent long-term thermal stability
Limited density variation (< 5%)
High processing temperature of 150°C (short-term curing temperature up to 180°C)
Very good thermal insulation properties
Closed cell: limited water & resin absorption, no corrosion and no degradation over time
Excellent mechanical properties
Thermo formable (3D-shape)
Easy processing (with most types of resin and lamination processes and no toxic out-gassing)
Good screw retention
Environmentally friendly (100% recyclable)
Best-in-class fire properties (M1/F1; DIN5510, EN 45545-2)
DNV and GL certified
Fatigue Testing
Fatigue is primarily important
for the edgewise gravity
induced bending.
Tested on sandwich
specimens
4-PB is preferable to 3-PB for
sandwich.
Modified ASTM C-393 set-up
Fatigue results are influenced
by
Load ratio
Frequency
R-value
ArmaFORM PET AC Foams
Fatigue testing AC 80
AC 80 Display a very high fatigue
threshold level of 60%. Red line
indicate static strength of the
Sandwich beams
Fatigue testing of sandwich core
materials
KTH report C2009-15
After being subjected to 3.6
million cycles beam F1 was
stopped and tested statically
again. Stiffness was intact
but strenght had actually
increased.
Comparision ArmaFORM AC grade vs. PVC core
For PVC 60 the fatigue threshold
limit is approx. 35-40%.
For AC 100 the fatigue threshold
limit is >60%
Useful shear strength:
PVC80 1.15 MPa * 40%
AC100 0.9 MPa * 60%
0.46 MPa
0.56 MPa
i.e. The PET core outperform PVC core if
fatigue strength is considerd.
Comparision ArmaFORM AC grade vs. PVC core
Temperature stability
§ 
ArmaFORM PET exhibits a glass transition temperature (Tg) close to 75°C, and melting of the
crystals at about 240° - 250°C (melting point Tm)
§ 
Crystallization in ArmaFORM PET foams produces a crystalline structure that will act as a static,
non-movable system until melting begins in the crystalline phase.
§ 
This allows a wide range of processing temperatures for PET foams. While a temperature of e.g.
140°C allows a process time of days, a temperature of 180°C allows a short process cycles of a
couple of hours with full vacuum.
§ 
PVC cores do not exhibit crystalline structure, their technical performance data changes
dramatically above the Tg (Tg for PVC core is 84-85 °C), typically mechanical properties will
deteriorate with increasing temperatures. Cross linked PVC will show a better performance than
linear PVC; but is still inferior to PET and it cannot recover once it has been heated above this
critical temperature.
§ 
Standard PVC core can not be processed above 85-90 °C
High temperature PVC core can be processed up to 130 °C
§ 
Higher curing temperature is translated into
Shorter cycle times- increased productivity
Better mechanical properties in the laminate and peel strength
Properties as function of temperature for AC grade
The stiffness and strength properties for AC
grade is very stable within the normal
operating range for W.E. application.
Property reduction at elevated temperature is
significantly lower than for PVC core.
Armacell –train floor project
Floor panels to be evaluated
The aim of the project is to find a composite sandwich floor panel
solution being at least as good as the honeycomb cored solution being
used today and still meeting the new EU fire norm EN 45545-2.
To evaluate this 6 different panels with 2 resin systems and 4 different
core material will be tested.
•  Fire retarded epoxy
•  Phenolic
• 
• 
• 
• 
Nomex Honeycomb, 56 kg/m3
End-grain balsa, 155 kg/m3
ArmaFORM AC 80, 80 kg/m3
ArmaFORM AC 100, 100kg/m3
Floor panels to be evaluated
Panel
Weight (kg)
Panel
Thickness (mm)
BFG 2903 With Nomex HC 15 mm
8,3
17,9
Phenolic
Vaccum bagged
BFG 2904 PET AC 80 15 mm
7,8
18,9
Phenolic
Vaccum bagged
BFG 2905 Balsa 15 mm
9,6
19,5
Phenolic
Vaccum bagged
BFG 2908 Nomex HC 15 mm
9,4
18,5
Epoxy
Vaccum bagged
BFG 2906 PET AC 80 - 15 mm
8,9
19,2
Epoxy
Vaccum bagged
BFG 2907 PET AC 100 - 15 mm
8,8
19,3
Epoxy
Vaccum bagged
Core type & thickness
PANEL TYPE
Phenolic skins 2
mm either side
Epoxy skins 2
mm either side
Resin Process
The epoxy panels were heavier and thicker than the corresponding phenolic ones
Lightest of all panels was the PET foam cored one with 80 kg/m3 with phenolic resin
Heaviest was the balsa (+25 %) with phenolic unsurprisingly.
The epoxy panels were on average 0.5 mm thicker and 1 kg/m2 heavier.
PET cored panels are always lighter than the Nomex honeycomb cored panels in
spite of the higher density of the PET foam core.
Floor panel testing program
As a first step the mechanical properties will be evaluated for the
different configurations.
TESTING PROGRAM
TESTING
4 Point bending
SCOPE
STD
RESPONSIBILIT
Samples to be tested
Y
Status
Static undamged bending stength
ASTM C 393
Armacell
2
done
Impact test
Establish drop height and weight to
achieve a barely visible damage
Inhouse
Armacell
1
done
4 Point bending
after impact
damage
Static damaged bending stength
ASTM C 393
Armacell
2
done
4 Point bending
after impact
damage
Fatigue mode -- damaged bending
stength
ASTM C 393
Armacell
2
wk 49-04 (2014)
Compression
Compression strength & modulus.
ASTM C 365
BFG
Spike or
indentation
hardness
Check point load, compression
As per defined
procedure
Armacell
done
1
need to source
equiment first
Static 4 –point bending test according to the ASTM C-393 method was
performed to establish the strength of the core material in the different
configurations..
Sample
BFG 2903
BFG 2904
BFG 2905
BFG 2906
BFG 2907
BFG 2908
Load at break ref.
(N)
1310
1400
1560
1210
4000
3780
1170
1150
1610
1590
2280
2060
Shear Load at strength, average break ref.
original normalised (N)
(MPa)
N/kg
Core
1355 Nomex HC 0,75
163,25
1385 PET AC80 0,77
178,71
3890 Balsa 2,16
405,21
1160 PET AC80 0,64
130,93
1600 PET AC100 0,89
181,82
2170 Nomex HC 1,21
230,85
Static 4 –point bending test according to the ASTM C-393 method was
performed to establish the strength of the core material in the different
configurations..
Sample
BFG 2903
BFG 2904
BFG 2905
BFG 2906
BFG 2907
BFG 2908
Load at break ref.
(N)
1310
1400
1560
1210
4000
3780
1170
1150
1610
1590
2280
2060
Shear Load at strength, average break ref.
original normalised (N)
(MPa)
N/kg
Core
1355 Nomex HC 0,75
163,25
1385 PET AC80 0,77
178,71
3890 Balsa 2,16
405,21
1160 PET AC80 0,64
130,93
1600 PET AC100 0,89
181,82
2170 Nomex HC 1,21
230,85
Big difference in strength depending on resin for the HC core
Impact testing set up. Picture 1 and 2, impactor of 2 kg with guiding jig.
Two impact areas.
IMPACT AREAS
Impact energy 30 J
Barely visable damage on
AC 100 panel
Free falling weight
Fully supported BC
Beam 2903 (honeycomb) after impact and 4PB,
Impact location on the top surface of the
sandwich marked , note the permanent
deformation and damage on the skin. Side
picture show typical buckling damage to the
HC core cell walls under the impact location.
Beam 2904 (80 kg/m3 PET foam) after impact
and 4-PB,
Impact location on the top surface of the
sandwich marked, note damage on the skin but
no permanent deformation. Side picture show
no visible damages under the impact area.
Beam 2905 (end-grain balsa), impact location
on the top surface of the sandwich marked,
note the significant indentation and
delamination around the impact area.
and 4-PB, impact location on the sandwich the
top surface not marked but can be seen as a
whitening in the skin due to matrix crazing, no
permanent deformation
and 4-PB,, impact location on the sandwich the
top surface marked and can be seen as a
whitening in the skin, but less than on 2906
due to matrix crazing, no permanent
deformation
Beam 2908 (honeycomb) after impact and 4PB,, impact location on the top surface of the
sandwich marked and can be seen as a
whitening in the skin due to matrix crazing.
Further whitening can be seen transversely
where the beam has collapsed at the impact
location and at the support during 4-PB. Side
picture show typical buckling damage to the
HC core and the permanent deformation.
Simply supported load case
All beams failed in core shear in this load case
so any 4-PB test was not possible
Beams 2905 (end-grain balsa) and 2907 (100
kg/m3 PET foam) after impact with simply
supported boundary conditions.
Both failed in shear but with very different
permanent damage. 2905 have skin
delamination over the whole width making
repair difficult while 2906 and 2907 have very
little skin damage that could be repaired by
injecting resin.
After impact was performed on the beams of different configuration they
were tested in same way as the undamaged ones and the results were
compared
Sample
BFG 2903
BFG 2904
BFG 2905
BFG 2906
BFG 2907
BFG 2908
Load at break after Load at break after Residual impact (N)
Core
break after impact (N) impact (N) strenght % Drop
892
860
876
64,6%
35,4% Nomex HC 729
769
749
54,1%
45,9% PET AC80 3810
2950
3380
86,9%
13,1% Balsa 747
846
797
68,7%
31,3% PET AC80 1290
1280
1285
80,3%
19,7% PET AC100 1080
1100
1090
50,2%
49,8% Nomex HC Shear strength, impacted (MPa)
0,49
0,42
1,88
0,44
0,71
0,61
Only two of the cores had a drop of less than 20% in failure load, the
balsa (but with big scatter) and the AC100. These same two were the
same that had the highest shear stress at failure.
31
EN 45545 - the new European
fire safety standard
Ø  Goal:
•  The objectives of this standard is to minimize the risk
of a fire starting and fire spreading within railway
vehicles and their effects on passenger and staff and
to offer, as a consequence, the best level of protection
against the occurrence of a fire on board.
Ø  Harmonization of fire standards:
•  All national Standards will be replaced by EN 45545
•  All trains will be build according new European law
•  All systems can be sold European wide
Ø  Fire standard EN 45545 takes in consideration:
•  Flame spread
•  Ignitability
•  Heat release
•  Smoke density
•  Smoke toxicity
EN 45545 - the new European fire safety
standard
32
Part 1 General
Part 2 Requirements for fire behaviour of
materials and components
Part 3 Fire resistance requirements for fire
barriers
Part 4 Fire safety requirements for rolling
stock design
Part 5 Fire safety requirements for electrical
equipment
Part 6 Fire control and management systems
Part 7 Fire safety requirements for flammable
liquid and flammable gas installations
EN 45545-1
4 Design categories
A
Automatic train having with no emergency
trained staff on board
D
Double decked vehicles
S
Sleeping and couchette vehicles
N
All other vehicles (standard vehicles)
33
EN 45545-1
34
4 Operational categories
1
Vehicles that are not designed or equipped to run on underground sections,
tunnels and/or elevated structures and which may be stopped with minimum
delay, after which immediate side evacuation to a place of ultimate safety is
possible.
2
Vehicles that are designed or equipped to run on underground sections, tunnels
and/or elevated structures, with side evacuation available and where there are
stations or emergency stations that offer a place of ultimate safety to
passengers, reachable within a short running time.
3
and/or elevated structures, with side evacuation available and where there are
stations or emergency stations that offer a place of ultimate safety to
passengers, reachable within a long running time.
4
and/or elevated structures, without side evacuation available and where there
are stations or emergency stations that offer a place of ultimate safety to
passengers, reachable within a short running time.
35
EN 45545-2
3 Hazard levels
Design N : Category Standard
vehicles Operation Category 1 HL1 2 HL2 3 4 Severity
degree
A : Automatic
vehicles having
no emergency
trained staff on
board HL1 D : Double
decked
vehicle S : Sleeping and
couchette cars HL1 HL2 HL2 HL2 HL2 HL2 HL2 HL2 HL3 HL3 HL3 HL3 HL3 Ø  HL1 = Tramway
Ø  HL2 = TGV, TER, RER, Subway ..... 90% of the market
Ø  HL3 = Subway, Tube, Sleeping and couchette cars
EN 45545 FST testing
In a second step the FST properties was evaluated for the best solution. Both
resin systems have already been evaluated for single skins structures.
EN 45545-2:2013 is now replacing the CEN/TS 45545-2:2009 and shall be given
offical status in september 2013. Older national standard shall be revoked not
later than march 2016.
Flame spread
Ignitability
Rate of heat release
Smoke
Toxicity
Tests for EN 45545-2: 2013 requirements set R1: Vertical surfaces etc.
ISO 5658-2: 2006 Spread of flame
ISO 5660-1 Heat release rate (Cone calorimeter method)
EN ISO 5659-2: 2006 50kW/m-2 Smoke Generation and Toxic Gas
Flame spread
Ignitability
Rate of heat release
Smoke
Toxicity
Tests for EN 45545-2: 2013 requirements set R10: Floors etc.
EN ISO 5659-2: 2006 50kW/m-2 Smoke Generation and Toxic Gas
ISO 9239-1 Flame spread
Also ISO 5660-1 Heat release rate (Cone calorimeter method)
Summary of test results EN 45545-2: 2013 requirements set R10:
Panels with Phenolic skin both AC 80 and Nomex HC are HL3 (highest
possible i.e. All applications possible including metro/subway trains)
SAMPLE 2982/83/84 Phenolic matrix with PET core (AC 80 core) Standards Parametre Results Final classification ISO 9239-1 CHF (kW/m²) 10,9 HL3 MAHRE ((kW/
ISO 5660-1 0 HL3 m²) Ds max 4 HL3 EN ISO 5659-2 ITCG 0 HL3 SAMPLE 2979/80/81 Phenolic matrix with nomex core Final
Standards Parametre Results classification ISO 9239-1 CHF (kW/m²) 10,9 HL3 MAHRE ((kW/
ISO 5660-1 2 HL3 m²) Ds max 58 HL3 EN ISO 5659-2 ITCG 0 HL3 © Armacell Enterprise GmbH & Co. KG
PET is even better than
nomex honeycomb in
smoke and toxicity
Summary of test results EN 45545-2: 2013 requirements set R10:
Panels with epoxy skin and AC 80 are HL1 (lowest classi.e. Only applications
possible in above ground lines)
SAMPLE Epoxy matrix with PET core (AC 80 core)
Standards
Parametre
Results
Final classification
ISO 9239-1
CHF (kW/
m²)
10,9
HL3
ISO 5660-1
MAHRE
((kW/m²)
38
HL3
EN ISO 5659-2
Ds max
ITCG
331
0,025
HL1
HL3
Summary of test results EN 45545-2: 2013 requirements set R1, R7 and R 17:
Panels with phenolic skin and GR 80 are HL2
(good results, HL2 cover 85-90% of all rolling stock).
Still waiting for the test data and certificate.
No more testing is planned at the moment!
42
Many opportunities for composite sandwich with
ArmaFORM PET core in trains!
ARMACELL –TRAIN FLOOR PROJECT
CONCLUSION AND SUMMING UP!
The project was carried out to prove that PET foam core could be used in
composite sandwich train systems having enough impact resilience as well
as meeting the new European FST standard EN 45545-2:2013.
The testing showed that the core does not have to be self-extingushing/
flame retardant so FR grade is normally not needed. Instead both AC and
GR grade pass the test with great results.
The fire response is normaly decided by the surface material and resin
system used. The core will only be important for the smoke and toxicity
levels as well as for the heat release to a lesser degree.
This means that PVC, PUR and balsa is more or less out of the picture.
Main competition will be PEI, PES and PMI cores but they are all more
expensive (significantly) so other PET is the main threat!
October 13-16, 2014
Orange County Convention Center | Orlando, FL
ARMAFLEX® Rail SD
THE FUTURE TODAY
45
Armaflex Rail SD - Key benefits
•  First flexible closed cell insulation that meets
hazard level 2 according to EN 45545
•  High-tech insulation with built-in fire protection
for railway vehicles
•  With Microban® antimicrobial product
protection
•  Achieves next-generation level of
performance at this stage
•  Superior fire and density of smoke properties
•  Avoids mold growth and the potential for
health problems resulting from water
condensate
•  Minimum energy loss through low thermal
conductivity
Armaflex Rail SD - Technical Data
• 
• 
• 
• 
• 
• 
• 
• 
• 
46
Highly-flexible, closed-cell insulation foam with improved fire retardant
properties, low smoke generation and in-built Microban® antimicrobial
protection for railway vehicles.
Elastomeric foam based rubber; manufactured with Armaprene® patented
technology; US patent no. 8,163,811, EU patent pending.
Colour Blue
Armaflex Rail SD is not designed for transparent insulation applications
(exposed to sun light) and is not UV stable.
Max. service temperature + 110 °C
Min. service temperature -50 °C
Thermal Conductivity @ 0 °C λ ≤ 0,040 W/(m · K)
Water vapour diffusion resistance µ ≥ 5.000
Reaction to fire Hazard Level HL2, R1 Classified acc. to EN 45545
… when do you
start using
ArmaFORM PET &
RailSD?
Questions?

Rail Coach Factory-Kapurthala Armacell products for train applications

Transcription

Similar documents

AC SAR - RWTH Aachen University

pamphlet - Muddy Paws

Northern News - Don`t Fret Pet

Gina Fresquez Reports on Olsen`s Grain Pet Event Hello, On April

event Partners aCtIvItIes

Don`t Forget! - Pet Food Warehouse

“Cats, dogs, lizards.. Oh my!” October 21, 2015

Coppertree - My

Show guide 2016 - the American Pet Products Association

NOZTONOZ Sof-Krate Indoor/Outdoor Pet Home