Page 6 - Research and innovation In advanced materials with application to the railway sector

These technologies are applicable, for example, in acrylonitrile butadiene styrene (ABS),
typically used in electrical equipment; in foams and resins for composite, pre-impregnated
or liquid-flow materials, both thermoplastics, mainly polypropylene, and thermosets
(epoxy, polyurethane, acrylic compounds, etc.).
Finally, the deepening of knowledge about the requirements and real conditions and the
practical interpretation of the standard can be highlighted. Also, the development of
simulation tools and techniques, which allow understanding the behaviour and optimizing
the solution in the materials development phases, and, in some cases, developing specific
protection solutions for each component.

ADVANCED MANUFACTURING

The impact of materials innovation in manufacturing processes is evident; and practically
incomprehensible. In a telegraphic way, the following can be highlighted:
The replacement of traditional methods by additive methods in all its variants:

 Energy sources (laser, electric arc, plasma, electron beam, etc.).
 Material supply (in the form of wire, powder projection or powder bed).
 Consolidation, as the process known as “Binder Jetting”.
The use of this type of additive manufacturing enables, on the other hand, a whole series of
topological optimization technologies, since they allow to put material where it is necessary
and avoid putting it in positions where it does not have a significant contribution, achieving
extremely optimized and lightweight designs.
The status of the introduction of composite materials in the sector has been commented on
in previous paragraphs, but given the link between consolidated material and its
manufacturing process, inherent in these materials, it seems necessary to also mention
some innovations in manufacturing processes and consolidation of these materials:

 Automated out-of-autoclave manufacturing processes (thermoplastics and
thermosets), curing in heated or self-heated moulds, or self-curing laminates, taking
advantage of the joule effect in the fibres themselves.
 Automated layering and consolidation in situ, assisted by laser in AFP and ATL
processes
 Additive processes by fused filament reinforced with continuous fibre.
 Welding and joining processes by ultrasound, electric resistance, or laser in parts
with thermoplastics

MAINTENANCE

Aspects related to maintenance are also impacted by innovation in materials. Such is the
case of the possibilities provided by digitization through, for example, the integration of
sensors, and technologies known as "Health monitoring", which allow online diagnosis of
the status of the most critical components through associated technologies: Internet of
Things (IoT), real-time data transmission and condition-based analysis. In this sense, the
development of new integration processes for these sensors is a fundamental way, including
wireless sensors based, for example, on passive NFC (Near field Communications) protocols
that do not require power, using technologies such as functional 3D printing.

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Position paper: Research and innovation in advanced materials with application to the railway sector
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