ALJOIN Crashworthy joints in aluminium rail vehicles. TRAVisions2016 EU Champions of Transport

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1 ALJOIN Crashworthy joints in aluminium rail vehicles TRAVisions2016 EU Champions of Transport

2 ALJOIN: Motivation In the UK, following the Ladbroke Grove rail accident in October 1999, where an aluminium rail vehicle was involved in a near head-on collision with a high speed train, a number of joints failed in a catastrophic manner from a phenomena know as weld unzipping. A public inquiry was carried out after the Ladbroke Grove accident and in the subsequent report, The Right Honourable Lord Cullen QC, stated the aluminium extrusions had fractured along the weld lines and that there was a lack of plastic deformation and that the structure appeared to have failed along the welds rather than deforming in a controlled manner [Rt Hon Lord Cullen: The Ladbroke Grove Rail Inquiry Part 1 Inquiry. HSE Books, 2001 ].

3 ALJOIN: Motivation Aluminium alloys are now in widespread use in Europe and elsewhere for rail vehicle construction from commuter to express trains. The main contributor to the success of aluminium alloys as structural materials in rail transport, is the development of closed cell aluminium extrusions that can easily be welded together to form lightweight rail vehicles with high inherent rigidity that could not be achieved with older designs. As rail transport is becoming more popular throughout Europe, there is an increased need to improve passenger safety by improving the crashworthiness of rail vehicles to minimise fatalities and injuries if an accident does occur. The strength, integrity and performance of aluminium welds in rail vehicles contribute greatly to the overall body shell strength and crashworthiness.

4 ALJOIN: The approach The ALJOIN project is the result of efforts by the rail industry, material suppliers, fabricators and research establishments to improve the crashworthiness of aluminium rail vehicles by addressing the following points: The use of alternatives to fusion welding; The use of improved grades of aluminium which are less susceptible to fusion weld weakening; The further development of analytical techniques to increase confidence in crashworthiness of rail vehicle structures, particularly those constructed of aluminium.

5 ALJOIN: Background Details: Project Acronym: ALJOIN FP: 5 Project Reference: G3RD-CT Total Cost: 2,177,806 EURO EU Contribution: 1,200,036 EURO Timescale: Project Coordinator: Dr. Donato Zangani Partners: D APPOLONIA S.P.A., Italy NEWRAIL The University of Newcastle, UK ALCAN TECHNOLOGY & MANAGEMENT AG, Switzerland BOMBARDIER TRANSPORTATION LTD, UK DANSTIR APS, Denmark THE WELDING INSTITUTE (TWI) LTD, UK

6 ALJOIN: Achievements Material Testing: Novel specimen in testing machine for assessing tearing failure in welded region

7 ALJOIN: Achievements Impact Testing: Testing facility to assess joint behaviour under highly dynamic loads

8 ALJOIN: Achievements Modelling: Finite Element Analysis model. Computer simulation of the collision of a rail vehicle. Model has been validated through data from real life collisions Trailing Car Intermediate Car 2 Intermediate Car 1 Lead car

9 ALJOIN: Impact on new standards ALJOIN has informed two new European standards: EN "Railway applications - Welding of railway vehicles and components" and EN 15227, Crashworthiness requirements for railway vehicle bodies. These two standards have been developed to ensure that the weld unzipping failure cannot re-occur in a rail crash (such as in the 1999 Ladbroke Grove rail crash, in which catastrophic failures of the rail vehicles resulted in loss of life and serious injury). The two standards were formally adopted throughout the EU in 2008, and are now mandatory for all aluminium rail vehicles used across Europe.

10 ALJOIN: Impact on the safety of railway Implementation of the recommendations from this project have enhanced the crashworthiness of new rail vehicles produced in the EU and consequently improved the safety of passengers using rail transport

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