Magnesium Alloys in Train Transportation in China ERIC NYBERG 1, PROF. JIAN PENG 2, DR. NEALE NEELAMEGGHAM 3 1 Pacific Northwest National Laboratory, 2 Chongqing University, 3 Ind, LLC Presented at the TMS Annual Meeting and Exhibition; Nashville, TN; February 14-18, 2016 May 11, 2017 1
Introduction History Applications Recent Developments Conclusions May 11, 2017 2
INTRODUCTION The concept of using magnesium (Mg) alloys in trains is at least 75 years old. In 1940, Dow Chemical had advertisements discussing the use of magnesium for trains, following their successful production of Dowmetal truck bodies in 1935. May 11, 2017 3
The History of Rail Traffic in China Zhang Tianyou From the 1890-1905, nearly all railways in China were planned, financed, and operated by foreign powers pursuant to concessions from the Qing government. In 1906, to help local economies develop and retain earnings from railways, the Qing government granted the provinces the right to organize their own railway construction ventures. The Father of China s Railway was engineer, "Zhang Tianyou. By 1911, there were around 6,000 miles of rails in China. However, the Railway Protest Movement was held against unfair compensation leading to the end of regional ownership, and contributed to the end of the Qing Dynasty. May 11, 2017 4
Railroad Station Grand Openings and Modern Engineering Designs
Foreign construction of railway in China was common at the start of the 20th Century. The Russian built, South Manchurian Railway in NE China, connecting the China Eastern Railway to Port Arthur, ca. 1900.
Railroad Network in China (1961)
Global improvement in train speeds 600 Development of the High Speed Train 500 400 Speed (km/hr) 300 200 100 0 1900 1920 1940 1960 1980 2000 2020 2040 Year
High speed trains in China The earliest example of high(er)-speed commercial train service in China was the Asia Express, a luxury passenger, steam powered train that operated in Japanese-controlled Manchuria from 1934 to 1943. Ran on the Southern Manchura Railway and had a top test speed of 130 km/h (81 mph). It was faster than the fastest trains in Japan at the time. Today, high-speed rail (HSR) in China refers to any railway in China with commercial train service at the speed of 200 km/h (124 mph) or higher as internationally recognized. China has the world's longest HSR network with over 19,000 km (12,000 mi) of track in service as of January 2016, which is more than the rest of the world's high-speed rail tracks combined, and a network length of 30,000 km (19,000 mi) is planned for 2020. May 11, 2017 9
21 st Century High Speed Trains The Speed Up Campaign was a consorted effort to improve efficiency of rail transport (the trains and the rail). Acquisition of Foreign Technology Step 1: Procure foreign built Step 2: Assemble in country foreign kits Step 3: Manufacture and assemble in China Re-Design and Improve Foreign Designs (Step 4) Japanese: E2 Shinkansen The CRH380A, the first indigenous high-speed train of the CRH series, entered service on the Shanghai-Hangzhou High-Speed Railway on October 26, 2010 [486 km/h (302 mph)]. Chinese CRH2 Chinese CRH380 May 11, 2017 10
RECENT DEVELOPMENTS In Dec. 2011, the China Daily reported that the CRH380BL, the latest Chinese bullet-train, reached a world record-breaking speed of 500 km/hr (311 mph). The newest train includes six passenger carriages, and the front end is tapered to a fine sword-like point. The power of this train is 22,800 kilowatts It is constructed of lightweight plastic, Mg alloy and reinforced with carbon fiber. Detailed application of Mg unattainable. May 11, 2017 11
Recent Mg Applications & Partnerships: In May 2015 Baosteel of China announced its entry into magnesium alloy market by a joint venture with BAIC Motor and Hua Sheng Rong Magnesium Industry with a main goal of providing components for transportation areas in automobile and rail transit. Examples of their Mg rail transit products include luggage racks and conduit/casing for electrical cables. Currently, Baosteel has 8 magnesium components in production for train applications 1 extrusion Photo Courtesy of Baosteel and 7 castings used in seats
Recent Mg Developments: Rails and Wire For rails, China has been moving on building 20,000km of new high speed train track that features CuMg contact wires. Here only a small quantity of magnesium is used for making oxygen free copper with lower electrical resistance.
APPLICATIONS: A Chinese patent shows the use of a Mg alloy in a composite structure in high-speed trains and other vehicles. This Mg Vent is over-molded with polymer, creating a strong, impact resistant, light weight Mg alloy composite panel. Magnesium Travels Light!!
FUTURE OPPORTUNITIES: 2015 FAA/SAE approval for use of magnesium in airplane seats. The same manufacturers will be looking for other industries to apply their light weight seats. High speed trains are an obvious opportunity. The reduction in weight of 33% compared to the Al alloy seat, significant advantages. Furthermore, the use of Mg alloys will provide reduced vibration and noise in the high speed trains - mainly by the superior damping capacity of magnesium alloys.
FUTURE OPPORTUNITIES: Magnetic Levitating Train - Shanghai Pudong Airport
LATEST APPLICATIONS Very few Mg applications have yet to find their way into the rail cars. Same situation as automobiles; relative cost is high, few risks. New developments in aerospace allow use of flame resistant Mg alloys in the construction of seats for passenger airplanes, opening significant weight-saving opportunities Automotive applications will help the railway industry as well. May 11, 2017 17
CONCLUSIONS The 20 th Century saw an explosion of railway expansion across China Foreign investment high Late 1990 s and early 21 st Century increasing use of High Speed Trains Based on foreign technology Use of Magnesium remains limited Flame resistant alloys open up opportunities Potential for increased Mg applications exist, especially with expanded use in the aerospace industry May 11, 2017 18