new materials for the railway infrastructure
DESCRIPTION
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE. The problem of current collection. JSC RAILWAY RESEARCH INSTITUTE. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection. WIRES : contact wires ; suspension cable. CURREN COLLECTION INSERTS : MATERIAL: - PowerPoint PPT PresentationTRANSCRIPT
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of current collection
1
JSC RAILWAY RESEARCH INSTITUTE
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
2
WIRES:- contact wires;
- suspension cable
CURREN COLLECTION INSERTS: MATERIAL:
Carbon; Carbon-copperDESIGN:
Simple; CompoundSHAPE:
Rectangular; Aerodynamic
OVERHEAD LINE SUSPENSION
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
Tightening of operating conditions for high-speed trafficCurrent collection for high-speed railway transport is characterised by a simultaneous increase in:• TENSION STRESS OF OVERHEAD CATENARY WIRES INCREASES
2–3-FOLD;wave propagation speed ~ √N/m (N = tension force, m = weight per unit length); wave speed must exceed train speed
• 2. SPEEDS INCREASE BY A FACTOR OF 2–2.5• • 3. CURRENT VALUE GROWS 1.5-2 TIMES• 4. ROLLING STOCK POWER IS PLANNED TO RISE TO 20 MW• 5. CURRENT AT THE CURRENT COLLECTOR: UP TO 4 kA FOR
DIRECT CURRENT, OVER 1 kA FOR ALTERNATING CURRENT
3
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
CURRENT COLLECTION FOR HIGH-SPEED RAIL TRANSPORTPROBLEMS:1. A SHARP INCREASE IN WEAR AND DAMAGE RATES;2. INCREASED IMPORTANCE OF LOCAL WEAR (UP TO 1.5 KM OF CONTACT WIRE MUST BE REPLACED OWING TO INCREASED WEAR OF A FEW METRES);
3. LOW TEMPERATURE CREEP OF CONTACT WIRES AND SUSPENSION CABLES.
• CAUSES OF THE UNSOLVED PROBLEM:• REGULATORY FRAMEWORK IS INSUFFICIENT OR NONEXISTENT;• NO SYSTEMATIC STUDIES AND TESTS OF MATERIALS USED IN THE COLLECTOR
ASSEMBLY ARE AVAILABLE;• MATERIALS FOR HIGH-CURRENT SLIDING ELECTRICAL CONTACTS OF HIGH-
SPEED RAIL TRANSPORT ARE NOT AVAILABLE4
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
CONTACT WIRES
Material Composition, % of alloying metals
Strength, MPa
Elongation, %
Resistivity, µΩ·m
Standards and regul
МF-120 Copper ≥ 357,7 ≥ 4 ≤0,0177 GOST 2584Cu-OF Copper ≥ 360 3 - 8 ≤0,01777 EN50149CuAg0,10 0,08-0.12 Ag ≥ 350 3 – 10 ≤0,01777 EN50149БрМг0,25Ф 0,2-0,3 Mg ≥ 401,8 ≥ 4 ≤0,0220 GOST2584CuMg0,2 0,1-0,3 Mg ≥ 430 3 – 10 ≤o,0240 EN50149CuMg0,5 0,4-0,7 Mg ≥ 490 3 – 10 ≤0,02778 EN50149CuCd0,7 0,5-0,8 Cd ≥ 430 2 - 7 ≤0,02005 EN50149БрЦр0,5Ф 0,4-0,6 Zr ≥ 421,4 ≥ 4 ≤0,0200 GOST2584CuSn0,2 0,15-0,55 Sn ≥ 420 ≥ 4 ≤0,02395 EN50149Бр0,15Ф 0,12-0,2 Sn ≥ 411,6 2 - 8 ≤0,0210 5
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
6
Wires: possible solutionsAlloying:
Improvement:mechanical and thermo-mechanical properties
Decline:Resistivity
New technologies:Severe plastic deformation (SPD):
Equal channel angular extrusion (ECAE);Conform process;
Simultaneous drawing of two metalsImprovement:
mechanical and thermo-mechanical propertiesNo decline in resistivity
Alloying + SPD:Lower alloying level;
Improvement:mechanical and thermo-mechanical properties
No declinein resistivity
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
7
WIRES: SPD SchemesECAE ECAE in parallel channels Conform process
0 50 100 150 200 250 300 350 400 4500
20
40
60
80
100
120
140
ИПД
Обычный контактный провод
Copper wire hardness vs. temperatureof one-hour-long annealling
Har
dnes
s (H
B)
Temperature (°C)
Conform-process:continuous technology
Improve the mechanical and thermo-mechanical properties
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
8
Material Strength, MPa
Elongation, % Resistivity, μΩ·m Softening point, °С
Cu-0,2Sn > 420 2 -8 <0,02395 330 EN 50149Cu-0,2Sn > 450 6 <0,02062 370 ConformСu-OF > 360 2 - 8 <0,0177 230 EN 50149Cu > 400 5 <0,0177 270 Conform
Properties of wires: conform - process
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
9
• Reconstructing areas of local wearwithout taking the wire down
Reconstruction: deposited layer
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
10
Properties of current collecting inserts produced by Morgan Carbon
Material grade
Material Permissible linear current density, A/mm
Resistivity, μΩ·m
Density, g/cm³
Flexural strength, MPa
Hardness, HS
In motion
Standing
CY3TA Coke 6 1 38 1.7 30 85CY280 Coke and graphite 6 1 38 1.6 35 75MY7A CY3TA, bronze
impregnated10 2 10 2.4 75 90
MY7A2 CY280, bronze impregnated
14 2.3 5 2.5 85 95
MY7D CY3TA, bronze impregnated
14 2.3 5 2,7 90 92
MY258 Modified MY7D 16 2,3 3 2,9 90 92
MY258A2 MY7A2 with additional bronze impregnation
18 2.7 <2 2.7 75 85
MY258P impregnation and crimping 20 5 <1 3.2 85 80MY259 CY280, bronze
impregnated16 2,5 3 2,8 90 90
MY131 Lightweight MY258P 10 2 8 2.2 80 105
The problem of current collectionCurrent collecting inserts
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
11
• CURRENT COLLECTING INSERTS:• Materials development and possible solutions
0 2 4 6 8 10 12 140
5
10
15
20
25
30
1
Current density, A/mm
Thermodynamic brunch
Bifurcation point
Dissipative structures
СНИЖЕНИUSING SELF-ASSEMBLY BEHAVIOUR OF SURFACE STRUCTURES, INCLUDING NANOSTRUCTURES, UNDER FRICTION: WEAR RATE IS REDUCED SEVERAL
FOLD
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collectionCURRENT COLLECTING INSERTS
_______ ____ _____________ _____ ______ ______ __ __ _ _ _________, ______ __ __ ___________ __ ____.
0
100
200
300
400
500
600
700
800
900
0 20 40 60 80 100 120 140 íÓÍ, Ä
àÌÚÂ
ÌÒË‚
ÌÓÒ
Ú̧ Ë
Á̇̄
Ë‚‡Ì
˽, Ï
„/̃‡Ò ÅÂÁ ͇ڇÎËÁ‡ÚÓ¾‡
ä‡Ú‡ÎËÁ‡ÚÓ¾ - 3%ä‡Ú‡ÎËÁ‡ÚÓ¾‡ - 6%ä‡Ú‡ÎËÁ‡ÚÓ¾‡ - 9%
Catalyst applicationWear resistance increase
Aerodynamic shape of currentcollection inserts.
Wear resistance increase (30-70 %)
Current, A
Without catalyst
With catalyst 3%
With catalyst 6%
With catalyst 9%
12JSC “VNIIZhT”
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
13
Traditional shape
• CURRENT COLLECTING INSERTS:• Materials and shape. Aerodynamic modelling
Temperature distribution Heat flux distribution
Alternative shape
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTUREThe problem of head current collection
14
• Research programme
1. Studies to investigate wear rate dependence on current density, sliding speed and contact force for various current collecting inserts and contact wires;
2. Studies of wear surfaces3. Studies and tests of copper-based wires manufactured using different technologies to investigate low-temperature creep and determine their electrical, mechanical and thermal characteristics;4. Developing a technology for reconstructing areas of local contact wire wear without taking the wires down;5. Developing standards: – for contact wires; – for current collecting inserts; – for fixtures
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
15
• THANK YOU !
• Mobile phone: +79161476190
• Business e-mail : [email protected]
• Home e-mail : [email protected]