NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
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NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of current collection 1 JSC RAILWAY RESEARCH INSTITUTE
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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 Presentation
Transcript of NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of current collection
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JSC RAILWAY RESEARCH INSTITUTE
NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE
The problem of head current collection
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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
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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
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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
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WIRES: SPD SchemesECAE ECAE in parallel channels Conform process
0 50 100 150 200 250 300 350 400 4500
20
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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
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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
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• Reconstructing areas of local wearwithout taking the wire down
Reconstruction: deposited layer
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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
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• CURRENT COLLECTING INSERTS:• Materials development and possible solutions
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10
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30
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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
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0 20 40 60 80 100 120 140 íÓÍ, Ä
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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
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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
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• 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
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• THANK YOU !
• Mobile phone: +79161476190
• Business e-mail : [email protected]
• Home e-mail : [email protected]
