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R&d of new methods thermal spraying technology for applications on chassis groups of railway coaches

The aim of the project is research, development and utilization of a complex surface treating of exposed railway coaches components, by utilization of new method of technology of thermal spraying.

Rail means of transport and railay transport in general, are a strategic item in the economic development of the Czech Republic. Daily dispatch of 7,000 passenger trains and more than 1,900 freight trains with shipment volume amounting to two hundred and fifty thousand tons of cargo poses a challenge for technological innovations with significant economic impact. The railway transport systems are not able to compete with other modes of transport due to low flexibility and limited transport infrastructure. On the other hand, market indicators show that the freight rail transport in the Czech Republic compared to Europe is relatively cost-effective and efficient. Income from freight transport converted to a thousand km is higher than the World Bank considers to be optimal and even the utilization of freight trains in the Czech Republic is high and significantly exceeds the best European railway carrier. The limiting factor for the stable increase of competitiveness is the profitability and productivity of the actual operation of the transportation system. Generally speaking, the high volume of vehicles with a limited degree of reproduction and innovation in the Czech Republic create increasing pressures on streamlining the renewal process of substantial volumes of the operating potential of the railway rolling stock. One method of achieving significant progress with an impact on the abovementioned characteristics is the introduction of advanced technological procedures for the production and restoration of components that limit the durability, reliability and profitability of these means and contribute to improvement of economic indicators and the overall competitiveness of the industry. The proposed project addresses a specific increase in reliability and lifetime of the most stressed parts of undercarriage assemblies by application of new methods of thermal spraying technologies, with a direct impact on the above aspects determining the general global intentions. Surface wear of the functional areas of the utmost stressed parts is a common cause of loss of device functionality and the reason for a repair or complete replacement of components that are often very expensive. In the process of rotational movements with high static and extreme dynamic loads, such parts are being gradually worn, and are usually closely monitored and controlled. Typical examples are the axles of driving or driven undercarriage assemblies, bearing suspensions, gears, pivots, hydraulic systems, shafts with friction bearing or generally all friction and sealing surfaces of the shafts. Wear of these components causes high losses to the operator, since the wear can result in the following collision situations, often with significant negative economic effect: • unscheduled equipment downtimes (decreased equipment reliability) • increased costs of the new undercarriage parts • increased costs of repairs and maintenance of complex operational units • risk of accident • environmental accidents • casualties Achieving the desired properties of the surface layers of such stressed components is currently being addressed by already sophisticated coating technologies of functional surfaces and components by applying the thermal spraying technology. The thermal spraying technology (hereinafter referred to as TST) enables creation of a surface layer with a thickness of the order of tenths of a millimeter on any metal substrate without the base material being thermally affected. The issue of wear resistance can be dealt with by simple spraying of a layer in those places where the friction and wear actually occurs. At present, the technology commonly utilizes coatings that can achieve a layer with a hardness of 1200 - 1500 HV. The possibility to create layers of different materials, not only metal but also ceramic or even a combination of metal-ceramic materials, or "cermet" creates room for a comprehensive solution to repair heavily damaged parts as imposed by the technological requirements of new surfaces with predicted properties. The subject of the design of the entire project is the need to improve surface properties of the utmost stressed undercarriage components, and thus prolong their service life, especially if they operate in extreme operating conditions, and constitute an assembly with significant functional importance. The way in which the project is designed focuses on the development and applied research of complex finishes of these components, brand new technology HVOF – eGun a APS – Sinplex (cascade plasma). Both methods represent a technological state of the art in the field of application methods of thermal spraying technology, while the two technologies appear on the Czech market for the very first time. The task of the proposed project is to optimize the parameters of the technology with regard to the required material and technical characteristics of different types of coatings, to verify the output characteristics.
Acronym: 
PLASMARAIL
Project ID: 
12 220
Start date: 
01-03-2018
Project Duration: 
46months
Project costs: 
1 540 000.00€
Technological Area: 
Iron and Steel, Steelworks
Market Area: 
Motor Vehicles, Transportation Equipment and Parts

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.