INTRODUCTION TO COMPOSITES MATERIALS FRP AND ITS USES IN INDIAN RAILWAYS'

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INTRODUCTION TO COMPOSITES MATERIALS (FRP) AND
ITS USES IN INDIAN RAILWAYS.

• ARVIND LAL
• Chief Instructor (Met)
• IRIMEE, Jamalpur.
• E-mail arvindlal65_at_ yahoo.co.in

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INTRODUCTION

• COMPOSITE MATERIALS.
• COMPOSITES, THE WONDER MATERIALS
• WITH LIGHT
  WEIGHT,
• HIGH
  STRENGTH TO WEIGHT RATIO,
• 
  HIGH STIFFNESS AND MORE CORROSION RESISTANCE
• HAVE COME IN A LONG
  WAY BY REPLACING THE CONVENTIONAL MATERIALS
  LIKE WOODS METALS ETC
• COMPOSITES MATERIALS ARE DERIVED BY
  COMBING OF TWO OR MORE OF MATERIALS WITH THE
  INTENT OF ACHIEVING SUPERIOR PROPERTIES/
  PERFORMANCE COMPARED TO EACH INDIVIDUAL
  MATERIALS.
• EXAMPLES- BONES, WOOD, MUSCLE FRP,
  CERMETS ETC.
• FRP- (FIBER GASS REINFORCED PLASTICS ) - IS A
  LARGE FAMILY OF COMPOSITE MATERIALS.
• ONE OF THE CONSTITUENT MATERIALS IS
  CALLED MATRIX WHILE THE OTHER IS CALLED
  REINFORCEMENT.

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CONVENTIONAL MATERIALS .

METALS AND ALLOYS. (A)
ORGANIC POLYMERS. (B)
CERAMICS AND GLASSES. (C)
BC FRP( FIBER-REINFORCED PLASTICS. AB-
MRP( METAL- REINFORCED PLASTICS. AC-
CERMETS
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FRP-FEW FACTS.

• IN FRP F FIBRE. (G-GLASS.)
• R- REINFORCEMENT.
• P- POLYMER ( PLASTICS) BEHAVES
  LIKE MATRIX.
• FIBRE- ANY POLYMER, METAL OR CERAMIC THAT HAS
  BEEN DRAWN INTO LONG AND THIN FILAMENT IS
  TERMED AS FIBRE. SOME OF THE FIBRES USED AS
  REINFORCEMENTS ARE - GLASS FIBRES, CARBON FIBRES
  ARAMID FIBRES
• GLASS FIBRE-GLASS FIBRES ARE THE MOST COMMON OF
  ALL REINFORCING FIBRES FOR POLYMER MATRIX
  COMPOSITES. THE PRICIPLE ADVATAGES OF GLASS
  FIBRES ARE THE LOW COST AND HIGH STREGTH.
• FORMS OF GLASS FIBRE.
• CHOPPED-STRAND MAT AND CONTIUOUS-MAT.
• FIBRE GLASS ROVING.
• WOVEN ROVING. 4. SURFACE MAT.

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MATRIX (RESIN) MAY BE - POLYMERIC MATRICES-
THERMOSETS- POLYESTER, PHENOLICS, EPOXY,
SILICONES. THERMOPLASTIC-
PS,PE,PC,NYLON-6,6 PEEK ETC. METAL MATRICES-
AL, Ni AND Ti POLYESTERS ARE WIDELY
USED BECAUSE OF THERE LOW COST. Phenolic resins-
high temperature resistance is required. Epoxy
resins impart good mechanical properties. Silicon
resins-excellent thermal elecrrical
properties.

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GLASS FIBERS- Glass fibers are the most common
of all reinforcing fibers for polymer matrix
composites. The principal advantages of glass
fibers are the low cost and high strength. TYPES
OF GLASS FIBERS their nominal
formula- E-glass - Calcium aluminoboroslicate. E
(Electrical)- 15 Al2O3, 17 CaO, 5MgO,
8B2O3 S-glass - Magnesium aluminosilicate. S
(HIGH-STRENGTH) --- 25 Al2O3 , 10 MgO C- glass -
Sodalime borosilicate. C (CHEMICAL) - 4
Al2O3,13CaO , 3 MgO, 8Na2O, 5 B2O3.

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Properties of E-glass S-glass fibers.
Propertied units E-glass
S-glass Density, g/cm3 2.54
2.49 Tensile strength, MPa 3448
4585 Elastic modules, GPa 72.4
85.5 Range of diameter Um
3.20 8-13 Coefficient of thermal
Expansion 10-6/0C 5.0
2.9
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Over 90 of the glass fibers made are E grade.
The more expensive S grade is used for the
highest strength, and the C grade for chemical
resistance. The composition of the glass that is
most commonly drawn into fibres is contained as
(composition, wt ) SiO2- 52-56, CaO-16-25,
Al2O3 12-16, B2O3 8-13, 4MgO.
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SELECTION OF RAW MATERIALS (FRP)
1.GLASS FIBRE . 2.RESINS. ISOPHTHLATE POLYESTER
RESINS IS6746/72. EXCEPTIONALLY GOOD
CHEMICAL RESISTANT TOWARDS MINIRAL ORGAIC
ACIDS. 3.STABILIZERS-TO GIVE RESIN A REASONABLE
SHELF LIFE. 4. CATALYSTS AND ACCELERATORS-TO
CONVERT RESIN TO A HARD AND INFUSIBLE SOLID
WITHIN A SHORT TIME TO MAKE MOULDING
POSSIBILITY. A. FOR COLD CURING- CATALYST-
MEKP ACCELERATOR-COBALT
NAPHTHENATE. B. HOT CURING- CATALYST-MEKP.
ACCELERATOR- DMA(DIMETHYL ANILINE)
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SELECTION OF RAW MATERIALS (FRP)
5. COLOURING MATERIAL FILLERS
IORGANIC PIGMENTS. 6. MOULD RELEASE AGENT - PVA
IN WATER. HARD WAX SUCH AS CARNAUBA. ARE
USED ON POLISHED METAL MOULDS.
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FIBRE REIFORCED COMPOSITES.(FIBROUS COMPOSITES)
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PARTICLE REINFORCED COMPOSITES (PARTICULATE
COMPOSOTES)
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LAMINATES COMPOSITES.
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ARRAGEMENT OF FIBRE
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ARRAGEMET OF GLASS FIBRE.
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ARRAGEMET OF FIBRE
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ADVANTAGE OF C.M.(FRP) OVER CONVENTIONAL
MATERIALS-
1. EXCELLENT CORROSION RESISTANCE. 2. LONG LIFE
OFFERS EXCELLENT FATIGUE, IMPACT , ENVIRONMENTAL
RESISTANCE AND REDUCED MAINTENANCE. 3. LESS NOISY
WHILE IN OPERATION PROVIDE LOWER VIBRATION
TRANSMISSION THAN METALS. 4. IMPROVED APPERANCE
WITH SMOOTH SURFACES DECORATIVES.
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ADVANTAGES (CONT)
5. WIDE PERFORMANCE RANGE.(BY PROPER SELECTING
FIBRES AND MATRICES) 6. LOW MANUFACTURING
COST. 7. SUPERIOR STYLING. 8. HIGH TENSILE
STRENGTH (4 to 6 times greater than steel
Al.) 9. MORE FATIGUE LIFE.( UPTO 60 OF UTS). 10.
HIGH STRENGTH TO WEIGHT RATIO.( 30 TO 45 LIGHTER
THAN AL. 11. ELIMINATE JOINTS INTEGRATED DESIG
COMPARED TO CONVENTIONAL METALLIC PARTS. 12.
LESS CHANCE OF THEFT.
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FUNCTION OF MATRIX PHASE.

• IT BINDS THE FIBRES TOGETHER BY VIRTUE OF
  ADHESIVE FORCE.
• IT ACTS AS A MEDIUM BY WHICH VIRTUE AN
  EXTERNALLY APPLIED LOAD IS TRANSMITTED AND
  DISTRIBUTED TO THE DISPERSED PHASE.
• IT PTROTEST THE INDIVIDUAL FIBRES FRON
  CHEMICAL REACTION WITH ENVIRONMENT AND FROM THE
  SURFACE DAMAGE DUE TO MECH.ABRACTION.
• IT KEEPS THE REINFORCING FIBRES IN THE PROPER
  POSITIO AND ORENTATION SO THAT THEY CAN CARRY THE
  INTENDED LOADS.
• IT PTEVENTS THE PROPAGATION OF BRITTLE CRACKS
  BY ITS RELATIVE SOFTNESS AND PLASTICITY.

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THE ESSETIAL REQUIREMETS OF A GOOD MATRIX
MATERIALS ARE -

• IT SOULD BE DUCTILE.
• THE BONDIG STRENGTH BETWEEN THE MATRIX AND THE
  FIBRE MUST BE HIGH.
• IT SOULD BE MORE CORROSION RESISTANCE.
• IT SHOULD BE MORE ENVIRONMENTAL RESISTANCE.
• IT SHOULD DETERMINES THE OVERALL SERVICE
  TEMPERATURE LIMITATIONS.
• ( POLYMERS ARE LIMITATED TO SERVICE
  TEMPERATURES BELOW 300c)

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COMPOSITES IN RAILWAYS INDIAN SCENARIO

• C.M. HAVE ALREADY BEEN IDENTIFY AS A POTENTIAL
  MATERIAL FOR ITS APPLICATION IN THE INDIAN
  RAILWAYS BY THE CONCERTED EFFORTS OF RDSO.LKO
  ICF.CHENNAI.
• WHY NEEDS FOR IR ?
• 1. HIGHER TRAIN SPEED.
• 2. LOWER PRODUCTIO, OPERATION MAINTENANCE
  COST FOR CARRIAGES.
• 3. LOWER ENERGY CONSUMPTION.
• 4 MINIMUM ENVIRONMENTAL IMPACT.
• 5. LOWER NOISE LEVEL.
• 6. IMPROVED PASSENGER COMFORTS AESTHETICS.
• LESS TRACK WEAR THE ABILITY TO CARRY GREATER
  PAY LOADS.
• TO PROVIDE GREATER VERSATILITY IN TRAIN DESIGN
  AND OPTIMIZATION OF
• TRAIN PERFORMANCE.( LOWERING THE
  CENTRE OF GRAVITY TO ENHANCE
• STABILITY).

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COMPONENTS USED IN IR

• COMPONENTS OF COACHES ARE GENERALLY MADE OF
  FRP-COMPOSITE MATERIALS.
• WINDOW FRAMES SHUTTERS.
• WALL PROTECTOR IN TOILETS.
• TRAYS FOR BATTERY BOXES ( FOR AC NON AC
  COACH.)
• SNACKS TABLE.
• CHAIN COVER FOR JMP JACK.
• FRP AIR GRILL FOR AC COACH.( RAJDHANI)
• TOILET PAN FOR GUARAD VAN BRAKE.
• FRP- TOILET MODULES.
• FRP-COMMODE ADOPTER.
• AXLE BOX COVERS.
• LUGGAGE BIN.
• PANELS.

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COMPONENTS USED IN IR (CONTINUE).
FLOOR, CEILING ROOF PANELS. 14. MODULAR
INTERIOR PANEL DOORS. 15. DOUBLE DECK
FLOORING. 16. INTERNAL SIDE WALL PANELS. 17.
EXTERNAL STRUCTURAL SIDE PANELS. IN ADDITION ,
RDSO HAS IDENTIFIED A NUMBER OF PARTS FOR
REPLACEMENT WITH COMPOSITES I N THE NEAR FUTURE.
THESE INCIUDES. 1. COMPOSITE BRAKE- BLOCKS
BREAK- GEAR BUSHES. 2. FRP-GEAR CASE FOR
LOCOMOTIVES. 3. AXLE BOX COVERS (SMC) 4. BERTH
CHAIR BACKINGS.
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COMPONENTS USED IN IR (CONTINUE).
5. PANELING IN THE COACHES. 6. ROOF WATER
TAKS. 7. TOILET MODULES. 8. LAVATORY CHUTES. 9.
WINDOW GUIDES. 10. DOORS. ( MAIN ENTRANCE
, SLIDING DOOR FOR 1ST AC COMPARTMENT, INTER
COMMUNICATION DOOR IN AC CAOCHES, SLIDING DOORS
FOR EMU/DMU, SLIDING/ FLUSH DOORS FOR TOILETS,
VESTIBULE DOORS ETC.) 11. CAOPY END FOR EMU/DMU
COACHES. 12. TOILET CABINETS. 13. FOLDING
TABLES. 14. FUEL IJECTION PUMP COVER. 15. LUGGAGE
RACKS ETC.
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SOME NEW PROJECTS ORCOMPOSITES FOR RAILWAYS
CASE STUDY

• ADVANCED COMPOSITES MISSION OF TIFAC
• ( TECHNOLOGY INFORMATION, FORECASTIG ASSESSMENT
  COUNCIL) AN AUTONOMOUS ORGANIZATION UNDER DST
  (DEPARTMENT OF SCIENCE TECHNOLOGY GOVT OF INDIA
  AND DRDO WORKING WITH SOME OF PVT AGECIES ON
  THE DEVELOPMENT OF COMPOSITES FOR THEIR USES
  UNDER THE GUIDE LINE OF RDSO ICF
• THESE ARE-
• FRP GEAR CASE FOR RAILWAY LOCOMOTIVES.
• A.C.M OF TIFAC IN PARTNERSHIP WITH
• M/S PERMALI WALLACE Ltd, BHOPAL. RRL,BHOPAL
• WHY IT IS FELT TO REPLACE THESE BY FRP GEAR
  CASE.
• 1. THE HEAVY WEIGHT OF STEEL GEAR-CASE
  SOMETIMES CAUSES ITS DETACHMENT FROM THE TRACTION
  MOTOR DUE TO VIOLENT JERKS OR IMPACT OR DAMAGE BY
  STONE BALLAST WHICH IS VERY COMMON FOR
  LOCOMOTIVES.

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COMPOSITES FOR RAILWAYS CASE STUDY (CONTINUE)
2. LOSS OF EXPESIVE LUBRICATING MEDIUM BY
LEAKAGE.
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CASE STUDY (CONTINUE)
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CASE STUDY (CONTINUE)

• 60-FRP-GEAR-CASES HAVE ALREADY BEEN
  INDUCTED BY IR AGAINST DEVELOPMENT ORDER.
• EFFOORTS ARE CURRENTLY UNDERWAY TO DEVELOP
  FRP-GEAR CASES FOR NEW TYPE OF TRACTION MOTOR
  WITH CYLINDRICAL ROLLER BEARING.
• HITACHI MODEL FOR ELECTRIC LOCOMOTIVES.
• 2. FRP SLEEPERS FOR RAILWAY GIRDER BRIDGES.
• THE PROJECT WAS INSTITUTED AT RESEARCH
  DEVELOPMENT ESTABLISHMENT(ENGINEER) , PUNE IN
  ACTIVE COLLABORATION WITH RDSO.
• SUBJECTED TO FIELD TRILS AT 3-4 LOCATIONS EACH
  AT DIFFERENT RAILWAY ZONES.
• VIBRATION DAMPING. HIGH RESISTACE AGAINST
  STRENGTH AND WATER RESISTANCE.
• DYNAMIC PANEL TEST OF 8 LONG SLEEPERS IS
  CURRENTLY UDERGOING AT RDSO.
• THE FULL LENGTH FRP SLEEPERS DEVELOPED BY RTM
  PROCESS AS PER RDSO.

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CASE STUDY (CONTINUE)

• 3. ENERGY EFFICIENT FRP AXIAL FLOW FANS. OR
  1680 MM DIA FAN FOR RADIATOR COOLING FOR DIESEL
  LOCOMOTIVES
• THE PROJECT WAS LACHED IN PARTERSHIP WITH
• PARAG FANS COOLING SYSTEMS Ltd, DEWAS
  ACTIVE SUPPORTED BY IIT, MUMBAI.
• EFFICIENCY OF THE FAN HAS BEEN PROVED SUPERIOR
  TO THE CONVENTIONAL FANS WITH ALUMINIUM
  IMPELLERS.
• 4. JUTE-COIR COMPOSITES- AN ALTERNATIVE TO WOOD
  PRODUCTS.
• M/S DUROFLEX LIMITED BANGALORE.
• APPLICATION.
• PARTITIONING. ( 80 NATURAL FIBRES SUCH AS
  JUTE COIR WITH PHEOLIC RESIN)
• FALSE CEILING
• SURFACE PAELING
• FURNITURE ( SLEEPER BERTH BACHING IN IR
  COACHES.)

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CASE STUDY (CONTINUE)
5. DEVELOPMENT OF FRP-PULTRUDED PROFILES. M/S
SUCRO FILTERS Pvt Ltd PUNE TECHNOLOGY SUPPORT
FROM NCL, PUNE. APPLICATION IN RAILWAYS FOR
FRAME SECTIONS FOR DOOR WINDOWS LUGGAGE RACKS
STRIPS LADDERS RODS ETC.
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Conclusion.
NOW THE COMPOSITES HAVE BECOME A PART OF
OUR EVERYDAY LIFE. COMPOSITES IMPART AN
AESTHETIC APPEARANCE FOR THE RAILWAY COACHES.
NOW WITH THE INTRODUCTION OF LHB COACHES IN
THE INDIAN RAILWAYS IN THE NEAR FUTURE, THE USAGE
OF COMPOSITES IS EXPECTED TO GROW MORE AND MORE.
GLASS FIBRE IS MOST WIDELY USED
REINFORCEMENT.E-GLASS FIBRE HAS EXCELLENT
CORROSION AND ENVIROMENT RESISTANCE. CARBON
FIBRES SHOW NO EXPASION OR CONTRACTION ACROSS
WIDELY TEMPERATURE DIFFERECE, APPLICABLE TO
ELECTRONICS. SELECTION OF CORRECT RAW
MATERIALS RIGHT MANUFACTURING
TECHNIQUE.
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CONCLUSION.(CONT)
DISPOSAL OF USED COMPOSITE MATERIALS.
TESTING FACILITIES OF COMPOENT MATERIALS SOULD
BE AVAILABLE AT PU.
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THANKS .