Aluminium has let people move at breakneck speed, across the ocean, fly in the sky, and even explore space. From bikes and cars to spaceships, we see an increased use of Aluminium in various modes of travel. As transportation accounts for one of the largest pie of Aluminium consumption, rail-based transport systems are not far behind. The use of Aluminium in rail transport began almost immediately after the emergence of the mass production of Aluminium. Since its origins during the Industrial Revolution at the beginning of the 19th century, the evolution of trains as a mode of transport has been making steady progress, adding speed and incorporating technology.
The push towards lighter and more efficient rail coaches has led to a significant change where steel has been replaced by Aluminium over time. Since first discovering that it could be used for rail-based transportation in the 1930s and its subsequent incorporation following field tests in a single specimen train and later many light metal trains, Aluminium has made its presence felt. However, the development of entire car shells has been recent and is increasing fast. Its lightweight properties, high strength, and durability put Aluminium ahead of other metals in rail-based transport, especially high-speed trains. The availability of aluminium alloys has given the manufacturing of low-weight transportation systems using trains a boost, reducing environmental impact and offering a high-quality exterior finish.
Less weight, more speed
Among materials used in high-speed
trains, Aluminium offers a balanced performance, with its characteristics of
being lightweight, good corrosion resistance, good formability, high specific
strength and relatively low cost. The density of aluminium alloy is only
one-third of steel, and when structural optimisation due to material
replacement is considered, the overall weight of rail car-body reduces
significantly using Aluminium. This study on Aluminium and putting it to use in
the manufacturing of trains began in the 1980s, leading to an increase in train
speeds. Its use can be widely seen in train cars that operate above 200km/h.
Railways in Germany, France, Italy, Japan and China have invested in using
Aluminium in their respective versions of a high-speed car-body for their
trains.
For instance, the vast expansion of
high-speed rail lines across the world has also given birth to a host of new
processes in manufacturing. Be it friction stir welding or laser welding coming
to the development and application of aluminium alloys; they have both changed
the workings of high-speed train systems over the last 25 years. Recognised as
a continuous contributor to energy conservation and climate change, the
aluminium alloys can also be increasingly seen across the entire rail
transportation sector, including rail-based urban mass transit systems like
metros. Since its success in high-speed trains, the industry has realised that
lightweight materials mean faster acceleration and a lower running cost for
rail operators. Combined with reduced wear and tear on cars and rails, lower
maintenance costs in the long-term have led to the adoption of Aluminium
witnessing a rise.
After being extensively used in
freight and goods trains, the use of Aluminium in passenger cars has opened the
doors for manufacturers to reduce a third of the weight compared to steel cars.
In suburban transit rail systems with many halt stations, significant savings
can be achieved as less energy is needed for acceleration and braking with
aluminium cars, which are also easier to manufacture and are made up of fewer
parts. In the area of high-speed rail systems, the use of Aluminium has led to
travel at speeds of 360 km/h and more, while the new technology being developed
promises speeds exceeding 600 km/h. Designers of high-speed trains prefer
Aluminium also because it offers an aerodynamic shape with a minimal number of
protruding parts, which is hugely beneficial in the train moving faster.
Increasing use of Aluminium in High-speed trains
Article by Mr. Deepak Mathur, Sr. Vice President, Global Marketing and
Sales
