"MODERN TRENDS OF FIRE PROTECTION IN ROLLING STOCK" FIRE PROTECTION OF FLEXIBLE METAL/RUBBER COMPONENTS INCLUDING ELEMENTS IN BOGIES PRESENTATION BY DR. DANA GREFEN page 1
Content 1. Flexible metal/rubber components conforming to EN 45545 Application examples Requirements Previous rubber-standard version versus requirements of EN 45545 2. Material development 3. Results of material and component tests 4. Summary page 2
Metal/rubber components conforming to EN 45545 sealings and profiles window profiles bellows anti-vibration elements page 3
Requirements of flexible metal/rubber components conforming to EN 45545 requirements test method reference parameter unit maximum or minimum HL1 HL2 HL3 R9 M1: flexible metal/rubber components EX9: air bags for pneumatic suspension EX10: parts of the drive EX11: tyres T03.02 ISO 5660-1: 25 kwm -2 MARHE kwm -2 maximum 90 90 60 T10.03 EN ISO 5659-2: 25 kwm -2 D s max. dimensionless T11.02 EN ISO 5659-2: 25 kwm -2 CIT G dimensionsless maximum - 600 300 maximum - 1,8 1,5 page 4
Previous rubber-standard version versus requirements of EN 45545 Optical smoke density according to EN ISO 5659-2 STANDARD-component NR-Elastomer 25 kwm -2, 10 min Hazard-Level - HL2 Hazard-Level - HL3 Time sec page 5
Content 1. Flexible metal/rubber components conforming to EN 45545 Application examples Requirements Previous rubber-standard version versus requirements of EN 45545 2. Material development 3. Results of material and component tests 4. Summary page 6
Project BATEGU - Fire Safety comparison of components of a fire retardant mixture (without required dynamicmechanical properties) and a natural rubber compound for use as anti-vibration element based on rubber and fillers fire protection NR-compound rubber 30 52 % fillers (carbon black and white) 40 % flame retardants (filler) 60 - % flame retardants (plasticizer) 5 - % fire protection properties + - anti-vibration properties - + CONFLICT!!! page 7
R&D targets fire protection in accordance with EN 45545 for flexible metal/rubber components, particularly for application in bogies, while maintaining the required functionality conversion of existing components to the current fire protection standard EN 45545 without any constructive changes of the previous components ensure emergency running properties abidance to international rules to protect human health and the environment (REACH, RoHS, Unife Railway Industry Substance List) page 8
BATEGU - Material development technical solution I BATEGU 9713: fire-protected material in a combination of material assembly of at least two elastomers in which one material ensures the mechanical properties (statically and dynamically) the second material provides the protective function in case of fire technical solution II BATEGU 9559: fire-protected material, which combines the static/dynamic properties and the fire protection in one material. page 9
Content 1. Flexible metal/rubber components conforming to EN 45545 Application examples Requirements Previous rubber-standard version versus requirements of EN 45545 2. Material development 3. Results of material and component tests 4. Summary page 10
Tests results EN 45545-tests Optical smoke density EN 5659-2 Hazard-Level - HL2 Time sec page 11
Test results of EN 45545-tests Requirement Test method Parameter Unit Max. or Min. HL1 HL2 HL3 Bategu 9713 Bategu 9559 R9 M1: flexible metal/rubber components EX9: Air bags for pneumatic suspension EX10: parts of the drive EX11: Tyres ISO 5660-1 EN ISO 5659-2 EN ISO 5659-2 MARHE kwm -2 Max. 90 90 60 HL 2/3 HL 2/3 D s max. dimensionless CIT G dimensionless Max. - 600 300 HL 2/3 HL 2/3 Max. - 1,8 1,5 HL 2/3 HL 2/3 hardness +/- 5 40 45 50 55 60 65 70 75 80 85 classification HL 2 HL 2 HL 2 HL 2 HL 2 HL 3 HL 3 HL 3 HL 3 HL 3! in the selection of suitable material for anti-vibration components continues to be: Spring deflection before shore hardness page 12
Laboratory test results BATEGU 9713 Dynamic testing test specimen: diameter x height: preload path in compressive direction: deformation amplitude in thrust direction: frequency: duration: cylindrical rubber-metal-buffer 34 mm x 25 mm 2 mm +/- 5 mm 6-10 Hz 10 mio cycles Test result: The test was ended positively after 10 million cycles. The material showed no damages (wear, cracks, etc.). page 13
Laboratory test results of BATEGU 9559 Service life - comparison page 14
Test result of BATEGU 9559 Service life - comparison Fatigue test NR 60 standard versus Bategu 9559 material 9559 NR 60 9559 NR 60 amplitude - thrust ± 4mm ± 4mm ± 6mm ± 6mm preload vertical 1mm 1mm 2mm 2mm cycles 1,80 Mio 1,75 Mio 1,10 Mio 0,95 Mio frequency 6 Hz 6 Hz 6 Hz 6 Hz damages no damage crack (5mm) no damage failure by depolymerization metal/rubber adhesion result X X page 15
Component test of BATEGU 9713 Static spring deflection F with load/ unload F with 18,3 mm load F with 36,6 mm load F with 55 mm load F with 36,6 mm unload F with 18,3 mm unload no dan dan dan dan dan max 358 860 3183 692 288 min 264 636 2353 512 213 BTG9713/NR 1 336 784 2675 645 270 NR-Standard 2 311 748 2768 602 250 art.no draw.no article : HIIA 1726 B : HS catalogue : Hollow Spring material : BTG 9713- material combination 60Sh / NR 60Sh Deflection in mm page 16
Component test of BATEGU 9713 Dynamic fatigue resistance test laboratory: test specimen: SZA-Prüfanstalt, Vienna Primary spring for ULF, Wiener Linien diameter x height: preload path in compressive direction: deformation amplitude in compressive direction: 250 mm x 220 mm 5 mm +/- 10 mm frequency: 1 Hz target: 1 million cycles, max. set after 1 mio cycles: 5 mm The test was ended positively after 1 million load cycles. The material showed no damage and a set of max. 3,5 mm. page 17
Component test of BATEGU 9713 Spring deflection after 1 mio load cycles specification / requirement free height 220 mm height under load 15,5 kn 190-198 mm after 1 mio load cycles BATEGU 9713 comparison standard natural rubber 196,15 mm 196,61 mm article no VFR 7566 draw. No BTG-1403-19001 article material Primary spring BTG 9713-/ NR Load in kn page 18
Component test of BATEGU 9559 Static spring deflection test specimen: material: F with load/ unload Hollow spring BATEGU 9559 to vers. NR-Standard F with 17,33 mm load F with 34,66 mm load F with 52 mm load F with 34,66 mm unload F with 17,33 mm unload dan dan dan dan dan Max. 117 239 862 186 90 Min. 87 177 638 138 66 NR-Standard 104 202 750 162 77 BATEGU 9559 109 200 677 148 70 Deflection in mm page 19
Component test of BATEGU 9559 Static setting test specimen: Hollow spring HIIA 1866-D diameter x height: 86 mm x 96 mm (M3 +/- 1) testing procedure: 4 weeks under permanent load of 2000 N temperature: 23 C test results: setting in % start conditions setting after 4 weeks H0 f1 f2 setting after 4 weeks [mm] [mm] [mm] [%] NR Standard 95,5 35,49 35,93 1,23 BATEGU 9559 96,3 36,15 36,58 1,19 Result BATEGU 9559: no significant difference compared to NR page 20
Component test of BATEGU 9559 Multi-axial dynamic fatigue test testing laboratory: SZA-Prüfanstalt, Vienna test specimen: Primary spring NR Primary spring BATEGU 9559 vertical strength: max. 80 kn horizontal deformation amplitude: +/- 10 mm frequency: 1 Hz materials: fire protected elastomer BATEGU 9559 versus standard NR (series) page 21
Component test of BATEGU 9559 Static spring deflection before and after 1 mio load cycles NR BATEGU 9559 Deflection in mm Deflection in mm Primary spring with three set cycles and one measurement cycle to 120 kn Result BATEGU 9559 : lower set compared to NR page 22
Component test of BATEGU 9559 Dynamic stiffness BTG 9559 NR Result BATEGU 9559: lower stiffness loss compared to NR page 23
Component test of NR - BATEGU 9559 Dynamic stiffness (excerpt) BATEGU 9559 247.00W NR Result BATEGU 9559: first visually visible damage at higher number of cycles compared to NR page 24
Component test of NR BATEGU 9559 Multi-axial dynamic fatigue test - Summary lower setting 247.00W less stiffness loss first visually visible damage at heigher number of loading cycles Cycles page 25
Summary Technology EN 45545-compliant elastomer materials developed especially for railway industry (BATEGU 9713 and 9559) are flame resistant, highly dynamic loaded, environement-fair, examined and confirmed maximum fire protection according to EN 45545 with optimal anti-vibration properties according to application and component type BATEGU-fire protection materials fulfill customers demands within the industry regarding the media and environmental resistance (ozone/uv, cleaning agents, salt, lubricant,...) temperature resistant: - 50 C up to +70 C paints/coatings (corrosion protection/colours) used by Bategu for components are EN 45545- compliant existing components can be manufactured to be fire resistant, dimensioned 1:1 emergency running properties maintenance-free fulfilment of highest safety and environmental standards: RoHS, REACH, Unife page 26
Summary strengthening of fire protection; no (legally covered) vehicle registration without EN to 45545 conform flexible metal/rubber components, particularly for application in bogies technically mature and tested EN 45545-compliant elastomer materials EN 45545-conforming BATEGU components are already available and operational all common anti-vibration components can be produced EN 45545-compliant (exception: air springs - is in progress) existing (not fire resistant) components can be produced 1:1 to fire-protected ones without any change of elastic properties (design modifications are not necessary) benefits for vehicle manufacturers/operators: NO constructive changes NO elaborate verification NO additional experts costs NO delays in the authorisation procedure almost constant LCC costs page 27
Thank you for your attention! BATEGU Gummitechnologie GmbH & Co KG Muthgasse 22, 1190 Vienna, Austria Tel: +43 (1) 368 21 53 0 Fax: +43 (0) 368 21 53 24 Email: frank.schmitt@bategu.at Internet: www.bategu.at page 28
References/Literature Literature: [1] EN 45545-2: Railway applications Fire protection on railway vehicles Part 2: requirements for fire behavior of materials and components; German version EN 45545-2:2013-08 Pictures [2] BATEGU Gummitechnologie GmbH & Co KG Other notices: all the presented tests were made just with materials and components by BATGEU (NR = natural rubber, EPDM = ethylene-propylene-diene-rubber). page 29