Rail-energy knowledge exchange on emerging materials (ALCHEMy)

In order to improve the management of railway networks and provide the timetables that passengers demand throughout the week, track components with greater durability that are easier to maintain are essential. With these in place less access will be needed to the track, keeping it free for trains.

The aim of this project is, through the use of process modelling and full-scale testing and modelling, to enable the effective design of a laser clad layer of premium material for application to a range of track components to reduce wear and the likelihood of rolling contact fatigue occurring. These are the two most prolific damage mechanisms in railway track. A major goal of the project is to comprehensively study the behaviour of cladded components on a test track to validate the modelling and laboratory work.

The technique, as well as improving component life and reducing maintenance needs, will reduce costs by allowing lower grade rail material to be used and also in-situ repairs could be facilitated eventually, negating the need for components to be removed from track when they reach the end of their life.

The project, while focussed on railway track applications will also consider vehicle components in parallel activity and ensure that the knowledge and fundamental knowledge gained on the integrity of cladded components through multi-scale modelling of different geometries and cladding parameters is transferred to other sectors where cladding is used, such as energy, oil and gas and aerospace.

Our study will have significant impact on the whole life costs of railway track components and through the need for less maintenance will ease network management in the push for a 24/7 railway. The benefits from the projects will also be transferred to impact on other sectors such as nuclear, energy and aerospace. This research will target EPSRC economic and societal criteria including:

- Contributing towards wealth creation and economic prosperity - the knowledge base of all partners involved will be enriched and exploitation, through the production of new longer life railway track or vehicle components, will be enabled. The problems to be tackled by ALCHEMy are faced by railways worldwide bringing global market opportunities for UK produced technology. Further exploitation is anticipated through transfer of knowledge to other safety critical industries.
- Enhancing the research knowledge and skills of businesses and organisations - through knowledge transfer to LCT as the cladding service provider, their clients who will manufacture the components and Network Rail who will use the components and the cladding process as a component repair option.
- Enhancing the effectiveness and sustainability of organisations - the main beneficiary will be Network Rail who will have reduced maintenance costs and improved network management in the future, but for other organisations it will open up new markets that will help ensure economic sustainability.
- The commercialisation of scientific knowledge leading to the generation of new processes, products and services - exploitation of the technique will lead to a range of new processes and products across the railway industry and other sectors.

Exploitation will be considered from the start of the project and supported by a specific work package. This will be enables through the industrial partners and their supply chains. These cover the railway industry and also give access to sectors including nuclear, energy and aerospace.

A key milestone for the project is the implementation of laser cladding in the field alongside a whole life cost and risk assessment. This will ensure that impact can be made in the life of the project. The parallel PhD studentship to be funded at UoS will run beyond the project life and extend the impact to railway vehicles.