The new Christian Doppler (CD) Laboratory for Structural Integrity in Rail Vehicle Design aims to boost energy efficiency and cut life cycle costs in production and operations.
Rail vehicles are exposed to extreme operating stress: strong dynamic forces and frequent load changing leave their mark during every journey. While lightweight design approaches, energy efficiency and resource conservation are increasingly important considerations, continued compliance with the strict safety requirements for rail transport still has to be assured. Officially opened today at Graz University of Technology (TU Graz), the Christian Doppler Laboratory for Structural Integrity in Rail Vehicle Design will focus on these challenges, as well as developing scientific principles for the next generation of rail vehicles.
Federal Ministry of Economy, Energy and Tourism promoting innovation in rail vehicle construction
“A modern industrial nation needs the best possible links into the future," said Wolfgang Hattmannsdorfer, Austrian Federal Minister of Economy, Energy and Tourism. "Rail transport is the backbone of our mobility and infrastructure policy, making it a key lever for competitiveness, energy efficiency and economic resilience. Mobility is one of the five core action areas in our industrial strategy, because high-performance transport and energy systems are the cornerstone of industrial strength. By developing lighter, longer-lasting and more energy-efficient rail vehicles, we are advancing climate action as well as securing technological sovereignty and value creation in Austria. The new CD Laboratory lays the scientific foundations for this, while also ensuring that new findings feed quickly into industrial applications.”
"Our goal is to deliver sound scientific methods that will form the basis for practical application in the industry," commented Head of Laboratory Martin Leitner of the TU Graz Institute of Structural Durability and Railway Technology. "This will enable us to make an important contribution to the development of safe, long-lasting and innovative rail vehicle designs." The team is cooperating with project partners Siemens Mobility Austria GmbH, Plasser & Theurer, Export von Bahnbaumaschinen, Gesellschaft m.b.H., and Miba Frictec GmbH.
Two modules with differing perspectives
The CD Laboratory is split into two research modules. The first will focus on the fatigue strength of welded steel structures, which are used in vehicle frames, various types of superstructures, and lightweight wheelset axles. Taking current standards and regulations as their starting point, the research team will examine how the choice of materials, as well as production and post-treatment processes influence component service life. They will also carry out systematic analysis of real-life load scenarios – from a range of different load types through to complex multiaxial stresses. The aim is to translate findings from lab-based experiments and the resulting design methods effectively into real-world vehicle structures.
Testing on state-of-the-art test rigs
The second module at the CD Laboratory will concentrate on the structural integrity of selected components and systems. One of the focuses will be on the dynamic behaviours of brake systems, especially in connection with friction-induced vibrations. Besides detailed simulations, the researchers will perform experiments on the brake test rig at TU Graz's Campus Inffeldgasse – which is one of the most advanced in this field. These experiments will serve as the framework for analysis and validation of new design approaches. The focuses of both modules will be linked by way of a final assessment of structural durability using the methods devised to examine vibration fatigue.
Additionally, the laboratory will investigate fatigue and wear processes caused by contact between the wheels and rails, as well as in friction braking systems. Thanks to the roller test rig developed within the CD Laboratory, the research team is able to analyse wheel-rail interaction using experiments performed under realistic conditions. Follow-up analysis of disc and block brake systems will also lay the foundations for innovative design and evaluation methods for these components.
About the Christian Doppler Laboratories
The Christian Doppler Laboratories perform high-level, application-driven basic research, with outstanding researchers working in collaboration with innovative companies. When it comes to funding for these partnerships, the Christian Doppler Research Association is recognised worldwide as an example of best practice. The laboratories are jointly financed by the public sector and the participating companies. The most important public-sector funding provider is the Austrian Federal Ministry of Economy, Energy and Tourism.