1. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of current collection 1 JSC RAILWAY RESEARCH INSTITUTE

2. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 2 WIRES: - contact wires; - suspension cable CURREN COLLECTION INSERTS : MATERIAL: Carbon; Carbon-copper DESIGN: Simple; Compound SHAPE: Rectangular; Aerodynamic OVERHEAD LINE SUSPENSION

3. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection Tightening of operating conditions for high-speed traffic Current collection for high-speed railway transport is characterised by a simultaneous increase in: TENSION STRESS OF OVERHEAD CATENARY WIRES INCREASES 2–3-FOLD; wave propagation speed ~ √N/m (N = tension force, m = weight per unit length); wave speed must exceed train speed 2. SPEEDS INCREASE BY A FACTOR OF 2–2.5 3. CURRENT VALUE GROWS 1.5-2 TIMES 4. ROLLING STOCK POWER IS PLANNED TO RISE TO 20 MW 5. CURRENT AT THE CURRENT COLLECTOR: UP TO 4 kA FOR DIRECT CURRENT, OVER 1 kA FOR ALTERNATING CURRENT 3

4. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection CURRENT COLLECTION FOR HIGH-SPEED RAIL TRANSPORT PROBLEMS: 1.A SHARP INCREASE IN WEAR AND DAMAGE RATES; 2. INCREASED IMPORTANCE OF LOCAL WEAR (UP TO 1.5 KM OF CONTACT WIRE MUST BE REPLACED OWING TO INCREASED WEAR OF A FEW METRES); 3. LOW TEMPERATURE CREEP OF CONTACT WIRES AND SUSPENSION CABLES. CAUSES OF THE UNSOLVED PROBLEM: REGULATORY FRAMEWORK IS INSUFFICIENT OR NONEXISTENT; NO SYSTEMATIC STUDIES AND TESTS OF MATERIALS USED IN THE COLLECTOR ASSEMBLY ARE AVAILABLE; MATERIALS FOR HIGH-CURRENT SLIDING ELECTRICAL CONTACTS OF HIGH- SPEED RAIL TRANSPORT ARE NOT AVAILABLE 4

5. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE CONTACT WIRES MaterialComposition, % of alloying metals Strength, MPa Elongation, % Resistivity, µΩ·m Standards and regul МF-120Copper≥ 357,7≥ 4≤0,0177GOST 2584 Cu-OFCopper≥ 3603 - 8≤0,01777EN50149 CuAg0,100,08-0.12 Ag≥ 3503 – 10≤0,01777EN50149 БрМг0,25Ф0,2-0,3 Mg≥ 401,8≥ 4≤0,0220GOST2584 CuMg0,20,1-0,3 Mg≥ 4303 – 10≤o,0240EN50149 CuMg0,50,4-0,7 Mg≥ 4903 – 10≤0,02778EN50149 CuCd0,70,5-0,8 Cd≥ 4302 - 7≤0,02005EN50149 БрЦр0,5Ф0,4-0,6 Zr≥ 421,4≥ 4≤0,0200GOST2584 CuSn0,20,15-0,55 Sn≥ 420≥ 4≤0,02395EN50149 Бр0,15Ф0,12-0,2 Sn≥ 411,62 - 8≤0,0210 5

6. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 6 Wires: possible solutions Alloying : Improvement: mechanical and thermo-mechanical properties Decline: Resistivity New technologies: Severe plastic deformation (SPD): Equal channel angular extrusion (ECAE); Conform process; Simultaneous drawing of two metals Improvement: mechanical and thermo-mechanical properties No decline in resistivity Alloying + SPD: Lower alloying level; Improvement: mechanical and thermo-mechanical properties No decline in resistivity

7. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 7 WIRES: SPD Schemes ECAE ECAE in parallel channels Conform process Conform-process: continuous technology Improve the mechanical and thermo- mechanical properties

8. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 8 MaterialStrength, MPa Elongation, %Resistivity, μΩ·m Softening point, °С Cu-0,2Sn> 4202 -8<0,02395330EN 50149 Cu-0,2Sn> 4506<0,02062370Conform Сu-OF> 3602 - 8<0,0177230EN 50149 Cu> 4005<0,0177270Conform Properties of wires: conform - process

9. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 9 Reconstructing areas of local wear without taking the wire down Reconstruction: deposited layer

10. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE 10 Properties of current collecting inserts produced by Morgan Carbon Material grade Material Permissible linear current density, A/mm Resistivity, μΩ·m Density, g/cm³ Flexural strength, MPa Hardness, HS In motion Standing CY3TACoke61381.73085 CY280Coke and graphite61381.63575 MY7ACY3TA, bronze impregnated 102 2.47590 MY7A2CY280, bronze impregnated 142.352.58595 MY7DCY3TA, bronze impregnated 142.352,79092 MY258Modified MY7D162,332,99092 MY258A2MY7A2 with additional bronze impregnation 182.7<22.77585 MY258Pimpregnation and crimping205<13.28580 MY259CY280, bronze impregnated 162,532,890 MY131Lightweight MY258P10282.280105 The problem of current collection Current collecting inserts

11. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 11 CURRENT COLLECTING INSERTS: Materials development and possible solutions СНИЖЕНИUSING SELF-ASSEMBLY BEHAVIOUR OF SURFACE STRUCTURES, INCLUDING NANOSTRUCTURES, UNDER FRICTION: WEAR RATE IS REDUCED SEVERAL FOLD

12. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection CURRENT COLLECTING INSERTS Catalyst application Wear resistance increase Aerodynamic shape of current collection inserts. Wear resistance increase (30-70 %) Current, A Without catalyst With catalyst 3% With catalyst 6% With catalyst 9% 12 JSC “VNIIZhT”

13. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 13 Traditional shape CURRENT COLLECTING INSERTS: Materials and shape. Aerodynamic modelling Temperature distribution Heat flux distribution Alternative shape

14. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 14 Research programme 1.Studies to investigate wear rate dependence on current density, sliding speed and contact force for various current collecting inserts and contact wires; 2. Studies of wear surfaces 3. Studies and tests of copper-based wires manufactured using different technologies to investigate low-temperature creep and determine their electrical, mechanical and thermal characteristics; 4. Developing a technology for reconstructing areas of local contact wire wear without taking the wires down; 5. Developing standards: – for contact wires; – for current collecting inserts; – for fixtures

15. NEW MATERIALS FOR THE RAILWAY INFRASTRUCTURE The problem of head current collection 15 THANK YOU ! Mobile phone: +79161476190 Business e-mail : bushe@vniizht.rubushe@vniizht.ru Home e-mail : isgershman@gmail.comisgershman@gmail.com