Solutions for weight

reduction in Bus and

Rail vehicles
Keeping Transportation
Engineering Moving

Henri Garcia
Tiphaine Flament
May 6th, 2020

3M Industrial Adhesives & Tapes

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Introduction
Henri GARCIA
- 3M Industrial Adhesives and Tapes Division
- European Adhesive Engineer (EAE) certified by the European Welding
Federation
- Chemical Engineer Degree
- 23 years of Experience in Adhesives for Transportation and General industry
Applications

Tiphaine FLAMENT
- 3M Industrial Adhesives and Tapes Division
- Chemical Engineer Degree
- Experience in the R&D and production
- 3 years in 3M Adhesives for Transportation and General industry
Applications

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Agenda and Control Panel details

1. Introduction – Bus & Rail

Market Trends

Open or close control

2. Lightweight Management panel

3. Vehicle structure For the confort of all the

conference is muted

4. Vehicle body shell Please ask your questions

in the Chat panel, answers
will be provided at the end
5. Interior parts of the webinar

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 3solutions for each step of vehicle life

Structure Body Shell & Painting Finishing Maintenance

Interior
Sanding Acoustic and thermo Masking Paint Protection Industrial sprays
Masking tapes insulation Protection during painting / Permanent film Degreasing, Lubricants,
Masking tapes / Fine-line Adhesives
3M Thinsulate, Thin Double
precise masking
Welding Coated Tapes
Pressure systems Impact protection Bonding
Stiffeners and Protection Films 3M 7070UV film Thin Double coated tapes, VHB
Temporary protection
Weld cleaning Interior Panel bonding Cleaning
Fibre discs, flap discs VHB tapes Roof Sealing
3M 4412N Extreme Sealing ta Sorbents, High performance cloths
Structural adhesives
Cleaning / deburring Paintshop Box
Exterior panels, Windows Windows Protection Antistress mats
Cubitron II, Air Tools Protection, Anti-dust
bonding and sealing 3M Dirt Trap Safety and graffiti protection Safety walk
Safety 3M PU590 and Silane Modified
Personal safety products Sealants, VHB Tapes Masking, sealing,
Conspicuity marking tapes
Panels bonding Safety marking 3M Polishing Reflective films
VHB Tapes Performance labels Systems
Adhesives Finesse it Graphic Films Instant adhesives
Recloseable bonding Perfect it Corporate identity 3M SiGel
Structural bonding 3M Dual Lock, Advertising
Structural adhesives 3M Hook&Loop Pictograms

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1. Introduction – Bus & Rail Market Trends

▪ Energy efficiency, increase Payload per passenger

▪ Increased use of composite and environmental

friendly materials, assembly of dissimilar substrates

▪ Design differentiation and accessibility challenges,

improved passenger experience

▪ Manufacturing and Mobility habits changes due to

Covid19

▪ Competition with other Transportation means e.g.

Cars and Aviation

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1. Introduction – Bus & Rail Market Trends
Some numbers on Energy, Environment and Urbanization:

In Europe, 2030 EU Goals establish(1):

▪ >40% reduction in greenhouse gas emissions (vs 1990)
24% of current emissions come from Transportation
▪ >27% total energy consumption coming from
renewable energies
▪ >27% increase in energy efficiency

Globally (2):
▪ 55% of people live in cities today
▪ 68% will live in cities by 2050
▪ +2.5 billion additional people in cities by 2050

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1. Introduction – Bus & Rail Market Trends
Some consequences in Bus & Rail markets:

▪ Electrification of Bus network in an

increasing CO2 restrictions landscape

▪ Commuter trains and intercity trains are

called to play a relevant role in a
decarbonized Economy(2)

▪ High speed and long distance Rail to gain

market share over Aviation and Cars

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Poll 1

Which of these trends are the most impacting in your

design of Bus and Rail vehicles? (several answers possible)

A – Energy Efficiency and Lightweighting

B – Improved comfort and passenger experience
C – Use of environmental friendly materials
D – Smarter vehicles and IoT
E – Design and operational changes due to social
distancing

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2. Lightweight Management
Lightweight Management has a primary objective of reducing energy consumption.
2 main strategies(4) can be used in this approach:

▪ System optimization: weight-optimized solution for the whole vehicle and its serviceability.
E.g. Double deck trains, 5 seats row, 1 axis per rail car, shape & aerodynamics.

▪ Use of Lightweight materials, while maintaining structural Integrity and optimizing

manufacturing process and maintenance.

Bogies&Traction Shape Serviceability

System Optimization Weight

New Design
Reduction +
Energy
Refurbishment Lightweight Materials Efficiency

Concept Validation Assembly

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2. Lightweight Management

BUS & Hydrogen Bus

Electric Bus
TRUCKS
Electric buses may have at
least 500kg of additional
battery Weight.

Electric Truck. Source: Ford

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2. Lightweight Management
A light rolling stock vehicle is a vehicle that can carry more passenger payload and yet be lighter than the
existing older stocks. This is sometimes quantified by a carried payload to carrying mass ratio.
Dead weight can vary from 350kg (suburban) to 1100kg (ICE) per passenger seat (3).

Battery electric train RAIL Double-deck train for the UK. Source: Andreas Vogler

Space and mass per seat optimization. Source: Talgo Bogies and axis optimization. Source: Talgo
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Poll 2

What is you major challenge in lightweighting? (several

answers possible)
A – Find materials having the desired weight and performance
B – Modelling lightweight parts and their connections
C – Noise and vibrations generated by lighter materials
D – Assembly of dissimilar materials
E – Integral approach of serviceability and energy efficiency

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Tendenze sui materiali
2. Lightweight Management – Materials and Assemblies
Material breakdown in
Transportation and Wind
in % of total mass.

Source: McKinsey & Company

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2. Lightweight Management – Materials and Assemblies

Source: McKinsey & Company

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2. Lightweight Management – Materials and Assemblies

Primary energy over whole life cycle for a high speed train car body with
4 different material compositions(7)

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2. Lightweight Management – Materials and Assemblies
How adhesives are becoming more relevant(6)

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2. Lightweight Management – Materials and Assemblies
How adhesives are becoming more relevant(6)

30

Overlap Shear Strength (MPa)

25

20

15

10

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2. Lightweight Management – Materials and Assemblies
How 3M Adhesives Technologies can help you to be at the forefront of
Lightweight Design:

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 2. Lightweight Management
Using characterization, FEA and prototyping for
bonded assemblies prediction:

Adhesive and substrates Adhesive Data Card FEA Prototype

compatibility verification
mode I

mode II

Characterization Generation of Finite Element Models and Analysis Verification of the model
through prototyping

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2.
3. Lightweight
Structure Management
Weight breakdown example in a High Speed train (5) :
▪ Bogies and propulsion equipment reach 47% of total train mass
▪ Car body and interior systems reach 38% of total train mass.

15% 10% Propulsion equipment

Powered bogies, motors and drives

22% Trailer bogies

17%
Car body shell

Interior equipment
15%
21% HVAC, Batteries and others

High speed train Weight breakdown. Source: Networkrail, 2010

“Comparing environmental impact of conventional and high speed rail”

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Poll 3

What parts of the vehicle are critical in your design efforts

for lightweighting? (several answers possible)

A – Vehicle structure
B – Car body shell including windows
C – Interior walls and ceilings
D – Floor panel and floor cover
E – Wheels, Bogies, traction system

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 3. Vehicle Structure
Differentiated and Integral Structures(4):

Hybrid Structures(4): Source: Modular Lightweight sandwitch bus concept – Inegi - INSIA

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3. Vehicle Structure
Example of welding replacement in Bus structure by adhesive joints using CFRP
connection parts:

Source: Study of the behaviour of adhesive joints of steel with CFRP

for its application in bus structures – UC3M Madrid

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3. Vehicle Structure

42% weight reduction

25% weight reduction
35% weight reduction
Total weight reduction 11 Ton → 8 Ton/rail car
Estimated energy savings 0,1 kWh/km
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3. Vehicle Structure
Lightweight composite or honeycomb floor panel: influence on floor structure weight.

(7)

Increase span distance by using 3M

SW7240 B/A FR structural epoxy adhesive
in composite or honeycomb panel

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3. Vehicle Structure
Lightweight composite or honeycomb floor panel: influence on floor structure weight.
Superior performance composite and honeycomb panels: very high modulus (3500 – 4000 MPa)
and superior strength 3M SW7240B/A FR adhesive increases significantly the panel resistance to
flexural stress and reduces the need of supporting bars(9).

19mm Thick
19mm Thick
composite panel
Plywood with Benefits of composite
bonded with 3M
1,5mm aluminium panel
SW7240B/A FR
skin
adhesive (Diab core)

Weight/m2 16 kg/m2 10 kg/m2 38% Weight Reduction

Reduction of 1 bar:
Supporting bars -33% structure weight
3 supporting bars 2 Supporting bars
per m2 -33% less welding
operations

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4. Vehicle Body Shell
- Lightweight Bonding & Sealing
- Wrapping & Window Films

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4. Vehicle Body Shell
3VHB™, Dual Lock™ and Extreme Sealing Tapes weight savings vs traditional 1K PU sealants:
Car body shell element Sealants weight % of Tape Weight proportion 3M Tapes Total Adhesive
(12m long Bus) (kg) replacing Sealant Tape vs Sealant weight (kg) Weight (kg)
Windows 42 0% 0,49 0 42
Exterior panels 68 50% 0,49 16,6 50,6
Interior panels 63 100% 0,49 30,7 30,7
Total adhesive weight (kg) 173 47,3 123,3
Weight reduction 29%
with 3M Tapes

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4. Vehicle Body Shell
3Wrapping Solutions: Paint replacement
▪ Wrapping Films help reduce weight up to 50kg per rail car
compared to paint
▪ 975 tons of VOCs* estimated global reduction per year in
Rail manufacturing and maintenance

*Volatile Organic Compounds reduction: baseline of 3.000 rail cars wrapped per year, 650kg of paint with 50% solvent content saved per car

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4. Vehicle Body Shell
3Thinsulate™ Window Film Climate Control: combination of solar control and insulating
window film.

A 12m long bus can have up to 500kg of glass

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5. Interior parts
Effects of Lightweighting on Noise and Vibrations

(10)

(10) Lightweight primary structures for high-speed railway carbodies –

De La Guerra, Eduardo – Talgo, 2018

(8)

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5. Interior parts
3VHB™, Dual Lock™ weight savings vs traditional 1K PU sealants:

Sealants weight % of Tape Weight proportion 3M Tapes

Example of 12m long Bus
(kg) replacing Sealant Tape vs Sealant weight (kg)

Interior panels 63 100% 0,49 30,7

Weight reduction 51%

with 3M Tapes

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5. Interior parts
3VHB™, Dual Lock™ tapes weight savings and
vibration reduction:

(8)

(8)

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5. Interior parts
Structural composite bonding(11)

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5. Interior parts 3M™ Adhesive Transfer Tape
9775WL (0,127mm)

Floor cover bonding weight comparison with 3M

9775WL tape vs 3M SW7231 liquid adhesive

For 20m2 vehicle floor Adhesive 3M Tape 9775WL

Density (kg/m3) 1200 1000
Thickness (mm) 0,5 0,127
Weight (kg/m2) 0,6 0,127 Tapes have the advantages of:
2,5 kg
Weight per car (kg) 12 kg (79% weight • Instant adhesion
reduction)
• Design for Maintenance
• Weight reduction
• No EH&S / Environmental impact
• No dispensing equipment required
• No staining, no mess. Less waste

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5. Interior parts
3M Glass Bubbles applications in interior Bus & Rail materials

▪ Improve SMC and ABS panels impact

strength, tensile strength, flexural
strength and elongation.
▪ Reduced breakage during
compounding and other higher shear
mixing processes.
▪ Provide significant weight savings,
dimensional stability improvement,
coefficient of thermal expansion
reduction, and process improvements+
savings in many applications
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3M Free Webinars- Register NOW and secure your place
Top tips for using Structural Adhesives in Rail Industry Solutions for weight reduction in Buses and Rail Vehicles
Thursday, 23rd of April 10:00–10:45 AM Wednesday, 6th of May 10:00–10:45 AM
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Top tips for using Structural Adhesives in Rail Industry Noise, Vibration and Harshness reduction in Rail Car interior
Thursday, 23rd of April 10:00–10:45 AM Wednesday, 13th of May 10:00–10:45 AM
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3M Tapes & Adhesives – From Experimental Characterisation to
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Wednesday, 29th of April 10:00–11:00 AM
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Thank you! Questions & Answers Session

References:
(1) European Commission Transport White Paper
(2) IE – Center for Transport Economics & Infrastructure Management
(3) Source: railway-energy.org
(4) Integral consideration of the lightweight design for railway vehicles - German Aerospace Center - Institute of Vehicle Concepts
(5) Analysis of Technological and competitive trends of Weight reduction in high speed Rolling stock Industry – Alvaro Prieto Moneo
(6) The promise of Lightweighting – 3M
(7) Light-Weighting Methodology in Rail Vehicle Design through Introduction of Load Carrying Sandwich Panels - David Wennberg Centre for Eco2 Vehicle
(8) A Systematic Approach to Identify Sources of Abnormal Interior Noise for a High-Speed Train Jie Zhang , Xinbiao Xiao, Xiaozhen Sheng, Zhihui Li, and

Xuesong Jin State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, China
(9) Diab Company, Nanotures.
(10) Lightweight primary structures for high-speed railway carbodies – De La Guerra, Eduardo – Talgo, 2018
(11) Functionally graded adhesive joints - A. Chiminelli / R. Breto Materials & Components Division, Aragón Institute of Technology, Zaragoza, Spain

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