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Rail components

Railcar parts and rail components

Constellium is a technology pioneer in structural and non-structural railcar components.

Ensuring competitiveness with cutting-edge components

Structural sub-assembly

We design and supply components based on extrusions, sheets plates and composite panels. Our customers enjoy the benefits of just-in-time, finished, ready-to-mount and welded solutions with all necessary cut-outs, fixations for seats and surface treatments, greatly reducing production time. All components meet the highest standards in terms of quality, weight savings and design.

Structural body shell sub-assemblies

Constellium works closely with a dedicated network of specialized sub‑suppliers to deliver welded, machined, assembled and painted sub-assemblies, such as structural floors, side walls, end walls and body bolsters for all types of rail vehicles.

Composite interior floor system

Ready-to-mount interior floor system

The interior floor system consists of a combination of different components. These usually take the form of resilient mounts onto which the lightweight aluminium composite panels are fixed. According to customers’ needs, we can supply ready-to-mount interior floors made of composite panels using optimized foam core materials, aluminium exterior sheets, extrusions and special inserts.

Lightweight and low-height, the system offers good sound and thermal insulation as well as integrated fixation points for elements such as seat attachments. It is quick and easy to mount due to simple handling of the large-scale elements, and it complies with fire safety standards DIN 5510 (Part 2) and NF F16-101.

Composite roofs for rail vehicles

Ready-to-mount structural roofs are made of composite panels using optimized foam core materials, aluminium exterior sheets, extrusions, and special inserts. They offer substantial weight reductions and improved thermic and acoustic insulation. The roofs also allow for their direct assembly into the body shell structure by means of bonding or other cold-joining techniques.

Ready-to-mount composite roof

According to customers’ requirements, Constellium can build these with or without additional components such as:

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    Panels with interior and/or exterior painting
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    Cut-outs with seals for cables and air ducts
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    Fixations and mounting of air-conditioning equipment
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    Fixations for handrails
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    Mounting of ceilings and air grilles

Crash concepts

Crash finite element analysis

Our customized ready-to-mount crash elements offer a number of advantages:

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    Low weight
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    Maximum and controlled energy absorption due to plastic deformation
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    Reduced crash forces and accelerations
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    Respect of occupants’ necessary survival space
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    Absorption of high static load
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    Possibility of re-equipping existing vehicles
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    Simple replacement of damaged modules
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    Standardized extrusions and solutions for various applications

We have two main crash concepts: a modular concept for use in low- and medium-speed rail, and a global concept for high-speed rail transport.

Crash concept

We have designed our modular crash concept to absorb collision energy in the low- and medium-speed rail range. An irreversible deformation will only occur in the energy-absorbing auxiliary component, while the cab and passenger areas remain safe. Two specially designed crash modules are fixed at the end of the under‑frame beside the coupler.

For high-speed trains, energy-absorbing auxiliary components are welded to the front end and under-frame to protect passengers and the driver. In case of collision, these components are plastically deformed, while the body shell structure remains intact. For the crash layout, the safety requirements for the structural integrity of the body shell are taken into account. Crash-absorbing aluminium extrusions are integrated in the under-frame ends in a way that allows for the introduction of high static loads.

Key-fact

Constellium has been involved in the design and finite element analysis of crashworthy vehicle structures for more than 20 years.

Your contacts

All countries

Sales contact

Patrick Wahl

Tel.: +41 44 438 66 26

Business unit: Extrusions
 

Max Hoegger-Strasse 6
P.O. Box 1812
CH-8048 Zürich
Switzerland

All countries

Technical contact

Gino Dallo

Tel.: +41 44 438 66 14

Business unit: Extrusions
 

Max Högger-Strasse 6
P.O. Box 1812
CH-8048 Zürich
Switzerland

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Last update 14 September 2016 Back to top