Light Join

Joining Technologies to Enable Implementation of Lightweight Structures in Automotive

The project aimed to investigate the opportunity for lightweight composite structures in the automotive industry. Specifically, this project focussed on the joining techniques of composites to metals.

There were two main deliverables; a full scale demonstrator of the engine bay of a Nissan Leaf, replacing aluminium structures with carbon fibre composites. Also, a robust database of the test results hosted by Granta, containing the data from material manufacture up to lap shear testing.

The database has been integrated with a selection tool, allowing the end user to specify the joint properties and fastening mechanism, then outputting all of the test combinations with such design.

Chamaeleon

The aim of Chamaeleon was to investigate the joinability of thin walled high-pressure die cast (HPDC) aluminium. Initially developing Jaguar Land Rover’s (JLR) use of Self Piercing Rivets (SPR), which developed into the investigation of Laser Welding and Resistance Spot Welding (RSW).

The aluminium cast manufactured by BCAST and Magna is a new alloy, so the joinability was unknown for the end user, JLR. Due to its microstructure, cast aluminium is less formable than conventional wrought aluminium. Therefore, as the material decreases in thickness it becomes more prone to cracking or malfunction. Three thicknesses of cast were analyses using 5 joint stack ups, ranging from two to three layers. This meant finding a joining solution for 15 different combinations.

The results show the boundary conditions when designing cast aluminium components within the vehicle. The strength tests were also used to validate their Finite Element Analysis.

Amicable

Anti-Microbial Grab Poles

AMICABLE was a product of the COVID 19 pandemic that hit the world. The researchers at WMG proposed a means of making public transport cleaner, as public perception of it declined during lock downs.

It was clear that a key point of contact for passengers within a bus or train was the grab-poles and other similar structures. Therefore, incorporating anti-microbial grab poles into vehicles could encourage more people to opt for public transport which is generally an environmentally efficient mode of transport.

The researchers embedded anti-microbial nano particles into the braided grab-poles which were shown to reduce germ growth.

Resi-Glaze

Resilient glazing for safer passenger vehicle operation

Resi-Glaze proposed a new form of window glazing utilising Polycarbonate instead of the traditional glass. This lightweight polymer with an advanced scratch-resistant coating has been installed on the Coventry Very Light Rail vehicle.

The new windows are highly resistant to breakage which provides passengers with a step-change in safety

The official report into the 2016 Sandilands (Croydon) tram crash made a number of recommendations for tram vehicle improvements. It called for development of windows and doors with improved strength. To address this need, researchers developed this product to make public transport safer.

Case Study
Coventry Very Light Rail - Tram

CVLR is a very light rail project in partnership with Coventry Council. The CVLR concept uses lightweight vehicles, each typically accommodating 50 passengers, with an goal to be driven autonomously. The vehicles are to be equipped with batteries, in combination with rapid charging systems. This reduces the need for overhead lines and continuous electrification.

Once fully installed the track will connect the city centre to the University of Warwick, the Ricoh Arena, Coventry Airport and University Hospital Coventry & Warwickshire.

Coventry Very Light Rail - Track

As part of Coventry Very Light Rail (VLR), Coventry City Council’s flagship transport project, a novel track form has been proposed together with design partners Ingerop/Rendel.

The track sits just 30cm into the road surfacing, in contrast to traditional tram tracks that are typically buried up to a metre down, which involves moving utilities such as water, gas and electricity.

As a result of its shallow depth and ability to be embedded in an existing highway the cost is significantly lower.

The urban VLR track may cost as little as £10m per km to install, compared to traditional trams which cost upwards of £25m per km, sometimes as much as £100m per km in city centre locations, making urban rail a possibility for smaller towns and cities in the future.

Very Light Rail - Revolution

The Revolution project was formed to create a light rail alterative to main line vehicles. It has been designed primarily for short routes where operating traditional heavy rail or tram solutions is uneconomic. Combining technology from the automotive and rail sectors has produced a lightweight, energy-efficient vehicle that is straightforward to operate and geared to the needs of communities.

Brainstorm

BRAIded Novel beam STructures with Opportunities in Railcar Manufacture

Brainstorm aimed to investigate the opportunity for lightweight braided structural composites in vehicle applications. Specifically, this project focussed on applications in the rail sector which were previously unexplored.

As the project progressed it became apparent that there were exploitation opportunities linked to the Coventry Light Rail project. This lead to a focus on a full-scale technology demonstrator or a trams front end cockpit.

The rail sector is undergoing a drive for innovative solutions both in terms of vehicle structures and in propulsion technology. The technology identified offered potential for cost-effective light-weighting with additional recycling opportunities.