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Project FaMeZug (Fiber-Reinforced Metal Composite Train)

Project volume: ~2.8 MEUR
Project term: Oct. 1, 2016 - Oct. 1, 2019

Project partners:
  • Bombardier Transportation GmbH
  • Deutsche Bahn Systemtechnik GmbH
  • Siltex Flecht- und Isoliertechnologie Holzmüller GmbH & Co.KG
  • Institute of Vehicle System Technology at Karlsruhe Institute of Technology (FAST - KIT)
  • wbk Institute of Production Science (KIT)

Project objective:
Lightweight construction is becoming increasingly important for manufacturers of rail vehicles, as the overall weight of the vehicles is restricted by legislation and a reduction in weight increases the possible payload. Light trains help operators to save energy and increase cost efficiency. Currently, trains are mainly built from steel and are therefore very heavy. The overarching goal of the "FaMeZug" Project is therefore to develop fiber composite-metal hybrids as components of rail vehicles. The innovative aspect is the intrinsic joining process, i.e. bonding with metals during the primary shaping of the composite material. As a result, downstream assembly stages are dispensed with, which results not only in shorter manufacturing times but above all greater economic efficiency.

Two technologies - centrifugal casting and filament winding - are being used to produce hybrid materials to best exploit the potentials of intrinsic joining for a wide range of components. Both processes are suitable for producing hollow hybrid structures and need to be further developed to meet the requirements for rail vehicle components. The concepts being investigated hold the promise of high load-bearing capacity and economic efficiency, which is a requirement of the rail vehicle industry. Following the development and manufacture of demonstrator models, thorough testing is planned.  As a result, a substantial increase in technical readiness (TRL) to Level 5 will be achieved.
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