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CSM for RailwayInfrastructure & Rolling
Stock
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Content
CSM General presentation
CSM for Railway
Technological Offer
CSM Labs & Competences
Stages in our 50-year history
2013
Building up of Corporate Know-Howfor product & process development
Start selling of K-Hto new clients and
markets
Widening through RINA
network
China
Over 250 resources 200 patent 50 publications/year
RINA Group
Training
Classification
Certification
Testing
Consulting Engineering
Operation&Maintenance
Design
Materials
Engineering
Technology
Innovation
Inspection
Testing, Inspection & Certification
Innovation & Consulting
Piena scala - impianto pilota Business lines
Oil & Gas
Energy
Trasportation
Aerospace and Defence
Steel
CSM Profile
SOLUTION FORMETALS
NEW TECHNOLOGY&MATERIAL INNOVATION
ENVIRONMENTAL SOLUTION
Analysis of customer needs
Market benchmarking
Fit for purpose analysis and lab testing Experimental check at real scale
Complementary technical competences Positive experience from similar cases
Product/process suitable for the application/market New product/process with higher
performances/cheaper
CSM Approach
SOLUTION
VERIFICATION
IDEA
ASSESSMENT
CSM has both high level technical skills and state of the art laboratories which allows to assess product/process performances as well as to develop new solutions
CSM facilities
CSM uses Transmission Electron Microscopy (TEM) to characterize materials. Accelerating Voltage: 300
kVResolution 0.19 nm
NANO AND MICRO-SCALE
Combustion Station,
CSM Dalmine
PILOT PLANT-SCALEMEDIUM-SCALE
Testing and modelling
From nano to pilot plant scale
Failure hydraulic testMulti axial load testing machine
Fully instrumented test line & on shore burst test
Tube indentation facility
Full scale plant for H2S testing on vessel
Full scale tests
CSM New offer of Services
Technological support and assistanceNew operative practices, through process problem solving, structural integrity, failure analysis and on site support, technical support for patenting
New products developmentMetallurgical design of special steels, process parameters, development of high performance products (plates, coils, pipes, bends, etc), components (descalers, burners, etc) and welds
Product qualificationSmall and full-scale testing. Conventional and special lab testing (including toughness, high strain and stress corrosion testing)
Personnel training (steelmaking, casting, rolling, finishing, chemical and metallurgical labs)Classroom courses and on site coaching (theory, modeling, norms and practice). Personnel skilling for laboratory testing and analyses
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CSM New offer of Services
Environment & SustainabilityEmission abatement, Energy recovery from organic waste and process gases, Waste inertization and valorization, Emulsions and Water treatment
Testing (lab & full scale)More than 20 labs are available, check the web site for deep details: www.c-s-m.it
Expert on SiteMore than 80 experts on more than 20 disciplines (corrosion, process, metallurgy, welding, rolling, claims).
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C-Mn High Steel GradeSour resistance C-SteelLined & CladCorrosion-Resistant AlloysPowders for ALMPowders for special coatingsMMC
Steelmaking & Casting & Rolling & Forging, Heat treatment & Surface conditioningOn-site problem solvingCommissioning & start upTraining
Carbon, Stainless, Electrical and Special Steels, Superalloys, Ceramics, Special coatingsFlat, Long Products and Tubes Automotive, Defense, Aerospace, Railway, Marine, White & Yellow Goods, Power Generation, Oil&GasApplication Engineering
Through process approachL2 / L3 Control SystemsTailor-made tools for qualityCustomer designed sensorsTechnological DB
Solid Waste ValorizationWater ManagementEmission ReductionEnergy Recovery
CSM Innovation Chain
FAR EASTBaosteelHandanJSWJISCOShigang
RUSSIAN FEDERATIONMMKOMKSant-Petersburg Electro-Technical CompanyUralmash
EUROPEAcroniArcelorMittalColakoglu MetalurjiErdemirLOI ItalimpiantiNLMK
Salzgitter AGSiemens VAITATA Steel EuropeThyssenKrupp StahlThyssenKrupp NirostaVesuviusVoestAlpine
ITALYABBABSAcciaieria ArvediAcciaieria di RubieraAcciaierie CalvisanoAcciaierie ValbrunaAcciaierie VeneteArvedi Tubi AcciaioBercoCogne AcciaiSpecialiDalmine Tenaris
GroupDanieli AutomationFeralpi GroupFerriere Nord PittiniFIAT Group FincantieriForge MonchieriForgiatura MaméGeberitElectroluxHenkelIndesitItalcementi
IvecoLucchiniMagnetto WheelsMarcegagliaMetinvestNLMK VeronaOriMartinPaul WurthPirelliSiemens VAISocietà delle FucineTechIntTenovaThyssenKrupp AST
LATIN AMERICAArcelorMittal (Brasil)
NORTH AMERICATernium HylsaTAMSA
MENAMobarakehJesco
AFRICAAfrican Industries (Nigeria)
Market & Main Clients
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Content
CSM General presentation
CSM for Railway
Technological Offer– CSM for Railway Infrastructures
– CSM for Rolling Stock
CSM Labs & Competences
CSM for Railway
Pearlitic & Bainitic rails
Head hardened rails
Wear resistance and rolling contact fatigue of rails
Rail welding, TW & FBW WPS
Rail Suppliers Qualification
Rail selection
RAILWAY TRACK
Failure analyses
Coatings and paints
Constructions for severe conditions
Special testing design & procedures
Total Cost of Ownerships evaluations
Training
RAILWAY INFRASTRUCTURES
Failure analyses
Special testing design
Innovative solutions for carriages
Design for high crash resistance
Full scale testing
Metallic spare parts suppliers qualifications
ROLLING STOCK
CSM experiences & solutions for Railway sector
For a Railway Operator and its main Suppliers and Contractors, CSM can provide support through the entire production line, from the rail development to the performance assessment of tracks. CSM own special facilities can be dedicated to develop project specific solutions, jointly with the suppliers, contractors and operators. Training is a central part of the services provided.
New Rail Development
Problem: Innovation in high performance rails, i.e. 350 grades or
higher, is daily carried out, even if their introduction seems rather slow.
Solutions offered are mainly generic, and hardly they are metallurgically designed from the real conditions of operation.
Approach: Multi scale, from steel microstructure up to rail in
operation Through process approach, from the production through
the use. A unique set of metallurgical models to design fit for
purpose rail microstructure and the production process with the supplier.
A complete set of labs for any kind of test, standard or designed for purpose.
Results: Roadmap for product development for specific railway
projects. Projects for technology transfer and research on rails and
joints. Support in rail choice and maintenance programmes Training for inspectors and operators.
CSM for Railway
Material & Component Qualification (also in severe conditions)
CSM for Railway
Problem: Rail is placed in operation as a welded component. Welding joints, if not accurately designed and qualified, is
the weakest point of failure.
Approach: Model aided joint microstructure design. Filler and procedure evaluation. Joint microstructure A unique set of metallurgical models
to design fit for purpose rail microstructure and the production process with the supplier.
A complete set of labs for any kind of test, standard or designed for purpose.
Results: Roadmap for product development for specific railway
projects. Projects for technology transfer and research on rails and
joints. Support in rail choice and maintenance programmes Training for inspectors and operators.
Design & Testing of Components & Structures (for severe conditions)
Problem: Train helps in shortening the distances and the time
spent in commuting safely. Nevertheless its passage in cities and towns can incur high levels of noise. Pre-painted barriers are available, but needing significant maintenance efforts.
Approach: Development of new steel sandwiches, based also on
stainless steel in order to drastically reduce maintenance.
Measurements of level of noise dumping are designed with full scale prototypes of barrier.
Environment attack resistance is also performed in different severe conditions.
Results: Total Cost of Ownership evaluations Design of barriers for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up
CSM for Railway
Design & Testing of Components & Structures (for severe conditions)
Problem: Road or railway tunnels are subject to significant corrosion
factors, including water stagnation and flowing, aerosol, condensation, presence of NOx, SO2, dusts etc..
Fire resistance and internal lighting are important concerns during design and operation of tunnels.
Approach: Development and design of innovative sandwich panels. Multimaterial approach, carbon steel stainless steels etc.. Sample and full scale testing of corrosion resistance under
several point of view following the most recent international standards (i.e. EN10169-2, EN10169-3, ISO 6270-1, ASTM B117, EN13523-23 etc.)
Results: Total Cost of Ownership evaluations for specific projects Design of panels and structures for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up
CSM for Railway
Material Selection (for severe conditions)
Problem: Selection of rails and joints suitable for service
in arctic environment
Approach: Fracture mechanics testing (CharpyV, DWTT,
KIC) at low temperature according to recognized Standards and Recommendations (GOST, EN, etc.).
Full scale rail joints testing on up to simulated -60̊ C.
Results: Nil Ductility Temperature determination,
Charpy-V and DWTT brittle-to-ductile transition temperature determination on laboratory (specimen) and full scale (rail) condition: rail and joints
DWTT lab test @ low temp
CSM for Railway
Design & Testing of Components & Structures (for severe conditions)
Problem: Thermal behaviour of certain infrastructures are of primary
importance in particular in territory subjected to a high seasonal spread.
Approach: Innovative coating characterized by very low solar reflectance index
have been individuated. A specific test with full scale demonstrators been tuned up to
establish the procedure to compare standard and innovative painted steel roofs.
Summer tests, July – September, carried out in different years.
Results: A new “cool” roof has been individuated Design of roofs and walls for specific client needs. Supply chain management and qualification On site monitoring of installations and follow up
CSM for Railway
Internal temperature evolution
Innovative roof thermal behaviour
Design & Testing of Components & Structures (for severe conditions)
Problem: There are environmental conditions where infrastructures are asked to
survive without any maintenance, because difficult and costly. Typical concrete solutions cannot guarantee to fulfill some
requirements, similarly as carbon steel proposals.
Approach: A prototype has been designed with a structural galvanised steel
frame made of both 50x50mm and 25x50mm 2mm thick cold profiles. Both floor and external wall are made of innovative stainless steel
sandwich panels with increased carrying capacity. Rigid soil with screw system to take care of not completely horizontal
surfaces. In operation from early ‘90 at CSM headquarters in Rome.
Results: Total cost of ownership evaluations. A real maintenance-less solution for very severe operating conditions. Simple design even for specific client needs. Supply chain management and qualification. On site monitoring of installations and follow up.
CSM for Railway
Full stainless steel office at CSM
Design & Testing of Components & Structures (for severe conditions)
Problem: Site construction, due to its temporary status, needs
certain infrastructures for staff, employees and operations.
After a disaster, for example an earthquake, cheap and quick to install houses and offices must be made available.
Approach: Easy to install, size tailored, weight limited. House focus Office focus Full scale demonstrators in service
Results: Several moveable houses and offices designed and
tested. TIR moveable solutions. Supply chain management and qualification. On site support.
CSM for Railway
Failure Analyses on components and structures
Problem: Components and structures of the railway infrastructure or
the rolling stock can be subjected to failure or present a performance lower than requested. The correct and unambiguous identification of the root cause is essential for identifying the proper countermeasures, towards the suppliers, the contractors, or for modifying the operational practices.
Approach: Verification of the requirements set in the purchase
specifications, the applied national or internationals standards, with identification of the tests and analyses to be performed.
Sample preparation, test execution with registration of all the parameters, analyses of the results of the tests and examinations of the microstructures.
Preparation of a detailed report for the client and discussion.
Results: Identification of the root cause of a failure or the lack of
performance Suggestion of modified prescription, tests or qualification
campaigns.
CSM for Railway
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Content
CSM General presentation
CSM for Railway
Technological Offer
CSM Labs & Competences– Coatings & Surface Treatments
– Corrosion
– Welding
– High Performance Computing
– Special facilities (Lab and Full Scale Testing)
The main Tribometer characteristics are:
• Test Load: max 5000 N• Shaft angular speeds with speed
continuous control• 100-500 rpm (both directions)• 100-1200 rpm (both directions)
Railtrack Operation: Special Testing Design
CSM Services for Railway
CSM Labs & Competences
Coatings & Surface Treatments
Surface Treatments Cleaning, Degreasing Surface conversion Mechanical finishing
Metallic & Ceramic Coatings
Hot dip coatings (Zn, Al, alloys)
Electrolytic coatings Thermal spray coatings Vapour deposition coatings
(PVD)
Organic Coatings Painting Fusion and film laminating
coating
Polymeric Materials Adhesives and sealants Metal-plastic composites Rubber & plastics
Hot Dip Technology
Physical Vapour Deposition (PVD)
Thermal SprayThick (0.5mm min) inner metallic protection up to 6m
Polymeric materialsAdhesive bonding
CSM Labs & Competences
Coatings & Surface Treatments
CSM experience for Railway contractors
Assessment of infrastructures coatings / paints: External paints for steel structures New coated steels Stainless steel use
Basic coating characterizations (microstructure, thickness, hardness, …).
Evaluation of the coating resistance to deformations
Evaluation of the coating resistance to environments simulating actual applications
Mechanical testingFull Scale Environment Resistance Test
Flexural Test
CSM Labs & Competences
High Performance Computing
Main fields of application are: Rolling Forging Hot forming processes Continuous casting process In service performances of components working
in severe thermo mechanical conditions Fluid Dynamics Casting
In almost all these fields microstructure solid phases evolution is taken into account by means of in house developed softwares.
Deep knowledge of related industrial processes
CSM Labs & Competences
High Performance Computing
Framework Field Software
Process design
Hot/Cold Forming
ABAQUS
LS-DYNA
MSC-MARC
Welding SYSWELD
Casting PROCAST
Fluid Dynamic analysis FLUENT
Product design
Stress/Fatigue/Thermal/Shock analysis
MSC-MARC
MSC-NASTRAN
ABAQUS
OPTISTRUCT
BallisticLS-DYNA
ABAQUS
Crash analysisABAQUS
LS-DYNA
CSM Labs & Competences
Lab & Full Scale Testing Facilities
Since 70’s CSM has been deeply involved in industrial research projects aimed at the experimental assessment of the structural integrity performances of materials and components for the oil and gas industry.
Essential tools for carrying such investigation are the CSM laboratories where both small scale (mechanical, corrosion and stress corrosion) and full scale testing is executed.
In particular the CSM’s Full Scale Testing Laboratory (FST Lab) is equipped with ad hoc design facilities for testing on a full scale base plates, pipes, welded joints, tubular connections, etc. reproducing the most severe in field service conditions (high pressure, low temperature, fatigue, combined loading, dynamic impact, aggressive environments, etc.).
Laboratories are located in Roma and in Sardinia (Capoterra, Elmas, Perdasdefogu).
CSM Labs & Competences
Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory
Evaluation of the mechanical behaviour of metallic materials and components on both small and large scale by means of conventional and innovative testing dedicated laboratories. Tests can be carried out simulating service life environment (air, saline fogs, sea water, cathodic protection) in a temperature range from -196°C up to +1100°C).
Testing typologies: Facilities:
20 Servo hydraulic testing machines from 100 up to 2500 kN
53 Testing machines mono e multispecimens (325 specimens in parallel can be tested) for creep tests (temperature max 1300°C)
1 Servo mechanical testing machine for creep fatigue
1 Servo mechanical testing machine for creep ceramic
Multipurpose platform for testing on component
Special testing carried out by sized frames
Mechanical testing at low and high temperature (tension, compression, bending). Hardness survey.
Fracture mechanics (CharpyV, KIC, CTOD, J-int. measured by SENB and SENT specimen, Segment test).
Creep and creep-fatigue on metallic and ceramic materials.
Fatigue (constant and variable amplitude, HLC, LCF and TMF).
Multi Plastic Straining Cycling (reproducing plastic strain history of interest).
Multiaxial fatigue testing on large scale components (pipes, plates, rails, welded joints)
CSM Labs & Competences
Lab & Full Scale Testing Facilities – Mechanical Testing Laboratory
Welded plate, fatigue, max
frequency 2 Hz, max load 1000 kN
Creep Testing LabMechanical Testing Lab
CSM Labs & Competences
Lab & Full Scale Testing Facilities – Residual Stress Laboratory
The Laboratory is located in Roma, within the Central Full Scale Testing Laboratory.
Methods that are available for residual stress measurement are: Strain gauge methods (Hole drilling, Sachs, sectioning, etc.); X-Ray Diffraction System (XRD).
Stress X-3000 Hole drilling
CSM Labs & Competences
Lab & Full Scale Testing Facilities – Stress Corrosion Testing Laboratory
Evaluation of the material corrosion behaviour by accelerated test campaigns in simulating operating conditions using dedicated laboratories :
Corrosion and electrochemical laboratory Stress corrosion laboratory. High Temperature High Pressure (300bar, 300°C) testing in autoclaves.
Uniform Corrosion and Stress Corrosion Resistance of stainless steels in industrial environments: inorganic acids, chlorides, heavy brines, sulphides, caustics.
CSM’s attendance of Corrosion Standardisation Committee: NACE, EFC, ISO, API
(CSM is qualified ACHILLES as a supplier for the Oil Industry of the North Sea)
CSM Labs & Competences
Lab & Full Scale Testing Facilities: EN, ISO, ASTM tests
CSM Labs & Competences
Lab & Full Scale Testing Facilities – Full Scale Testing Laboratory
Drop Weight Tear Test (DWTT) Device
Equipment main features: Max fall height : 4m. Max Impact energy available : 29,000 Joule. Test at low temperature cooling down the sample at
the required temperature
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Thank you for your attention!