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ADVANCED TECHNOLOGICAL SERVICES FOR THE RAILWAY SECTOR

TECNALIA · LAB_SERVICES

TECNALIA INSPIRING BUSINESSLAB_SERVICES I RAILWAY SECTOR

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At TECNALIA, we offer testing, certification, product development and engineering services for our clients in the railway sector.

In addition, we have a network of multi-disciplinary laboratories.

TECNALIA can help you to:

Obtain the assessment required to become a sector supplier;

Benefit from independent tests and assessments on your products and processes, in compliance with safety requirements;

Meet compulsory, voluntary, or contractual requirements; and

Complement your expert assessment skills required for your R&D projects.

ADVANCED TECHNOLOGICAL SERVICES FOR THE RAILWAY SECTOR

TECNALIA HAS THE CUTTING-EDGE TECHNICAL EQUIPMENT AND PROFESSIONAL RESOURCES REQUIRED TO PROVIDE ADVANCED TECHNOLOGICAL SERVICES TO SUPPORT YOUR OPERATIONS IN THE RAILWAY SECTOR AT EACH LEVEL OF THE SUPPLY CHAIN.

INSPECTION AND ENGINEERING CENTRE

PRODUCT SAFETY CENTRE

MATERIALS TECHNOLOGY CENTRE

SERVICES

Testing and Analysis under specific standards or specifications.

Analysis and diagnosis of “non-conformities”.

Quality Control / Conformity Assessment.

Characterisation and reverse engineering.

Design of tests and trials

Review and design of product and process specifications.

Failure Analysis and Prevention (RCA).

Selection of protection materials and systems.

Product validation.

Predictive maintenance.

Structural integrity (ECA, FFS-FFP).


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Metallic materials (steels, castings, aluminium alloys, copper, nickel, titanium, etc.)

Plastics and Composites.

Ceramic materials

Paints and Coatings.

Adhesives and Sealants.

Welding.

Ceramic materials.

Glass.

Plywood panels.

etc.

Mechanical testing.

Chemical analysis.

Materialographic / metallographic analysis.

Microanalysis and electronic microscopy.

Vibration tests.

Acoustic tests.

Durability tests.

Optical characterisation.

Reaction to fire tests.

TECNALIA’s materials technology centre has a multi-disciplinary team of experts capable of addressing the characterisation and evaluation of a wide range of materials.

The characterisation of materials studies the material structure and properties, and their relationship with the material composition and thermal-mechanical history.

Therefore, the knowledge of the properties, behaviour and performance of the materials in the face of different service requirements becomes the basis of multiple disciplines, ranging from quality control, or the development of new products, to status or residual life evaluation.

MATERIALS TESTING AND ASSESSMENT

AT TECNALIA WE ADDRESS CHARACTERISATION FROM A COMPREHENSIVE POINT OF VIEW.


Mechanical testing on materials and components

Static and dynamic tests: tensile, compression, flexure and bending.

Fatigue tests: axial (HCF and LCF), rotating bar bending, crack growth (da/dN).

Brinell, Rockwell and Shore hardness tests.

Charpy impact tests from -85 ºC to 300ºC and at -196 ºC.

Creep and stress rupture tests up to 900 ºC.

Fracture mechanics: CTOD, KIC

, JIC

.

Test conditions:

• Room temperature.

• In chambers from -70 ºC to +300 ºC.

• In furnaces up to 1100 ºC (only for tensile, compression and fatigue tests of specimens).

• Resonant fatigue up to 250 Hz.

Multiaxial Fatigue Test RIG (with 3 actuators):10 kN, 50 kN and 100 kN.

Tested materials Types of tests


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OUR LABORATORIES ARE ACREDITED BY CURRENT NATIONAL AND INTERNATIONAL STANDARDS AND HAVE RECEIVED MULTIPLE RECOGNITIONS.

Chemical analysis

Chemical analysis of a wide variety of metallic materials, such as:

Ferrous materials: medium and low alloy steels, stainless steels, castings, manganese steels, tool steels, easily machined steels, etc.

Non-ferrous materials: aluminium alloys, cobalt, copper, magnesium, nickel, lead, tin, titanium, etc.

Chemical characterisation of raw materials: sand, carbons, dolomites, magnesite, direct reductions, briquettes, ferro-alloys, etc.

Characterisation of waste from melting processes (slag, steel dust, sand, etc.)

Chemical control of surface treatment baths: alkaline cleaning, Tartaric-Sulphuric Anodising (TSA), chemical conversion, passivation, acid pickling, etc.

Materialographic / metallographic analysis

Macroscopic examination of welds.

Macroscopic examination of all types of materials (micro structure, grain size, inclusions, coating thickness measurements, etc.) amplified up to 1000 times.

Micro-hardness tests (Vickers, loads from 10 g to 30 Kg) and determination of surface treatment depths.

Metallographic replicas.

Phase/particle quantification through image analysis.

Analysis of unions in electronic components.

Microanalysis and electronic microscopy

Scanning electron microscopy (fractographic analysis, etc.).

Energy Dispersive X-ray Spectroscopy (EDS): qualitative and semi-quantitative analysis.

Wavelength dispersive spectroscopy (WDS): qualitative analysis, mappings...

X-ray diffraction (XRD): Identification of phases, textures, measurement of residual stress...

X-ray photoelectron spectroscopy (XPS): Semi-quantiitative surface analysis.

Atomic force microscopy (SPM-AFM): topographical analysis.

Raman spectroscopy: identification of chemical compounds.



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Acoustic tests

Determination of sound absorption in reverberation room and impedance tube.

Airborne and impact sound insulation tests.

Optical characterisation

Optical characterisation of finishings and surfaces by UV-VIS-NIR spectroscopy.

Tests and calculations to determine light, sun and UV transmittance, reflectance and absorption and surface emissivity.

Evaluation by optical characterisation before and after ageing and durability tests.

Calculation of colour coordinates.

Brightness and colour measurements.

MATERIAL TECHNOLOGY CENTRE

Reaction to fire testing

Characterization of reaction to fire performance, smoke toxicity and density by means of bespoke protocols or standardized methods.

Test methods for classification according to EN 45545-2 “Requirements for fire behaviour of materials and components”:

Smoke toxicity test EN 45545-2 Annex C.

Smoke density tests ISO 5659-2 / ASTM E 662 / NFX 10702.

Spread of flame test ISO 5658-2.

Reaction to fire test ISO 5660-1 / ASTM E 1354.

Oxygen index test ISO 4589-2.

Ignitability test EN ISO 11925-2.

Flammability and spread of flame test according to UL 94; EN 60695-11-10.


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Rolling stock

Bogies

Springs

Axles

Hardware

Seats

Floors and ceilings

Windows and enclosures

Panels

Access, escape and automatic doors...

Loads on vehicle bodies and components

Floor panels and plywood

Glass elements

WC modules

Electronic components

Driving consoles and desks, external end and front cars, cowling

The product safety centre consists of a team under continuous development to adapt to the assessment needs related to innovation and safety of railway sector products.

PRODUCTS TESTING AND ASSESSMENT

Tested products

Durability tests

Hygrothermal tests.

Moisture resistance tests.

UV resistance tests.

Biological agent resistance tests.

Corrosion tests.

Wear testing.

Abrasion test.

Thermal behaviour test. Thermal-environmental performance

Acoustic performance

Physical-mechanical performance

Fire safety performance

Electro-magnetic performance

Types of tests



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Fire performance analysis of products for railway vehicles

Design of bespoke protocols for fire resistance and reaction to fire tests.

Guidance and assessment of results regarding compliance with more demanding technical specifications. Proposals for improvement in the event of non-compliance with specifications.

Scanning and performing of indicative tests on product ranges to analyze expectations of compliance with more demanding requirements of reaction and resistance to fire.

Reaction to fire test methods for classification according to:

EN 45545-2 “Requirements for fire behaviour of materials and components”.

EN 45545-3 “Fire resistance requirements for barriers”.

ASTM E 119 Fire resistance test for the railway sector.

Fire resistance and smoke control tests for doors, shutter and openable window assemblies and building hardware.

Fire resistance tests for non-loadbearing elements (suspended ceilings).

Fire resistance tests for loadbearing elements (flooring and roofing).

Physical-mechanical performance

Evaluation of structural safety of components and service life analysis.

Thermal-environmental performance

Thermal transmittance testing of railway rolling stock.

Climatic testing in actual mock-ups: cold, heat, snow, ice. etc.

Acoustic performance

ISO 10140-2 (former ISO 140-3). Determination of airborne sound insulation in vehicle elements solutions.

ISO 354. Measurement of sound absorption in a reverberation room: panels, seats and screens.



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The study and knowledge of the service performance of materials and systems is an essential part of the different life cycles of a component. Materials are critical not only in the design phase but also in the manufacturing, assembly and useful service life stages.

Knowledge of materials and their properties is determinant in redesign tasks, failure analysis and prevention, status assessment, life forecast and extension, damage tolerance and structural integrity. Furthermore, such knowledge is crucial throughout the whole life cycle of the component in terms of efficiency, durability, integrity and safety.

Our studies cover the four basic types of failure mechanisms:

Mechanical

Corrosion

Wear

High temperature

TECNALIA has broad experience in the field of materials, material properties and damage and failure mechanisms.

Our expertise enables TECNALIA to offer services related to the service performance of materials and components (material selection, failure analysis, residual life assessment, damage tolerance, etc.) in the different possible scenarios (mechanical, corrosion, wear and high temperatures).

Studies of fractured rails in thermite welding zone.

Root cause analysis of rail breakage during straightening.

Damage tolerance studies in train wheels.

Pathologies of bearings in railway axle boxes.

MATERIALS ENGINEERING

REALITY CAPTURE, 3D DIGITALISATION

Services:

Geometric design capture

Accurate as-Built 3D model for rolling stock refurbishment projects.

Complex geometry capture for design/repair/maintenance of new components and equipment.

3D modelling based on captured data - Skills in different CAD3D softwares.

Geometry capture during manufacturing

Three-dimensional control of plastic elements and components: operator consoles and desks, interior design, front and rear skirting, cowling and other plastic and composite components.

Three-dimensional control of metallic components: wheels, axles, bogies and other metallic components.

Design and installation of automated measurement and monitoring systems. Generation of automated inspection routines based on geometrical data in templates.

Rolling stock gauge verification for destination route (tunnels, stations, vegetation, etc.) - UIC 505.

Geometry capture during maintenance

3D inspection of components - Matching CAD design with reality (point cloud)

Geometry capture of misaligned or damaged elements.

Reverse engineering in components. Chemical and dimensional analysis and report generation for manufacturing. Highly indicated for out-of-stock components.


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Inspection of pathologies in road and railway tunnels

Quality assurance of railway works

Revision of subcontractors’ and assistance contractors’ quality assurance plans

Follow-up audits for subcontractors and technical assistance contractors

Control of suppliers’ processes

Test plan supervision

Audits for quality control laboratories

On-site quality control testing

Characterisation of specific materials: track ballast and sub-ballast, concrete prefabricated elements

Slope examination

Inspection of buildings close to the works

ON-SITE QUALITY CONTROL AND TECHNICAL ASSISTANCE

ACCREDITATIONS AND RECOGNITION

Laboratory with management system certified by UNE-EN 9100:2018.

Laboratory certified by the environmental management standard ISO 14001.

ILAC-ENAC accredited laboratory in accordance with standard UNE-EN ISO/IEC 17025:2017 for metallic materials, concrete, by-products and their constituents Coatings, sealants and adhesives, fire and acoustic performance, accreditation no. 4 /LE063, 4/LE024 and LE456.

AIRBUS authorised laboratory for Control testing of surface treatment plating and metallic materials.

ESA (European Space Agency) authorised laboratory for “SMT Microsectioning” in accordance with ECSS-ST-Q-70-38.

Nadcap accreditation for Chemical Processes.

Nadcap accreditation for Material testing.

Tunnel inspection authority for Bizkaia (OITB) since 2008; over 80 tunnel inspections.

Technical Assessment Body (TAB) for the issue of European Technical Assessments (ETAs).

Laboratory registered in the General CTE Register, section 5-1: PVS-L-013 in geotechnical engineering, roads, concrete, service tests, steel structure, masonry.

Collaboration in the working group GT116 of ADIF standardisation committee on railway acoustic screens.

Member of the Spanish Railways Technological Platform (PTFE).

Member of the European Group of Organisations for Fire Testing, Inspection and Certification (EGOLF ).

Laboratory approved by CERTIFER to perform tests according to EN 45545-2 and for I & F classification.


Materials TestingChemical Processing


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TECNALIAIS A BENCHMARK RESEARCH AND TECHNOLOGICAL DEVELOPMENT CENTRE IN EUROPE

FROM SCIENCE TO MARKET

COMPANIESUNIVERSITIES AND PUBLIC RESEARCH CENTRES

TECNALIA

Basic Research Applied Research Experimental Development

Advanced technological services specialised in the evaluation and diagnosis of products, processes and materials.

R&D and Innovation projects for the development of new products and processes or for the improvement of existing ones.

Development of technological assets ready to generate new business

ADVANCED TECHNOLOGICALSERVICES _

INVESTMENT OPPORTUNITIES _

R&D AND INNOVATION PROJECTS _

YOUR PROJECT

We transform technology into wealth to obtain beneficial visible results for companies, society, our environment and in short, for people.

We transform technology into GDP

MISSION

TYPE OF SERVICES


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TECNALIAParque Científico y Tecnológico de Bizkaia Astondo Bidea, Edificio 700 E-48160 Derio (Bizkaia) (Spain) Tel.: +34 902 760 000

Our work is not understood without yours; we want to work together so your company can compete better.Because together, we can develop technologies that transform the present.

The future is technological,let's share it!

WE CAN DO SO MUCH TOGETHER

www.tecnalia.com

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Industry Labs Director:

Virginia [email protected]. +34 678 671 594

Industry Labs Market Manager:

Angel Doblado [email protected]. +34 647 402 327

tecnalia · lab services advanced technological … · analysis and prevention, status assessment,...

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