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The Use of Structural Adhesives in the Construction of Rail Vehicles

Conventional railway vehicles are generally fabricated using traditional welding techniques. An extensive investigation of adhesive bonding technology as an alternative is reported. A description of how an optimum adhesive was selected and the characterization of its important properties—lap shear, fatigue, shear modulus, durability and impact—is given. The crashworthiness of large bonded details is compared with similar welded constructions. The manufacturing procedure used to produce large bonded bodysides (5.8 times 2.2 m) is described. The structural testing of bonded bodyside modules is reported and compared with a traditional welded structure. Bonded bodyside modules were incorporated into a production multiple unit. The modules had excellent finish and the unit has performed satisfactorily in passenger carrying service. Non-destructive techniques which allow disbonds to be detected during manufacture/assembly and at major service inspections are also discussed.