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26 Oct 2005  -  Switzerland

New core materials for rail applications - BALTEK® SB.100 and AIREX® T90

The lighter weights and increased stiffness of cored composite construction are as ideally suited to the requirements of the rail industry as they are to marine and windblades, where composite construction has now become the norm. With increasing energy costs, lighter weight construction generates real economic advantages for both existing and future cars. From the early use of core materials in rail applications BALTEK® end-grain balsa has been one of the preferred core materials with either metal or composite skins. The extremely high compression and shear strength of BALTEK® balsa and the exceptional Flame, Smoke and Toxicity advantages of sandwich structures made with balsa are well suited to the requirements imposed on the rail industry. Balsa, the only core that is a completely renewable resource, also exhibits very good thermal and sound insulation qualities. Properly installed balsa will offer a lifetime of reliable service. However, with the recent introduction of BALTEK® Gold with a Limited Lifetime Warranty, the reliability of balsa is further enhanced. These combined properties make BALTEK® SB.100 and BALTEK® SL end-grain balsa versatile core materials for flooring, side walls, roofs and interiors in many rail applications.

The recent introduction of AIREX® T90 PET foam core by Alcan Composites Core Materials offers a complementary core to balsa in the rail industry. Like Balsa, AIREX® T90 has exceptional FST properties that suit it to use in rail transportation. T90’s high compressive strength and screw holding abilities allow its use to “close out” the edges of balsa cored panels, or as high density inserts to replace balsa in areas of thru-bolts or screw attachments. This new PET based structural foam provides a unique combination of mechanical, chemical and thermal properties that are not available from existing foam core materials. AIREX® T90 is very easy to machine and is compatible with all commercially available resins or lamination technologies. AIREX® T90 foam passes relevant European rail transit fire specifications like NF 16-101 and DIN 5510. High density T90.320 passes the FAR 25.853 flammability, smoke density and toxicity tests as well. This high degree of fire resistance and ability to withstand long term service temperature, (up to 100°C), combined with ability to bond to different surface materials such as aluminium, steel or GRP Skins makes this new structural foam core ideal as complementary core material to end-grain balsa in rail applications. T90 is also free of out gassing or after expansion during laminating or long term service at elevated temperature

The combination of BALTEK® SB.100 balsa cores and AIREX® T90 - Easy Processing Structural Foam – achieves high mechanical values with easy processing possibilities, excellent chemical and thermal stability and outstanding FST properties. This unique combination makes BALTEK® balsa and AIREX® T90 ideally suited for floors, sidewalls, interior panels and roofs in any rail application. Alcan Composites Core Materials with its two leading companies Alcan Airex and Alcan Baltek offer AIREX® T90 foam core in a density range from 100 to 400 kg/ m3 in a wide variety of thicknesses.

Source : Alcan Airex AG