Research | Photon Research on Pioneering Lightweight Casing System for Trains, Busses and Ships — Photon

One of the most exciting tasks of the Photon experts is the research and development of new types of construction methods and suitable manufacturing processes.

For example, Photon recently worked on a research project together with the Brandenburg University of Technology (BTU) in Cottbus and other partners to develop a pioneering lightweight casing system (LCS), which could be used in trains, buses or on ships to protect air conditioning systems, batteries, transformers or gas tanks from falling rocks or other accidents. This is in line with efforts to use more lightweight components in the mobility sector in order to increase efficiency and reduce emissions. Lightweight construction is seen as a key technology here.

Less weight, fewer emissions, same stability

The new feature, compared to the individual special solutions currently in use, is a modular design that can be extended flexibly and thus adapted to a wide range of possible applications. The prerequisite for this is, of course, a suitable design.

For the novel LCS, a shear-panel based design was chosen, a concept known from aviation. This was combined with pioneering lightweight components (3D printing) and joining technologies (laser welding). The aim of the design: a material and thus also weight reduction of up to 20%.

Laser welding offers advantages

The involvement of Photon resulted from the specific qualities of laser welding, which make it particularly suitable for lightweight construction. The precise heat input into the joint, the low demand for filler material and the higher strength of the joint are decisive factors.

Prototype test successfully passed

Thanks to Photon’s laser welding expertise, the hybrid laminate thrust panels could be laser-welded to a frame that is connected by flexible, 3D-printed and (through simulation) load-optimised joints.

With the process windows developed for the selected components, it was possible to meet the objective of creating process-reliable and firmly bonded connections between frames and shear panels. In the course of the tests, it was determined that the production process tested under prototypical conditions could be technologically transferred to small-scale production with little effort. A concept was also developed that describes how the LCS can be produced modularly and automatically in medium quantities (<200/year).

Ready for future projects

As part of the project, which was funded by the German Federal Ministry of Education and Research, the Photon experts also defined potential for improving the design, especially with regard to the 3D-printed flexible connection joints. A challenge still to be tackled is the development of a manufacturing concept for the cost-effective production of large quantities. This requires further research and development projects in which the Photon laser welding experts can once again demonstrate their in-depth knowledge and expertise.