CYTEC.

COM

Composite Materials for

Rail Structures & Carriage Interiors
Light Weighting and Fire Protection
CYTEC INDUSTRIES | INDUSTRIAL MATERIALS

Cytec leads the way in the provision of structural and interior prepregs to the rail industry,
supplying epoxy and phenolic resin systems formulated to comply with stringent fire
requirements. Our portfolio includes a comprehensive range of processing consumables
and tooling solutions, all of which are fully compatible with our prepregs.

A typical composite panel weighs Reduced weight lowers initial inertia, allowing higher speeds
• 50% less than aluminium to be achieved quickly and efficiently. This also has the
potential to reduce track load, decrease wear and lower
• 80% less than steel
trackside maintenance costs.

Our design, engineering and application support departments

offer a unique service to assist customers in converting
existing structures from current material configurations into
weight-saving, cost effective prepreg formats.

Cytec Offers Prepregs and Composite Materials

• Phenolic and epoxy prepregs qualified by major Original Benefits of Cytec prepregs
Equipment Manufacturers (OEMs) and their Subcontractors.
• Suitable for low cost vacuum bag processing, and press and
With our in depth understanding of the rail rolling stock
autoclave moulding
market, Cytec is ideally placed to offer the correct prepreg
resin system from our range to meet any of the myriad of • Ease of use with a broad processing window
international fire regulations.
• Ideal for monolithic and sandwich structures
• Tooling materials for the manufacture of the tooling
hardware necessary to form our prepregs • Ideal for simple and complex shapes

• Film adhesives • Provide an excellent surface finish

• Vacuum bagging consumables • Offer good mechanical performance

• Extensive collaborative R&D capabilities • Supplied across a wide range of fabrics and fibres

• Global materials manufacturing facilities

• A commitment to short lead-times

• Worldwide support from sales representatives and

technical staff

Everything we do is underpinned by our customer-first

approach and a commitment to creating tomorrow’s
solutions, today.
Composite Materials Product Selector Guide
Our MTM® prepreg technology allows for the manufacture of lightweight advanced composite panels for carriage interiors,
and interior and exterior structural applications.

Applications

Prepreg Resin Type Carriage Interiors Exterior Panels Structural Parts

MTM® 82S-C Phenolic Yes Yes Limited

MTM® 29SFR Epoxy Yes Yes Yes

MTM® 348FR Epoxy Yes Yes Yes

XMTM® 30 Bio-resin Yes Limited No

Applications Fire Performance

• Carriage Interiors: MTM ® 82S-C phenolic resin prepregs comply with:
– Wall panels and partitions • BS476 Parts 6 and 7
– Window frames • BS 6853 Cat 1a
– Connecting archways • NF P 92-501 Rating M1
– Floors, ceilings and decking • NF F 16-101 Rating F1
– Bulkheads and standbacks • DIN5510 Rating S4, SR2, ST2
– Luggage racks and compartments • EN45545-2:2013, Categories HL1, HL2, HL3
– Seating and furnishings
MTM ® 29SFR epoxy resin prepregs comply with:
– Hatches and doors
• BS 6853 Cat 1b (exteriors)
– Drivers’ cab instrument panels
• BS 6853 Cat 2 (interiors)
• DIN5510 Rating S4, SR2, ST2
• Exterior panels and structural parts
MTM ® 348FR epoxy resin system recentlydeveloped meets
– Front end fairings
the requirements of:
– Energy absorbers
• EN45545-2:2013, Category HL2
– Doors and inspection covers
• ASTM E662-09
– Bogie debris inspection plates
• ASTM E162-08
– Stone guards
• ASTM E1354-08
– Sundry interior and exterior structural parts
• BSS 7239
– Composite rooves and carriages
XMTM 30, a bio-derived resin development product
– Bogie leaf springs
complying with:
– Bogie frames and fittings
• EN45545-2:2013, Category HL3
– Tunnel reinforcement props and panels
– Fishplates
Process Materials
We offer composites processing materials and consumables optimised for this market and which are completely compatible
with our structural prepreg range.

Prepreg Processing Value-Added Consumables & Engineering Solutions

We offer a select range of consumables for high-temperature We focus on reducing the cost of resin infusion processing,
curing (over 212°F/100°C), including: and offer:
• VACFILM450V 338°F (170°C) vacuum bagging film • Welded/tailored vacuum bags
• High air flow breathers • Combination assemblies of consumables to reduce
• High temperature sealant tapes lay-down time

• Quick release/high temperature peel ply • Reduce labour costs

• Release films • Reusable vacuum bags and kitted consumables

• Flash tapes We support our customers by providing tailor-made, kitted

solutions offering total cost of manufacture reductions
Resin Infusion Processing through time savings, excellent process repeatability and
reduced wastage.
We offer unique consumables, including INFUPLY, VMS2 and
CW3, designed to cater for market requirements, including: Customers also benefit from onsite support, technical
• Reduce labour costs expertise and labour-saving consultancy.

• Minimise the scrap rate Other items are available upon request and our technical
• Improve part repeatability data sheets are available online.

Tooling
Cytec innovation extends to providing a complete solution to the customer part manufacturing experience. As such, we not
only offer the structural materials and their process consumables, but also a complete range of composite tooling solutions.
Our tooling prepregs offer outstanding surface finish and longevity for the manufacture of complex mould tools. Our design
service can support tool design optimisation to ensure a fit-for-purpose solution. In addition we offer soft tooling technology
including reusable vacuum bags, integral heater blankets, intensifiers and caul sheets.

CASE STUDY: Bombardier Passenger Trains

Ipeco Composites manufactured 960 standbacks for Bombardier Class 379 Electrostar
EMU passenger trains with Cytec’s MTM® 82S-C phenolic prepreg (meets BS6853 Cat.1a).
Prepreg, in comparison with wet layup, reduced manufacturing thanks to:
• Improved surface finish
• Improved dimensional tolerances
• Reduced overall weight

The robust composite standbacks were installed without rework, reducing onsite labour costs
Standback on the National
and contributing to the quality and timely delivery of this fleet of trains.
Express trains.
National Express, operating the trains, will benefit from reduced in-service operation and
maintenance costs thanks to a significant weight saving. Indeed, at only 6.4kg (14lb) per unit,
the standbacks provide a 40% reduction over a typical 10.5kg (23lb) wet layup structure.
 RAIL STRUCTURES & CARRIAGE INTERIORS

Process Materials Product Selector Guide

Prepreg product °F
Bagging film Release film Sealant tape Peel ply Breather Flash tape
(°C)

VACFILM 450V A6000 FT1

LTS90B A100 AB100
250 (120) Epoxy OOA HS8171 A5000 FT2
UCS180 B100 AB10
STRETCHVAC 3000 A2000 FT5

VACFILM 450V A6000 LTS90B FT1

250 (120) Epoxy in- A100 AB100
HS8171 A5000 UCS180 FT2
autoclave B100 AB10
STRETCHVAC 3000 A2000 SM5142 FT5

SM5142 FT1
HS8171 A6000 A100 AB100
350 (180) Epoxy OOA SM5127 FT2
STRETCHVAC 3000 A5000 B100 AB10
SM5130 FT5

SM5142 FT1
350 (180) Epoxy in- HS8171 A6000 A100 AB40N
SM5127 FT2
autoclave STRETCHVAC 3000 A5000 B100 AB10
SM5130 FT5

A6000 SM5142 AB100 FT1

60001
Phenolic VACFILM 450V A5000 SM5127 AB10 FT2
G500
A2000 RS200 AB40N FT5
AB100
VACFILM 200 AB10 FT1
A2200
VACFILM 300R FT2
A2000 LTS90B VMS2
Epoxy Infusion VACFILM 400Y A100PSI FT5
E2760 UCS180 Vi1
VACFILM 450V GFMT (bonding
A6200 Vi2
VACFILM 800G tape)
Infuply (resin carrier)
AB100
VACFILM 200 AB10 FT1
VACFILM 300R A2200 FT2
LTS90B VMS2
Polyester Infusion VACFILM 400Y A2000 A100PSI FT5
UCS180 Vi1
VACFILM 450V E2760 GFMT (bonding
VACFILM 800G Vi2 tape)
Infuply (resin carrier)

CASE STUDY: Kuala Lumpur Monorail

DK Composites used Cytec’s MTM® 29SFR epoxy prepreg to manufacture the skin of sandwich constructions for the cab masks
and apron doors of the new, lower weight, trains for the Kuala Lumpur monorail system.

MTM® 29SFR:
• meets the fire requirements of DIN 5510 for rolling stock
• has the added advantage of being able to bond directly to both foam core and aluminium
honeycomb by vacuum bag processing alone and without the need for any additional
adhesive film, thus significantly reducing manufacturing costs and part weight
• can be moulded to complex shapes
• offers good surface finish

Significant weight savings were achieved with the new apron doors and the cab masks in
Kuala Lumpur Monorail comparison with the older trains. See table below:

Construction Weight Reduction

Old New Kg/Train %
Aluminium composite panel with Epoxy/glass prepreg with aluminium
Apron door 745 49
tubular steel frame honeycomb
Hand-laminated polyester/glass/
Cab mask Epoxy/glass prepreg with PET foam 268 30
PVC foam
 CYTEC.COM

COMPLETE COMPOSITES PORTFOLIO

Suitable for low cost vacuum bag processing, excellent surface finish, ease of use with
a broad processing window, good combination of mechanical performance, fatigue
resistance and toughness, and supplied across a wide range of fabrics and fibres.
Resin chemistries include epoxies, phenolics, vinyl esters, bismaleimides,
thermoplastics, cyanate esters, HT polyimides, polyesters, ceramics.

Carbon Fibers: Standard modulus, Epoxies, phenolics, vinyl esters, cyanate

intermediate modulus, pitch fibres. esters, bismaleimides, HT polyimides,
Composites surfacing films, structural films, bond
Textiles: Standard weaves, bias
primers, lightning strike, silicone
weaves, internally consumed. & Prepregs
sealants, paste/potting/foams.

Carbon Fiber Film & Paste

Design: Supporting tool & Textiles Adhesives
design optimisation.
Tooling Materials: Tooling
prepregs for outstanding
surface finish and longevity. Ablatives, pre-forms,
friction materials,
Tool Manufacture: cross-plied materials,
Complete manufacturing Specialty
Tooling high-drape formats,
service. Products
selective impregnation,
Reusables: Soft tooling core materials.
technology including
reusable bags, heater
blankets, intensifiers
and caul sheets.
Technical
Kitting
Competencies
For increased part manufacturing Material science, polymer chemistry,
productivity, quality, reliability Process processing science, and technical
and reduced waste. From simple Materials service and application engineering,
shapes to complex kits of any/all e.g. design assistance with resin
of our products. From CAD to fully infusion networks, design for
assembled vacuum bag kits. manufacturing, crashworthiness
and intrusion analysis.
Vacuum bagging films including film welding, perforating and
processing, breather fabrics, peel plies, release films, flow media,
release fabrics, sealants, reusable vacuum systems to suit specific
tooling requirements, elastomeric tools, and design services.

Contact Information:
Industrial Materials Process Materials
tel: +44 (0) 1773 766200 - Heanor, UK tel: +44 (0) 1274 550500 - Keighley, UK
tel: +44 (0) 161 653 4876 - Manchester, UK tel: +33 (0)5 61 37 89 89 - Toulouse, France
tel: +1 (0) 918 252 3922 - Tulsa, USA tel: +39(0) 039 6892987 - Milan, Italy
tel: +86 21 64228920 - Shanghai, China tel: +1 (0)562 906 3300 - Santa Fe Springs, USA
[email protected] tel: +86 21 64228920 - Shanghai, China
[email protected]

© 2014 Cytec Industries Inc. A4 Rail Flyer Feb-2014