Research Development MOTTO The Future Belongs To Those

Research & Development MOTTO: - The Future Belongs To Those Who See Beyond Today! Faiveley Transport Birkenhead Ltd 1

400 km/h + u The Milestones 300 – 360 km/h 515 km/h record 250 km/h 200 km/h 160 km/h <145 km/h Faiveley Transport Birkenhead Ltd 2

u Tread Braking Faiveley Transport Birkenhead Ltd 3

u 200 km/h and above. 8 Small wheel > high power/ swept area > steel discs. Wheel mounted discs Bogie mounted caliper Faiveley Transport Birkenhead Ltd 4

u Development of disc materials. UK Compacted graphite. Steel (15 CDV 04) 8 Higher crack resistance. 8 Lower wear resistance 8 Sensitive tribology 8 Cost x 2 High strength Good tribology. Good conductivity. Low distortion Low cost + 10% Carbon % 0, 15 - 0, 20 Silicon % 0, 60 max Manganese % 0, 40 Europe Grey Cast irons. Spheroidal Graphite Good tribology. High strength Good conductivity. Reasonable tribology. Low distortion Good conductivity. Low cost High distortion - 0, 80 Phosphorus % 0, 040 max Sulphur % 0, 040 max Chromium % 0, 80 - 1, 20 Molybdenum % 0, 85 - 1, 15 Vanadium % 0, 15 - 0, 30 Nickel % 0, 50 max Low cost +10% Faiveley Transport Birkenhead Ltd 5

u Material Development Ceramic particle reinforced steel Faiveley Transport Birkenhead Ltd 6

u Crazy Ideas Faiveley Transport Birkenhead Ltd 7

u Not so crazy ideas. Aluminium Brake Disc Advantages • High thermal conductivity and low Young‘s modulus. • Therefore low tendency to thermal cracking. • Low wear of pad and disc material. • Light • No squealing • Low emission of odours as the friction contact remains cooler than with iron Brake Discs. Faiveley Transport Birkenhead Ltd 8

Aluminium Brake Disc Material Properties Comparison Density [kg/dm³] Specific Heat 150°C [J/(kg*K)] Heat Conductivity [W/(m*K)] Heat Expansion (50 – 300 °C) [10 -6 K] Tensile Strength Rm [MPa] Modulus of Elasticity [GPa] Hardness [HB] Maximum Operating Temperature [°C] Melting Temperature [°C] Faiveley Transport Birkenhead Ltd Grey Cast Iron GG D GJL 250 Aluminium DURALCAN F 3 S 20 S Comparison Factor [Al / GG] 7, 20 460 47, 5 12, 3 200 103 197 450 (500) 1250 2, 77 955, 32 185, 2 (T 6) 21, 1 165 98, 6 75 350 (400) 700 0, 385 2, 1 3, 9 1, 7 0, 83 0, 96 0, 38 0, 78 0, 56 9

Aluminium Brake Disc Thermography of a SG iron and an Al MMC Brake Disc SG Brake Disc Faiveley Transport Birkenhead Ltd Al MMC Brake Disc 10

Aluminium Brake Disc Wear of Al MMC und SG Brake Discs Faiveley Transport Birkenhead Ltd 11

Aluminium Brake Disc Pad Wear on Al MMC and SG Brake Discs Faiveley Transport Birkenhead Ltd 12

Axle Mounted Disc Development WKS Faiveley Transport Birkenhead Ltd 13

Axle Mounted Disc u Analysis of Air flow and Heating and Cooling Faiveley Transport Birkenhead Ltd 14

Aluminium Brake Disc Performance of Al MMC Brake Discs Aluminium Brake Disc ICE Performance Maximum Dissipated Energy 13 MJ Maximum Short Time Brake Power at vmax 365 k. W Maximum Continuous Brake Power at 400°C ~30 k. W Faiveley Transport Birkenhead Ltd 15

Pad Material u Pad Material Development. 8 Partnership with innovative Lining Manufacturers. 8 Pad Construction Faiveley Transport Birkenhead Ltd 16

Research & Development u Temperature variations Faiveley Transport Birkenhead Ltd 17

Research & Development Thermal stress Low speed effect High speed effect Hard lining Material Faiveley Transport Birkenhead Ltd 18

Pad Material u Pad Conformability Faiveley Transport Birkenhead Ltd 19

Pad Material u High Temperature, Soft Underlayer Pad. 8 In conjunction with Ferodo 3204 underlayer High temperature friction material Faiveley Transport Birkenhead Ltd 20

Pad Material u Improving Conformability for VHST 8 NT Sinter pad construction for use on steel discs. Faiveley Transport Birkenhead Ltd 21

u Why lighter discs? Faiveley Transport Birkenhead Ltd 22

Research & Development CERAMICS - THE FUTURE. Faiveley Transport Birkenhead Ltd 23

Research & Development THE PROBLEM Faiveley Transport Birkenhead Ltd 24

Research & Development u Development Programme (High speed Trains) 8 Targets • • • 100 MJ/ axle (88 MJ on TGV) 2 x 640 mm discs ( To replace 4 steel discs on TGV). 10 year disc life Economical pad life - 1 year. 50% weight reduction, both unsprung and total. Faiveley Transport Birkenhead Ltd 25

Research & Development Solution? u Fibre Reinforced Ceramic Discs / Ceramic Pads 8 Carbon fibre reinforced Silicon carbide: • Tough • Good thermal performance • Good wear resistance Faiveley Transport Birkenhead Ltd 26

Research & Development Research Route Ceramic coated steel. 1987 Monolithic ceramic 1988 Fibre re-inforced ceramic 1990 - 2003 Faiveley Transport Birkenhead Ltd 27

Research & Development Ceramic Disc Weight: - 60 kg Energy Capacity: - 30 -50 MJ Faiveley Transport Birkenhead Ltd Weight: - 96 kg Energy Capacity: - >50 MJ 28

Research & Development u Faiveley Transport Birkenhead Ltd Weight 75 kg 29

Research & Development u Ceramic and low loss steel disc Faiveley Transport Birkenhead Ltd 30

Research & Development u Friction Pair 8 Fibre reinforced ceramic disc / Ceramic pads • >1200 o. C peak temperature, >800 o. C average • > 55 MJ capability at 1, 3 m/s 2 from 370 km/h. • 0, 27 coefficient of friction. Faiveley Transport Birkenhead Ltd 31

Research & Development u Stable Friction. Faiveley Transport Birkenhead Ltd 32

Research & Development u Surrounding Temperature Distribution @ 52 MJ Actuator 90 deg C Brake gear 100 deg C Pad holder 200 deg C Disc 900 deg C Bogie Frame 35 deg C Faiveley Transport Birkenhead Ltd Ambient 35 deg C 33

Research & Development u Results 8 > 55 MJ capability. 8 >10 year disc life. - 20+ years being tested today. 8 5 month pad life. - 12 month life being tested today. 8 Potential for greater performance. 8 Target price within reach. 8 Life Cycle Cost looking attractive against sinter/ steel combination Faiveley Transport Birkenhead Ltd 34

Research & Development u Cost of operating 1 Axle over 30 years. Faiveley Transport Birkenhead Ltd 35

Research & Development u Initial cost of purchase if new actuation is required for ceramic. Faiveley Transport Birkenhead Ltd 36

Research & Development Effect on TGV fleet costs. Euro 5342 / axle/30 years. 18 axles/train. 450 train sets. Saving at today’s state of the art = Euro 1, 4 million/year. Faiveley Transport Birkenhead Ltd 37

Research & Development u Bottom Line 8 Low weight of brake installation 8 Low rotating inertia 8 Compact installation • smaller wheels. • less brakes. 8 Brakes are much less of a restriction in vehicle design. 8 Potential for significantly reduced brake running costs Faiveley Transport Birkenhead Ltd 38

Research & Development u Project Market Potential Date Volume TGV proto TGV new trains Overhaul TGV fleet ¾ - 2001 8 brakes 2003 - 2004 1300 Start 2004 - 2005 14000 Japan Not known Faiveley Transport Birkenhead Ltd 31 - 61 000 39

Research & Development A Predicted Financial Effect on the ICE Fleet Faiveley Transport Birkenhead Ltd 40

Research & Development Faiveley Transport Birkenhead Ltd 41

Research & Development Financial Effect on total ICE 2 fleet 48 axles/ train. 40 train sets. Saving / axle/ 20 years = 38 000 Euro. Total saving/ fleet/20 years = 76 000 Euro. Faiveley Transport Birkenhead Ltd 42

Research & Development Next Steps In Technology Development Faiveley Transport Birkenhead Ltd 43

Research & Development Faiveley Transport Birkenhead Ltd 44

Research & Development Faiveley Transport Birkenhead Ltd 45

Research & Development We have just begun. This is the potential of Ceramics 2003 -5 2002 Here in 1997 We are here in 2000 30 year life 20 year life 10 year life 4 year life We were down there in 1988 Faiveley Transport Birkenhead Ltd Industry is behind us - now. 46

SAB WABCO UK Faiveley Transport Birkenhead Ltd 47