Lightweight Design worldwide

, Volume 10, Issue 6, pp 12–17 | Cite as

Train Front Module in Aluminium-foam-sandwich Design

  • Susi Rybandt
  • Carsten Lies
  • Thomas Hipke
Cover Metal Foam

Rail vehicles shall be lightweight but also meet the high requirements for crash resistance, long life fatigue strength and fire protection. A developed front module made of aluminium foam composites fulfills these demanding requirements. In addition to its construction, the project team developed manufacturing concepts for this composite material.

Lightweight Front Module

Not only automobiles shall become lighter, more efficient, more ecological and affordable. Due to customer’s increasing environmental awareness and social responsibility in dealing with resources, issues such as electro-mobility or the use of high-performance materials are more and more in the focus of developmental work. People’s need for mobility, high demands on environmental compatibility, crash behaviour, fire protection as well as comfort, thus, create also completely new demands for rail vehicles.

Until now, two material strategies have been used — the fibre composite construction and the metallic...



The results presented here are the result of a joint project entitled “Development of a Front Module for High-Speed Trains in aluminium-foam-sandwich Design” with the project number 100067610. It was funded under the European Regional Development Fund (ERDF) by the European Union and the Free State of Saxony. The authors thank for the financial support.


  1. [1]
    Hohlfeld, J.; Hipke, T.: Aluminiumschaum Eigenschaften, Herstellung, Anwendungen. In: Volkova, O. (Hrsg.); Metallurgisches Kolloquium zu Ehren von Prof. Dieter Janke; Freiberger Forschungshefte; B 366 Werkstofftechnologie; 67. Berg- und Hüttenmännischer Tag 2016; pp. 92–102Google Scholar

Copyright information

© Springer Fachmedien Wiesbaden GmbH, part of Springer Nature 2017

Authors and Affiliations

  • Susi Rybandt
    • 1
  • Carsten Lies
    • 2
  • Thomas Hipke
    • 2
  1. 1.Institut für Werkzeugmaschinen und Produktionsprozesse at TU ChemnitzChemnitzGermany
  2. 2.Functional Integration/Lightweight Design at the Fraunhofer Institute for Machine Tools and Forming Technology (IWU)ChemnitzGermany

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