Fast spare parts production for rail vehicles

View of an arc processing center from Gefertec. It only took a few hours to print the anti-roll damper. © Gefertec

But can additively manufactured parts meet the extreme requirements of rail transportation? For Jurdeczka, the answer is clear: "WAAM is the right process to achieve the required quality." In the WAAM process, metallic workpieces are built up layer by layer using arc deposition welding - with the help of a melted wire and digital production data that is processed in automated machining centers.

Alstom had already worked with Berlin-based machine manufacturer Gefertec, which offers WAAM solutions, both as a machine supplier and as a service provider, on previous projects. The first axle box covers were manufactured using WAAM in 2020. Jurdeczka turned to Gefertec again for the wobble damper: "The positive experiences and the team's high level of expertise were decisive factors."

First, a feasibility study was carried out - based on material and geometry data. It quickly became clear that production using WAAM was possible. This was followed by material selection, path planning for the welding head and the definition of all production parameters. The design data had to be adapted for the additive process - including additional radii and production allowances, which were later milled over to achieve smooth surfaces.

After finishing, the dampers underwent extensive testing. "The anti-roll bar bracket underwent extensive static and dynamic testing," confirms Jurdeczka. The requirements are high - after all, the components have to withstand extreme loads and comply with strict regulations.

100 days to the finished component

Ready for use in just 100 days, the wobble damper from Alstom. The spare part was manufactured using the WAAM process instead of cast steel. © Gefertec

Only 100 days passed from the first study to the tested anti-roll bar console. "That was ambitious - and a record," says Jurdeczka. He expressly praises the collaboration with Gefertec: "The transparency in the course of the project and the uncomplicated evaluation of the results were convincing."

For Alstom, WAAM is a real alternative to traditional manufacturing - especially where fast availability and a long service life are required. The switch from physical to digital warehousing becomes possible. Alstom already offers additively manufactured parts via the StationOne platform. Jurdeczka draws a clear conclusion: "In future, it will make sense to gear the design towards additive manufacturing from the outset."