US3836394A - Method of manufacture of a conductor rail - Google Patents

Method of manufacture of a conductor rail Download PDF

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Publication number
US3836394A
US3836394A US00275517A US27551772A US3836394A US 3836394 A US3836394 A US 3836394A US 00275517 A US00275517 A US 00275517A US 27551772 A US27551772 A US 27551772A US 3836394 A US3836394 A US 3836394A
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United States
Prior art keywords
layer
wear
aluminum
conductor rail
intermediate layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00275517A
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English (en)
Inventor
T Kugler
H Rieger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rio Tinto Switzerland AG
Original Assignee
Alusuisse Holdings AG
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Filing date
Publication date
Application filed by Alusuisse Holdings AG filed Critical Alusuisse Holdings AG
Application granted granted Critical
Publication of US3836394A publication Critical patent/US3836394A/en
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60M—POWER SUPPLY LINES, AND DEVICES ALONG RAILS, FOR ELECTRICALLY- PROPELLED VEHICLES
    • B60M1/00—Power supply lines for contact with collector on vehicle
    • B60M1/30—Power rails
    • B60M1/302—Power rails composite

Definitions

  • the present invention relates to a method of manufacture of a conductor rail, consisting of a body of aluminum or an aluminum alloy with a layer of more wearresistant material arranged on the body and forming a sliding surface.
  • a conductor rail consisting of a body of aluminum or an aluminum alloy with a layer of more wearresistant material arranged on the body and forming a sliding surface.
  • Such conductor rails serve for supply of energy to a device, such as a locomotive, a elevator or similar electrically driven apparatus.
  • intermetallic compounds are brittle, electrically poorly conducting, and in particular the layer is not stable in its size, but continuously increases, because by means of it an electrical resistance is produced which develops heat, while its growth with rising layer thickness rapidly increases.
  • the invention starts from this and has set itself the task to provide a method of manufacture of a conductor rail, the product of which shows optimum mechanical and electrical characteristics such as resistance to wear and electrical conductivity, and the task is solved by a method of manufacture of a conductor rail consisting of a body of aluminum or an aluminum alloy on which is a layer of a second material more resistant to wear in which method the second material is applied while it is in its liquid condition and simultaneously the heat content is carried away through the body.
  • the invention in contrast to the teaching of the state of the art, sets out to make the most of the good thermal conductivity of the aluminum body for a deliberate forced carrying away the heat content of the layer of wear resistant material which is applied as liquid.
  • the aluminum body is ready formed previously. It is coated with metal only in the places where necessary.
  • deliberate forced carrying away the heat content there is to be understood the maintenance of the body temperature before application of the coating of wearresistant material, even with introduction of auxiliary means.
  • the wear-resistant material can, for formation of the sliding surface, be cast, or applied by flame spraying or spray welding. It is preferred to melt the wear-resistant material in an arc and to apply it onto the aluminum body by means of a plasma jet.
  • the method which is known under the term plasma spraying" for coating of turbine blades and the like has, for avoidance of intermetallic intermediate layers in the manufacture of conductor rails of material of the kind mentioned, the special advantage that locally sharply defined heat can be introduced into the aluminum body with the consequence of good removal on account of the remaining great cross sections with their favourable temperature gradients.
  • the method according to the invention is furthermore advantageously carried out, in that before application of the wear-resistant material on the corresponding surface of the body, an intermediate layer is applied which has good adhesion on the body and on the wear-resistant material and hinders diffusion of the wear-resistant material into the body or vice versa, whereby the intermediate layer advantageously consists of nickel, or a nickel-aluminum alloy, of tin, zinc,
  • FIG. 1 shows a sectional extrusion of aluminum intended for formation of a conductor rail 10, which consists of a box-shaped hollow section 11 and a T-section 12 connected with the box-shaped hollow section 11.
  • the box-shaped hollow section 11 has three sides 13, 14, 15 suitable for pick-up of current, each of which as required carry a layer of wear-resisting material 19.
  • the flange 17 is intended for mounting of the conductor rail at both sides. According to the shape or arrangement of the pick-up 18, the current flowing through the conductor rail 10 is taken up either from the side 13, the sides 13 and 14, the side 15, or combinations of them.
  • the layer 19 of wear-resistant material connected to the sides l3, l4 and provides a remedy against this alteration.
  • the layer 19 consists suitably of a ferrous alloy such as steel. It can however also consist of an alloy of the metals nickel, chromium, or copper, with such metals, which provides for the layer the required resistance to wear.
  • the layer 19 is applied in liquid condition to the sides, 13, 14, 15 with simultaneous rapid removal of heat, to avoid the formation of an intermetallic layer of for example steel and aluminum.
  • During said forced heat removal there is transfered heat from the layer to a third medium in contact with the body in such amount until the heat content of the layer is equal to that of the body and the transfer is performed so quickly that no increase in heat content of the body is noticible.
  • the sides 13, 14, 15 can be cast out of the wear-resisting material, in doing which it is suitable to carry out the application layer by layer, that is to say in individually thin layers with simultaneous good distribution of the liquid material over the sides 13, 14 and 15.
  • the conductor can in addition be cooled.
  • Flame spraying or spray welding are similarly suitable methods for application of the wear-resistant layer 19 in liquid form, which permit an even better distribution of the liquid with simplified additional provisions such as molding means in case of casting.
  • Especially good results concerning the adhesion of the applied layer 19 on the corresponding surfaces of the conductor rail 10 and with reference to as small as possible an electrical transfer resistance between each layer 19 and the conductor rail 10 are obtained, if the material of the layer 19 is applied by means of a plasma spray pistol.
  • the material of the layer 19 is melted in an arc, the material being generally supplied in powder from to the are burning in the spray pistol and is conveyed under high pressure in the direction out of the spray pistol onto the conductor rail 10, by means of an ionised carrier gas supplied to the spray pistol, which can be an inert gas or also disassociated water ionised into its constituents.
  • an ionised carrier gas supplied to the spray pistol which can be an inert gas or also disassociated water ionised into its constituents.
  • an intermediate layer 20 which has good adhesion to the body, i.e., to the conductor rail 10 and to the layers of wear-resistant material, and which hinders diffusion of the wear-resistant material into the body or vice versa, which can consist of nickel, of a nickel-aluminum alloy, of tin, zinc, silver, copper, or alloys of these metals.
  • the thickness of the intermediate layer 20, which can amount to between 51.1. and 300p, conforms substantially to the requirements of the wear-resistant layer 19, such as life with 'pre-determined coefficients of friction and frequency of rubbing operations, permissible tolerances of layer thickness, etc, which substantially call for the thickness of the layer 19.
  • the lowering of thermal stresses or tensions on the ground of external influences and also those brought about by coating is further supported, in that the intermediate layer 20 has pores.
  • the materials of the intermediate layer are, in a possible embodiment of the method, melted in an arc and applied by a plasma jet onto the corresponding sides 13, 14, 15, cooperating with the pick-up 18. Since these materials form no intermetallic compounds, which could disturb conduction of current, suitable considerations of manufacture, such as a rational assembly, simplification of the expenditure on apparatus etc., call for this mode of application. in addition it has appeared surprisingly that, by the application of the wear-resistant layer by means of a plasma jet, the thickness of the layer to achieve the same life as those produced according to the remaining methods, can be reduced by reason of its increased resistance to frictional wear despite the same material composition, as used for the remaining methods. Under certain conditions the wear-resistant layers produced according to the invention should subsequently be ground. The danger of a local formation of cells favouring corrosion is counteracted, in that on the narrow sides of the layers which are exposed to the surrounding atmosphere sealings can be applied.
  • the layers of wear-resistant material is applied in a thickness of 0.3 to 2 mm.
  • Method of manufacture of a conductor rail consisting of a body of aluminum or an aluminum alloy on which is a layer of a more resistant to wear material selected from an alloy of a metal of the group consisting of iron, nickel, chromium, and copper in which method the material is applied while it is in its liquid state, and simultaneously the heat content of the material is carried away through the body.
  • the intermediate layer is of a metal selected from the group consisting of nickel, nickel-aluminum alloy, tin, zinc, silver, copper and alloys thereof.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Coating By Spraying Or Casting (AREA)
US00275517A 1971-07-29 1972-07-27 Method of manufacture of a conductor rail Expired - Lifetime US3836394A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CH1121671A CH527488A (de) 1971-07-29 1971-07-29 Verfahren zur Herstellung einer Stromschiene

Publications (1)

Publication Number Publication Date
US3836394A true US3836394A (en) 1974-09-17

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Family Applications (1)

Application Number Title Priority Date Filing Date
US00275517A Expired - Lifetime US3836394A (en) 1971-07-29 1972-07-27 Method of manufacture of a conductor rail

Country Status (4)

Country Link
US (1) US3836394A (enExample)
CH (1) CH527488A (enExample)
FR (1) FR2147317B1 (enExample)
IT (1) IT963447B (enExample)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5126514A (en) * 1989-09-07 1992-06-30 Delachaux S.A. Process for producing an electrical supply rail
EP0522955A1 (fr) * 1991-07-09 1993-01-13 Delachaux S.A. Dispositif d'alimentation en électricité par contact avec un frotteur et procédé de réalisation d'un tel dispositif
FR2683955A1 (fr) * 1991-11-19 1993-05-21 Delachaux Sa Dispositif d'alimentation en electricite par contact avec un frotteur et procede de realisation d'un tel dispositif.
WO1993009972A1 (en) * 1991-11-13 1993-05-27 Inesscon, Inc. Power conductor rail
US5279397A (en) * 1991-09-28 1994-01-18 Brecknell, Willis & Co. Ltd. Conductor rails
US5310032A (en) * 1991-11-13 1994-05-10 Plichta Dietmar G Power conductor rail
WO1997022491A1 (en) * 1995-12-19 1997-06-26 Howell Corporation Composite electrical conductor rail
US6318529B1 (en) * 1998-11-02 2001-11-20 Alusuisse Technology & Management Ltd. Conductor rails, the use thereof and methods of manufacture
US20060032705A1 (en) * 2004-08-16 2006-02-16 Isham William R Lightweight composite ladder rail having supplemental reinforcement in regions subject to greater structural stress
US20060237101A1 (en) * 2005-04-25 2006-10-26 Daido Metal Company Ltd. High temperature sliding alloy
US20070205053A1 (en) * 2004-08-16 2007-09-06 Isham William R Molded composite climbing structures utilizing selective localized reinforcement
US20080251969A1 (en) * 2007-02-16 2008-10-16 Isham William R Bladder Molding Systems and Methods For Fabricating Composite Articles
CN104773093A (zh) * 2015-04-03 2015-07-15 株洲瑞泰装备技术有限公司 铜铝复合导电轨及其制作方法
CN105171436A (zh) * 2015-09-06 2015-12-23 苏州市宝玛数控设备有限公司 一种切割机钢轨

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4985313A (en) * 1985-01-14 1991-01-15 Raychem Limited Wire and cable
GB8502316D0 (en) * 1985-01-30 1985-02-27 Raychem Ltd Electrical components
DE29503490U1 (de) * 1995-03-02 1995-04-27 Bovender, Franz, Dipl.-Ing., 47800 Krefeld Fahrzeugschiene mit Metallbeschichtung
CN104439897B (zh) * 2014-11-13 2017-01-25 苏州工业园区得意机电设备有限公司 利用龙门五面体数控机床加工贴片机导轨座的方法

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US26189A (en) * 1859-11-22 Ditching-machine
US3077659A (en) * 1958-12-24 1963-02-19 Gen Motors Corp Coated aluminum cylinder wall and a method of making
US3148086A (en) * 1961-10-09 1964-09-08 Philip M H Seibert Process of placing a copper layer on an aluminum electrical connector
US3198662A (en) * 1962-08-20 1965-08-03 Philip M H Seibert Process of applying a silver layer on an aluminum electrical contact
US3285680A (en) * 1963-06-26 1966-11-15 Helen G Dailey Bearing
US3326714A (en) * 1964-01-08 1967-06-20 Union Carbide Corp Wear and corrosion resistant coating
US3341669A (en) * 1964-03-11 1967-09-12 Porter Co Inc H K Current conductor rail system
US3349722A (en) * 1964-11-27 1967-10-31 Cleveland Technical Ct Inc Electrical resistance rail heater
US3602655A (en) * 1968-10-30 1971-08-31 Insul 8 Corp Composite conductor bar and method of manufacturing
US3674544A (en) * 1968-12-31 1972-07-04 Citroen Sa Methods of coating surfaces and in elements comprising such surfaces
US3679460A (en) * 1970-10-08 1972-07-25 Union Carbide Corp Composite wear resistant material and method of making same
US3705818A (en) * 1968-12-31 1972-12-12 Citroen Sa Methods of coating rubbing surfaces and elements comprising such surfaces

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US26189A (en) * 1859-11-22 Ditching-machine
US3077659A (en) * 1958-12-24 1963-02-19 Gen Motors Corp Coated aluminum cylinder wall and a method of making
US3148086A (en) * 1961-10-09 1964-09-08 Philip M H Seibert Process of placing a copper layer on an aluminum electrical connector
US3198662A (en) * 1962-08-20 1965-08-03 Philip M H Seibert Process of applying a silver layer on an aluminum electrical contact
US3285680A (en) * 1963-06-26 1966-11-15 Helen G Dailey Bearing
US3326714A (en) * 1964-01-08 1967-06-20 Union Carbide Corp Wear and corrosion resistant coating
US3341669A (en) * 1964-03-11 1967-09-12 Porter Co Inc H K Current conductor rail system
US3349722A (en) * 1964-11-27 1967-10-31 Cleveland Technical Ct Inc Electrical resistance rail heater
US3602655A (en) * 1968-10-30 1971-08-31 Insul 8 Corp Composite conductor bar and method of manufacturing
US3674544A (en) * 1968-12-31 1972-07-04 Citroen Sa Methods of coating surfaces and in elements comprising such surfaces
US3705818A (en) * 1968-12-31 1972-12-12 Citroen Sa Methods of coating rubbing surfaces and elements comprising such surfaces
US3679460A (en) * 1970-10-08 1972-07-25 Union Carbide Corp Composite wear resistant material and method of making same

Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5126514A (en) * 1989-09-07 1992-06-30 Delachaux S.A. Process for producing an electrical supply rail
EP0522955A1 (fr) * 1991-07-09 1993-01-13 Delachaux S.A. Dispositif d'alimentation en électricité par contact avec un frotteur et procédé de réalisation d'un tel dispositif
FR2679065A1 (fr) * 1991-07-09 1993-01-15 Delachaux Sa Dispositif d'alimentation en electricite par contact avec un frotteur et procede de realisation d'un tel dispositif.
US5279397A (en) * 1991-09-28 1994-01-18 Brecknell, Willis & Co. Ltd. Conductor rails
WO1993009972A1 (en) * 1991-11-13 1993-05-27 Inesscon, Inc. Power conductor rail
US5263561A (en) * 1991-11-13 1993-11-23 Inesscon, Inc. Power conductor rail
US5310032A (en) * 1991-11-13 1994-05-10 Plichta Dietmar G Power conductor rail
FR2683955A1 (fr) * 1991-11-19 1993-05-21 Delachaux Sa Dispositif d'alimentation en electricite par contact avec un frotteur et procede de realisation d'un tel dispositif.
WO1997022491A1 (en) * 1995-12-19 1997-06-26 Howell Corporation Composite electrical conductor rail
US6318529B1 (en) * 1998-11-02 2001-11-20 Alusuisse Technology & Management Ltd. Conductor rails, the use thereof and methods of manufacture
US20060032705A1 (en) * 2004-08-16 2006-02-16 Isham William R Lightweight composite ladder rail having supplemental reinforcement in regions subject to greater structural stress
US20070205053A1 (en) * 2004-08-16 2007-09-06 Isham William R Molded composite climbing structures utilizing selective localized reinforcement
US20060237101A1 (en) * 2005-04-25 2006-10-26 Daido Metal Company Ltd. High temperature sliding alloy
US7666519B2 (en) * 2005-04-25 2010-02-23 Daido Metal Company Ltd. High temperature sliding alloy
US20080251969A1 (en) * 2007-02-16 2008-10-16 Isham William R Bladder Molding Systems and Methods For Fabricating Composite Articles
CN104773093A (zh) * 2015-04-03 2015-07-15 株洲瑞泰装备技术有限公司 铜铝复合导电轨及其制作方法
CN104773093B (zh) * 2015-04-03 2017-01-18 株洲瑞泰装备技术有限公司 铜铝复合导电轨及其制作方法
CN105171436A (zh) * 2015-09-06 2015-12-23 苏州市宝玛数控设备有限公司 一种切割机钢轨

Also Published As

Publication number Publication date
FR2147317B1 (enExample) 1980-08-14
IT963447B (it) 1974-01-10
CH527488A (de) 1972-08-31
FR2147317A1 (enExample) 1973-03-09

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