Performance Composites Inc.

Technicians installing composite part without a crane
Locomotive Nose Fairing Conversion
Performance Composite’s (PCI) customer in Florida has had numerous field incidents of their locomotives colliding with pedestrian vehicles. It was very costly to replace the front fairing as it shipped from Europe and was fairly complex to manufacture. PCI successfully converted the aluminum train nose fairing to fiberglass using vacuum infusion. One of the most prominent advantages lies in the substantial reduction of weight achieved through the transition from aluminum to fiberglass construction. By replacing the two-piece aluminum fairing with a single-piece fiberglass counterpart, the overall weight of the component is significantly diminished which significantly helped in ease of installation and handling.

Metallic to Composite Front Fairing

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Vacuum Infusion in a Nutshell
Vacuum infusion is a composite manufacturing process where resin is drawn into dry fiber reinforcements using vacuum pressure. This method ensures even resin distribution, resulting in lightweight and strong composite parts. Its superiority lies in its ability to produce high-quality, void-free components with excellent fiber-to-resin ratios, enhancing strength and durability. Compared to other processes like hand layup or autoclave curing, vacuum infusion reduces material waste, minimizes air entrapment, and offers greater control over part consistency. Its efficiency and reliability make it a preferred choice for industries demanding precision and performance in composite manufacturing.
Customer Locomotive

Moreover, the conversion to fiberglass also yields substantial cost reductions in both manufacturing and maintenance. Fiberglass materials are generally more cost-effective than aluminum, offering a more economical alternative without compromising on structural integrity or durability.

Additionally, the simplified design of the one-piece fiberglass fairing reduces production complexity, streamlining manufacturing processes and minimizing associated costs.

Another critical technical advantage of fiberglass over aluminum is its superior impact absorption properties. Unlike aluminum, which tends to deform and dent upon impact, fiberglass has a greater capacity to absorb and distribute energy, thus minimizing damage and maintaining structural integrity of the locomotive main body. This inherent resilience to impacts enhances the longevity and durability of the fairing, reducing the frequency and costs of repairs and replacements over the locomotive’s lifespan.

Aftermath of impact with a vehicle
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