Europe’s railway industries require a step change in technologies and design for the next generation of rail vehicles in order to remain competitive globally. Innovative materials and modular design for rolling stock are considered to become key to success. Composite materials with their unique properties (lightness, repairabillity, corrosion resistance…) have demonstrated a high potential for lighter, more energy- and cost-efficient structural components in relevant sectors such aeronautic or automotive industries. However, currently available structural composites do not meet Fire, Smoke & Toxicity requirements of the railway sector, and thus cannot be used for the manufacturing of carbodyshell parts. Mat4Rail will face these challenges through a two-tier approach: In work stream I, our materials team (including resin producers, composite manufacturers, and experts on joining technologies and testing) will: i) synthesize novel fire retardant resins (epoxy, benzoxazine or hybrids) and manufacture composite batches; ii) modify fatigue and static load cases according to new requirements for polymeric materials; iii) further develop structural adhesive bonding combined with riveting and bolting for permanent and non-permanent joints and the repair of the new composites; and iV) assess novel design concepts for access door systems using new materials and joining technologies. In work stream II, our specialised design and engineering teams will develop new concepts for interior design of rolling stock including: i) plug and play systems which function like a limbic technical and power system for new electric utilities; ii) innovative lightweight seats and iii) a compact and ergonomic driver’s desk. Together, our multi-disciplinary consortium of 7 SMEs, 3 large industries, 5 RTDs and 1 UNI clearly has the experience and skills required to deliver innovations for uptake by the Shift2Rail JU members and the European railway industries.

The SeNSE proposal aims at enabling next generation lithium-ion batteries with a silicon-graphite composite anode and a nickel-rich NMC cathode to reach 750 Wh/L. Cycling stability is the key challenge for the adoption of this cell chemistry. The objective is to reach 2000 deep cycles by (i) reducing the surface reactivity of the active materials by a combination of novel film-forming electrolyte additives and active materials coatings, (ii) compensating irreversible lithium losses during the first cycles employing pre-lithiated silicon and providing an on-demand reservoir of excess lithium in the cathode, (iii) identifying and controlling critical cycling parameters with data provided from in-cell sensors. Adaptive fast charging protocols will be integrated into the battery management system based on dynamic in-cell sensor data and by implementing thermal management concepts on materials and electrode level. To improve the sustainability of the battery and to lower production cost, the content of the critical raw materials cobalt and natural graphite will be reduced. Enabled by protective coatings, aqueous slurry processing will be developed for the cathode. Costs will be further lowered and energy density improved by the development of thinner textured current collector foils offering enhanced adhesion. The feasibility and scalability of the SeNSE battery technology with respect to the call targets will be demonstrated through 25 Ah pouch cell prototypes and a 1 kWh module. Scalability to the gigawatt scale and cost-effectiveness of the proposed solutions, including aspects of recycling and second-life use, will be continuously monitored via regular briefings led by Northvolt, which currently undertakes one of the most ambitious efforts to establish a European cell manufacturing plant at scale. To strengthen the European IP portfolio in the battery field, patent applications are the preferred way of dissemination of technology developed within SeNSE.