Nanometal-Thermoplastic Elastomer Hybrids as Durable, Low Cost Flangeway Gap Materials

The proposed program seeks to develop flangeway gap filer materials that will fill the gap under light loads such as wheelchairs, but will compress under heavy loads, such as freight systems, without increasing the likelihood of track derailments. A materials technology optimization and evaluation program is proposed, based upon previous proprietary developments by the applicants in the area of cost-effective production of nanocrystalline metal coatings on thermoplastic and elastomeric substrates. Proposed is the development of a novel nanocrystalline metal-thermoplastic elastomer (TPE) hybrid material which is expected to undergo very little deformation under light loads, but show excellent flexural fatigue resistance at higher loads while imparting durability through superior strength, lubricity and abrasion resistance. Through the use of established, low cost electroplating methods, it is expected that the nanomaterial coating will be readily applied to the thermoplastic elastomeric substrate with optimized adhesion. Phase I activities will demonstrate the mechanical performance enhancement potential of the nanometal-thermoplastic elastomer hybrid material under high and low loads, through a series of well controlled mechanical testing under static, as well as flexural fatigue loading conditions. The successful execution of this Phase I initiative will identify the process conditions required to produce the nanometal-TPE hybrid materials and generate baseline mechanical property and performance data.