Case Study: High-Performance Aluminum Profiles for China Fuxing High Speed Train

As the flagship model of China’s high-speed rail network, the Fuxing (CR400 series) EMU operates at a sustained speed of 350 km/h, setting strict requirements for structural strength, lightweight design and long-term operational reliability of train body materials. At the core of its advanced carbody system are high-performance aluminum profiles, which replace traditional steel structures to achieve an optimal balance of weight reduction, rigidity and corrosion resistance.

As a leading high-end industrial aluminum enterprise with over 30 years of R&D and manufacturing experience, Conglin Aluminum-Tech (Dalian) Co., Ltd. has deeply participated in the material supply of the Fuxing high-speed train project. Relying on  vertically integrated full industrial chain, large-tonnage extrusion equipment and proprietary processing technology, we provide stable, batch-qualified aluminum profile solutions for the project. This case study analyzes the material selection, structural application, manufacturing process and practical value of aluminum profiles for the Fuxing train, offering a reference for global rail transit procurement teams and engineering clients.

 I. High Speed Train Body Aluminum Profiles: Core Structural Materials for Fuxing EMU

1. Application Layout of Fuxing EMU Aluminum Extrusion Components

The carbody of the Fuxing CR400 series adopts a full-aluminum modular design, and almost all main load-bearing and decorative structures are formed by extruded aluminum profiles. Fuxing EMU aluminum extrusion components cover the entire train body system: large-section hollow profiles form the underframe, side walls and roof as the main force-bearing structure; special profiles are used for door and window frames, coupler housings and conductor rails; and precision extruded sections are applied to interior partitions, cable trays and ventilation systems.

Among them, train body hollow aluminum profiles with multi-chamber design are the most core structural parts. Different from the traditional steel carbody which requires welding of numerous steel plates, one-piece extruded hollow profiles can be directly assembled as modules, which greatly reduces weld seams, improves overall airtightness and reduces assembly man-hours by more than 40%.

2. High Strength Corrosion Resistant Train Aluminum Profiles: Alloy Selection Logic

To adapt to long-term high-speed operation, alternating load vibration and complex outdoor climate conditions, high strength corrosion resistant train aluminum profiles use carefully matched 6000-series and 7000-series rail-grade alloys. For the main carbody structure, 6082-T6 alloy is selected, with a tensile strength of 310 MPa and excellent weldability, which can maintain stable performance under long-term dynamic loads. For key stress-bearing parts such as the underframe and coupler area, 7N01-T6 high-strength alloy is used, with a tensile strength of up to 450 MPa, which can withstand more than 10 million cyclic load impacts.

In terms of corrosion resistance, the aluminum alloy naturally forms a dense oxide layer on the surface. With anodizing or powder coating surface treatment, it can effectively resist rain, dust and industrial atmospheric erosion, avoiding the regular rust removal and repainting required by steel car bodies, and greatly reducing later maintenance costs.

II. Rail Transit Lightweight Aluminum Profiles: Performance & Engineering Value

1. Weight Reduction Effect of CR400 High Speed Train Aluminum Profiles

The most direct value of rail transit lightweight aluminum profiles is to achieve efficient weight reduction of the train body under the premise of ensuring structural safety. The density of aluminum alloy is only 2.7 g/cm³, about 1/3 that of carbon steel. With the optimized design of multi-chamber hollow sections, CR400 high speed train aluminum profiles achieve an overall weight reduction of about 35% compared with steel car bodies of the same rigidity level.

Taking a standard 8-car Fuxing EMU as an example, the all-aluminum carbody design reduces the total weight of the train by about 18–22 tons. Corresponding to actual operation, this weight reduction directly brings 18–23% reduction in traction energy consumption, and the reduced axle load also slows down the wear of track facilities, cutting track maintenance costs by about 15% throughout the service cycle.

2. Comprehensive Benefits of High Speed Rail Lightweight Aluminum Solution

A mature high speed rail lightweight aluminum solution brings far more than just energy saving. Lighter carbody improves the acceleration and braking performance of the train, shortens the stopping distance, and enhances operational safety and schedule reliability. At the same time, the one-piece extrusion structure has fewer weld seams, which improves the overall airtightness of the carbody, reduces noise inside the train at 350 km/h, and improves passenger comfort.

From the perspective of full life cycle management, aluminum profiles have a service life of more than 30 years and are 100% recyclable. For rail operators, this means lower long-term operation and maintenance costs and higher asset residual value, which is in line with the development direction of green rail transit.

 III. Large Cross-Section Aluminum Extrusion for Railway: Conglin’s Manufacturing Capability

The stable supply of Fuxing train aluminum profiles cannot be separated from the support of large-tonnage extrusion and precision manufacturing capabilities. As a core supplier of the project, Conglin has industry-leading large cross-section aluminum extrusion for railway production capacity, which can fully meet the requirements of ultra-long, wide-section and high-precision rail transit profiles.

The company is equipped with 15 advanced extrusion lines with tonnage ranging from 1000T to 10000T, including 7 heavy-duty lines ab ove 6000T, with an annual production capacity of 150,000 tons. We can produce super-large profiles with a maximum width of 950mm, a maximum diameter of 600mm and a single length of 30m, which perfectly matches the production demand of large-section hollow carbody profiles for high-speed trains. The whole production process is completed independently in the factory, from mold manufacturing, alloy casting, extrusion to surface treatment and deep processing, realizing full-process quality control and stable delivery cycle.

Our proprietary T4 processing technology completes bending, stretch-wrap forming and punching within the 12-hour golden window after extrusion, which avoids performance fluctuation caused by natural aging, ensures dimensional stability of profiles and greatly improves the first-pass yield. Before delivery, all rail profiles undergo strict non-destructive testing, mechanical property testing and dimensional inspection to ensure that each batch of products meets railway industry standards. It is worth mentioning that while focusing on the rail transit field, we also have 30 years of experience in marine aluminum alloy production, and our DNV certified marine aluminum products are widely used in global shipbuilding projects, which verifies our quality control capability in high-end industrial scenarios from another dimension.

IV. Custom Railway Aluminum Profiles Manufacturer: Full-Cycle Support for the Fuxing Project

As an experienced custom railway aluminum profiles manufacturer, Conglin does not only provide standardized products, but also participates in the whole project cycle from preliminary design to batch delivery for the Fuxing project.

In the early stage of the project, our R&D team worked closely with the train manufacturer to optimize the profile section design according to the load and installation requirements of different parts of the carbody, adjusting the wall thickness distribution and chamber structure to achieve the best balance of strength, weight and cost. In the trial production stage, we quickly opened molds and produced small-batch samples for loading verification, and iterated the process scheme according to the test data. In the mass production stage, the vertically integrated production system ensures stable product consistency and on-time delivery, supporting the steady increase of Fuxing train production capacity.

Up to now, the aluminum profiles supplied by Conglin have been applied to multiple batches of Fuxing CR400 series EMUs, maintaining a zero structural failure record during long-term high-speed operation. This project has also further accumulated our technical experience in the field of high-speed rail, and can provide mature and replicable lightweight aluminum solutions for global high-speed rail, metro and light rail projects.

 FAQ

Q1: What aluminum alloys are commonly used for Fuxing high-speed train body structures?

A1: The Fuxing train mainly uses 6082-T6 and 7N01-T6 rail-grade aluminum alloys. 6082-T6 is used for the main carbody structure with balanced strength and weldability, while 7N01-T6 high-strength alloy is applied to key load-bearing parts such as the underframe. Both alloys meet long-term fatigue resistance and corrosion resistance requirements for 350 km/h high-speed operation.

Q2: What are the core advantages of train body hollow aluminum profiles?

A2: Train body hollow aluminum profiles adopt one-piece extrusion molding, which greatly reduces weld seams and assembly workload. The multi-chamber structure optimizes the force-bearing path, providing higher rigidity per unit weight. It also improves the airtightness and sound insulation performance of the carbody, and is currently the mainstream structural solution for modern high-speed trains.

Q3: Can you produce large cross-section aluminum extrusion for railway projects of different scales?

A3: Yes. Conglin is equipped with 15 extrusion lines from 1000T to 10000T, and can produce large-section profiles up to 950mm in width and 30m in length. We can support both small-batch customized trial production and large-batch stable supply for large-scale railway projects.

Q4: As a custom railway aluminum profiles manufacturer, what full-cycle support do you provide?

A4: We provide full-cycle services including section optimization design, mold development, small-batch trial production, mass manufacturing, testing and certification, and after-sales technical support. Our engineering team will follow up the whole process to match the rhythm of customer projects.

Q5: Do your rail transit aluminum profiles have relevant industry certifications?

A5: Our rail aluminum products are produced in strict accordance with international railway industry standards, and the quality management system covers the whole process from raw materials to finished products. We can provide complete test reports and certification documents according to project requirements to support customers’ project bidding and acceptance.

If you are looking for reliable high-speed rail aluminum profile solutions, or need customized lightweight solutions for metro, light rail and other rail transit projects, welcome to contact our technical sales team for free consultation and project quotation.

Email: Eric@aluminum-pm.com

Conglin Aluminum-Tech (Dalian) Co., Ltd. provides one-stop aluminum profile R&D, manufacturing and global delivery services for rail transit and marine industries worldwide.

The Fuxing train aluminum material case study fully demonstrates the core value of high-performance aluminum profiles in the upgrading of modern rail transit equipment. From material selection, structural design to precision manufacturing, every link needs strong technical accumulation and production capacity as support.

With over 30 years of industry experience, vertically integrated full industrial chain capabilities and large-tonnage extrusion equipment, Conglin Aluminum has successfully supported the mass application of aluminum profiles for Fuxing high-speed trains with stable product quality and professional full-cycle services. For global rail transit customers, whether it is standard mass-produced profiles or customized lightweight solutions for special projects, we can provide reliable, cost-effective and compliant aluminum products to help projects achieve efficient operation and full-life cycle cost optimization.