Objective As a critical component of urban rail transit vehicles, the front-end head cover plays a decisive role in the overall vehicle mass balance due to its unique shape and installation position. Therefore, head cover designs that are easy to form and lightweight have become a major research focus in the industry. Prepreg, as an intermediate material for composite materials, exhibits properties between those of conventional FRP (fiberglass reinforced plastics) and carbon fiber, making it necessary to conduct in-depth research on its application.

Method The head cover structure and selected materials are introduced, and a comparative performance analysis between prepreg FRP and existing products is conducted. By matching mature composite material forming processes, experimental specimens are manufactured. The comprehensive performance of prepreg FRP specimens is compared with those of traditional FPR and carbon fiber specimens, including mechanical properties, bonding strength, material density, cost, and process performance, thereby obtaining a head cover structural configuration that meets vehicle requirements.

Result & Conclusion  A 3.5 mm prepreg FRP structure can be selected to replace a 6.0 mm traditional hand lay-up FRP structure, achieving a weight reduction of approximate 40% while meeting performance requirements. This substitution scheme has been applied in an actual project, demonstrating its feasibility and high potential for broader application.