The "strongbox theory," as it used to be called a few decades back, is a valid argument as far as it goes. The problem is that you get into a cycle of diminishing returns as the weight of the vehicle goes up. This happens for a several reasons, the first of which is physics: force equals mass times half the square of the velocity. This the heavier the vehicles get, the greater the impact when they hit. Some of our New York area members may be familiar with the ghoulish photo that graced the cover of the
Daily News, about half a century ago when tow trains of MP54s hit head on at speed, and the two lead cars completely telescoped, the one on the bottom having been sheared-off at the belt rail. These were all-steel cars built to the Pennsy's take on heavyweight construction, and were well designed for their type. The cause of the accident was human error: IIRC one of the trains was wrongly routed at an interlocking. Similarly, many of us will be familiar with the Chase, MD wreck, in which a Conrail train ran a red block and ended up in front of a passenger train at speed. The lead unit of the passenger train was effectively vaporized, according to the report. The engineer of the Conrail train was intoxicated. Most of the hideous wrecks involving large death tolls were due to negligence and/or irresponsibility, even in the wooden car era. Improved communications and operating discipline did more to alleviate the problem than everything else combined.
The second problem you get into with attempting to harden the rolling stock is that you quickly reach a point at which the infrastructure needs to be rebuilt to accommodate heavier vehicles. A few decades back, we still had the benefit of the foresight of the early civil engineers who built railroad infrastructure with a safety factor of four - that is about four times more rugged than it needed to be for what they were running then. They knew from the then-brief history of railroad operation that locomotives and rolling stock were liable to become much larger and heavier, even though they didn't know quite how that would be accomplished - mechanical stokers, for example, had not yet been invented - so they took their best guess as to what the future would look like. We got a break, beginning in the '20s, as metal alloys became stronger and more durable for a given weight, allowing much of this infrastructure to function with a minimum of maintenance, and many railroads got used to cutting back those expenses first. Several breakthroughs in design and construction began to push freight car design from the 15-ton axle loadings that were still typical of freight cars when I was in high school in the late-60s, and 20- to 25-ton axle loadings quickly became typical and didn't stop there. That's when the deferred maintenance began to catch up with them, as the track structures began to fail under the heavier traffic and the first of a rash of spectacular derailments involving petroleum products and/or chemicals began to happen. Railroading was a low-margin business, at best, in those days, and this resulted in the abandonment of a lot of lines that simply couldn't be rebuilt because their traffic, however heavy (in some cases), couldn't generate the income to pay back the capital investment at market rates.
As of now, a 35.75-ton axle loading is becoming an industry standard. The reason for this is economic: when I was in high school, a typical freight car could carry, at best, about twice its tare weight (take
tare weight as
empty weight, in this case, although the terms are not strictly equivalent). Currently, a car grossing 143 tons is carrying about 110 tons of payload, two thirds better than the best case, and better than double the typical case of my high school days. This is the primary reason railroads are becoming investment-grade businesses again, but the income isn't sufficient to reconstruct the entire network for substantially heavier rolling stock, nor can they afford to operate the network at the lower speeds necessary to make the strongbox theory workable. An excellent discussion of the problems related to higher axle loadings begins on Page 83 of this document (
http://www.ct.gov/dot/lib/dot/documents ... 1-8-12.pdf). It's probably in other State Rail Plans as well, but I'm most familiar with this one because I reviewed an early draft of it back in 2011.
Even assuming they could make it work economically, the problem you get into is one of human nature, in that people tend to become over-reliant on the safety technology and tend to lose operating discipline - intentionally or otherwise - as a result. A study of highway safety measures over the years is very instructive, in this respect, mainly because the database is larger than it is for other modes. Every improvement in headlight technology, for example, has been followed by an increased tendency of drivers to "over-drive" their headlights in conditions of bad visibility. It's one of the reasons I have misgivings about the implementation of PTC: it would not have solved the root problem of the Chatsworth wreck, which was irresponsible behavior in the cab. It would have the unintended consequence of making it possible to get away with the behavior, then leaving the passengers vulnerable to the consequences of dumping the air at speed: for most of them, the experience would only have been nominally better than the collision itself
Based on the evidence I've seen, Chacal's point about risk-based problem solving would appear to be the most valid approach; and the evidence seems to indicate pretty clearly the biggest risk is the human factor. It's less a question of how big the crew is than it is how responsible their behavior is - SNCF has been running one-man crews on freights trains with an enviable record for a long time now, for example. When the cab-forwards were introduced to Donner Pass, one of the engineers was heard to have objected to the possibility of ending up with a caboose in his lap. The Superintendent was quoted as having replied, "Do your job right and you won't have a caboose in your lap!" It's as true now as it was then, and earlier, when my great grandfather organized his local of the Brotherhood of Railway Trainmen, early in the last century.