Use of Polymers in automobiles

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Recent transition of metals to polymers in automotive industry

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  • aajtak.intoday.in/story/lamborghini-veneno-roadster-unveiled-1-748430.html
  • The heat deflection temperature or heat distortion temperature (HDT, HDTUL, or DTUL) is the temperature at which a polymer or plastic sample deforms under a specified load. This property of a given plastic material is applied in many aspects of product design, engineering, and manufacture of products using thermoplastic components
    Polycarbonate (HDT=140 °C) will not deform at 120 °C but acrylic (HDT=90 °C) would deform
  • Use of Polymers in automobiles

    1. 1. PRESENTATION BY NAWAL KISHORE BABUL 100109034
    2. 2. Plastics vs. Metals  Polymer Applications in Automobiles - Instrument Panels - Engine - Windows - Tires - Body Panels 
    3. 3.  Compete with other materials based on: ◦ ◦ ◦ ◦ Weight savings Design flexibility Parts consolidation Ease of fabrication
    4. 4. Car Part Polymer Trim Panels (3) Polypropylene (PP) Impact Absorber Thermoplastic Olefin (TPO) Radio Housing ABS/ Polycarbonate(PC) Door Outer Panel ABS/ Polycarbonate(PC) Handle Polypropylene (PP) Fog Light Cover Thermoplastic Elastomeric Olefin (TEO) Elastomers Tire
    5. 5. Application Material Processing Method Load-Bearing Glass-fiber reinforced Pressing of resin - bumper beams polyester resins compounds Moldings/covers Polyurathane Injection Molding - front apron Polypropylene - spoiler Polyethlene - wheel-well liners Acrylonitrile-butadiene- radiator grill styrene (ABS) - hood Polycarbonate - fenders - trunk Protective Moldings Energy Absorbing Foam Polyvinyl chloride Ethylene-Propylene Terpolymers Polyurethane Injection Molding/ Extrusion Liquid Reaction Foaming
    6. 6. Polycarbonate/ABS resins  Introduction of airbags in IP design  Injection Molding vs. Blow Molding 
    7. 7.  ULTEM polyetherimide (PEI) resin to replace aluminum under the hood for 1st time • High-performance amorphous resin from GE • Complete air management modules can be made of thermoplastic Throttle Body
    8. 8.  Plastic Body Panels Chevy Corvette since 1953 Sheet Steel - still most commonly used for vehicle body structure Aluminum - weighs less but costs more Plastics - increasingly used for metals parts replacement
    9. 9. 1. 2. 3. 4. 5. 6. Cost Flexural Modulus Coefficient of Thermal Expansion Chemical Resistance Impact Resistance Heat Deflection Temperature (HDT)
    10. 10. Advantage of plastics • Better color match • Incorporate in existing facilities • Assembly line temperatures exceed 200oC Alloys: Polyphenylene ether/polyamide ABS/Polyesters ABS/Polycarbonates • Larger choice in materials • Additional steps take time • More plastics will enter the market as assembly lines are redesigned
    11. 11. Highly cross-linked and highly filled  Polymer component is polyester  Suitable of compression molding  Molded product combined high modulus with high strength  Body panels (hoods and deck lids)  More expensive than metal, but lower tooling cost 
    12. 12.  Bottom line benefits ◦ Tooling for SMC hood was 23% of steel ◦ Weight savings of 18% • Growth of applications - Body panels on GM’s Lumina, TransPort, and Silhouette - Structural components - valve covers, grilleopening reinforcements, fascia supports, etc. • 250 million lbs. of SMC was used in 1997
    13. 13. Composite front fenders and hood design for 1995 Lincoln Continental  Result of need for lighter-weight and more cost efficiency integrated system  SMC fenders and hood  Bottom line benefits:  ◦ SMC fender tooling was 40% of projected tooling for steel fenders ◦ Comparative weight saving was 33%
    14. 14.  Toughened Safety Glass (TSG) - tempered glass  Laminated Safety Glass (LSG) - two panes of glass bonded together using polyvinylbutyral
    15. 15. SGL Group and car company BMW
    16. 16. JV by SGL Group and car company BMW  carbon fiber-reinforced plastics (CFRP)   Costs around $100m 
    17. 17. THANK YOU

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