Carbon Composites used for Automotive

1. Carbon
Composites For
Automotive

2. Hello!
I am Shubham patil
MDTI5004 – THEORY OF MANUFACTURING PROCESSES
AND TECHNOLOGIES.
MSC – TEXTILE DESIGN, TECH AND INNOVATION.
P2610915

3. Contents
• Aim/Objective
• Selected Methodology
• Market Research
• Research Rationale and Problem Statement
• Background and Definition of Carbon Composite
• Importance of Carbon Composites in Automotive Industry
• Properties of Carbon Composites
• Manufacturing Methods for Carbon Composites
• Comparison between Carbon Composites opposed to Steel and other metals
• Carbon Composite Implementation in Automotive
• Summary of Findings of innovation
• Recommendations
• Conclusion
• References

4. AIM –
• Evaluate the efficiency of manufacturing processes in the automotive industry and the assessment of
innovativeness of implementing Carbon Composite for Automotive manufacturing and developing
processes.
Objectives -
● To identify various methods by which manufacturing processes of carbon composites are conducted
within Automotive industry.
● To evaluate the efficiency of Carbon Composites to attain proper operations for automotive body.
• To recommend methods to improve manufacturing processes of Carbon Composites for utilization in
Automotive body.

5. Selected Methodology
• The positivism philosophy has been selected within this study due to its ability to use logical thinking
(Marsonet, 2019).
• It can help to collect information regarding the importance of carbon composites within automotive and
can present logical thinking regarding the best method for its use.
• This design has been selected to be able to logically explain the deductions made from the collected
information and to provide a detailed result that is not based on probabilistic views (Rahi, 2017).

6. Market research
• CFRPs are expected to comprise a $35 billion market by 2022 which require large-scale mainstream
production and supplies to sustain the usability of CFRPs (Hadigheh et al. 2021).
Grand view Research (2020) Grand view Research (2020)
Grand view Research (2020)

7. Research Rationale and Problem Statement
• The major problems - fuel-effective vehicle. - Weight of the car is very important.
• Complicated shape, Aerodynamics, Corrosion resistance.
• Eco-friendly and re-cyclable.
• High resistance to fatigue and have good tensile strength.

8. Background and Definition of Carbon Composite
• Very strong with HIGH STRENGTH TO WEIGHT RATIO.
• Five times more effective than steel.
• Formed by collaborating Resin and carbon fibre reinforced. Porous Structure.
• Used in specialized, high-performance products like aircraft, race cars and sporting equipment.
• Carbon fibre comprises carbon atoms gives stiffness to composites made from fibres.
• Environmentally friendly practices, Eco-Friendly & Lightweight.
• Mercedes-Benz SLR McLaren, the first car with an entire body made from composite carbon fibre.
(Composites uk 2017)
(Taylor, 2020)

9. Importance of Carbon Composites in Automotive Industry
• Composite materials have certain advantages over steel in automobile manufacturing industries.
• Safer, Stogner, Lighter and more Fuel-Efficient vehicles.
• Significantly increase vehicle Fuel economy and reduce Vehicle weight up to nearly 60% as recommended
by Oak Ridge National Laboratory.
• With the help of moulding, composites can be transformed into different complex shapes without involving
high-pressure tools, therefore making them stronger and providing resistance to bending.
(Vibin P Vijay 2018)
(Easy Composites)
(Easy Composites)

10. Properties of Carbon Composites
• Unique Mechanical and Thermal properties. Flame resistance at 600°
• 5 times more rigid than aluminium and steel and Corrosion resistance.
• High Stiffness, high Tensile Strength, high Chemical Resistance, low Weight, low Thermal expansion and high-
Temperature Tolerance properties.
• Improve vehicle architecture and aerodynamics.
• High modulus of elasticity up to 200 GPa and Tensile strength of 200 to 500 MPa.
• Compressive strength of 150 to 200 MPa and fracture toughness of 5 to 10 MPa alongside excellent thermal
resistance, low coefficient of thermal expansion and high electrical connectivity (Kumar et al. 2018).
• Good damping behaviour.

11. (Dexcraft 2015)
(Dexcraft 2015)
(Dexcraft 2015)

12. Manufacturing Methods for Carbon Composites
1. Carbon Fibre Manufacturing
• Raw material – Precursor - PAN, Acrylic, Pitch – Should be fully drawn yarn
• Stabilization – 150 - 230°c – Oxygen atmosphere
• Carbonization - 1300°c – Inert – Nitrogen atmosphere – Pure carbon fibre.
• Graphitization
• Surface coating.
2. Composite Manufacturing
• Additive manufacturing
• Compression moulding
• Curing
• Filament winding
• Infusion
• Injection/Over moulding (GommeBlog.it: Car & Performance 2019)
(Composites uk) (Composites uk)
(Composites uk)
(TRUMPF)
Resins for Composite
• Epoxy
• Phenolic
• BMI Cyanate
• Polyester
• Thermoplastic

13. Comparison between Carbon Composites opposed to Steel and other metals
• Five times more rigidity than metals like aluminium or steel.
• Carbon composites made from the fibres of carbon are way safer than steel making them environment
friendly.
• They possess high durability than most metal polymers.
• Corrosion-resistant and 30% lighter than aluminium with incredibly high firmness.
• The biggest benefit of composite materials is their ability to mould into different complicated shapes without
the need for high-pressure tools (García, 2019).
(Bhargav 2017)
(TRUMPF)
(THE LIFE BEYOND SPORT)
(THE LIFE BEYOND SPORT)

14. Carbon Composite Implementation in Automotive
• Carbon fibre and composites including carbon fibre-reinforced plastics (CFRPs) are creating comprehensive
opportunities for automotive companies to adapt structural engineering transformation towards sustainability
and affordability (Krishnan et al. 2020).
• Steel and other metals not sustainable in nature as well as high in weight.
• However, as metal and alloys are still critical to automotive design and vehicle foundation, carbon composites
can be used in various distinct parts such as Chassis, Engine, Body, doors, lift gates, seat and interior designs
to enable car bodyweight reduction up to 25 to 60% compared with metallic mouldings.
(Loughran 2018)
(Jacob 2011)
(Ethan 2020)
(Warfield)
(Jacob 2011)

15. Summary of Findings of innovation
• It was found that composites are too expensive to produce.
• The machines modifications that were proposed were not as effective as initially conceived
• The industrial revolution and globalization attributes have created the global automotive industry as one of the world's
largest manufacturing industries while considering techno-capitalism perspectives and technology-driven innovations
and usage of cutting-edge carbon fibres have largely influenced MNCs for leveraging cost-effective production
methods.
• Key manufacturers including BMW, Ford, General Motors and Toyota have leveraged customised manufacturing
practices, multi-domestic expansion policies, JDA alliance between OME and composite material suppliers and
venture development programs to produce truck, vehicles equipped with CFRPs (Szász et al. 2021).
• Mutually conducting R&D pipelines, aerodynamically advanced vehicle design, usage of carbon composites and
electrical engineering principles are effective for the betterment of safety and quality of the public.

16. Recommendations
• The Carbon Monoxide (CO) and Dioxide (CO2) produced during the development of PAN (Polyacrylonitrile)
can be stored via the use of BECCS (Bio-energy with Carbon Capture and Storage)
• This can allow the use of CO or CO2 during the carbonization or surface treatment processes for easier
development of the Carbon Composites.
• The use of modernized technologies such as the MIS and Artificial Intelligence (AI) can help to ensure
more efficient planning processes.
• The use of proper planning can ensure the development of carbon composites are more efficient and large-
scale developments can be done with ease.

17. Conclusions
• Based on the study, it can be concluded that the use of Carbon composites has a positive impact on
automobile operations.
• Carbon composites are highly shock resistant and can sustain significantly high temperatures which
contribute to their utilization in cars and automobiles.
• Other materials such as steel and similar metals are good conductors of electricity and heat energy which
can contribute to major damage to other components of the car.
• Similarly, the use of Carbon Composites for the car hoods or the battery holder can be highly efficient as its
shockproof abilities can help to keep damage to internal components of the car at bay in case of major
accidents.
• This is beneficial in saving lives and also ensure continued subtenance of the car or automobile.

18. References
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