The types, methods and areas of application of composite materials and engineering plastics in automotive industry

1. Atul Menon
Megha R
Siddharth K Achar
Siddhanth Gupta

2. Pie chart on composite usage in various industries

3.  Stout 46 (Scarab)
 Minivan by Stout Engineering Laboratories
 After WWII, replaced aluminum framework with an eight piece fiberglass
body
 This was the first vehicle to use air suspension

4.  Mclaren F1 MP4/1 was the first vehicle to use carbon composite materials
for it’s body
 The chassis itself was built by McLaren using carbon supplied by Hercules
Aerospace (U.S.A.)
 Carbon0-Fibre-Composites used

5.  Other vehicles after Stout 46
 Chevrolet Corvette fiberglass body – 1953
 FordThunderbird – 1954
 Tires:
 In 1946, Michelin developed the radial tire method

6.  Metal or plastic outer body
 Steel or aluminium components
 Chassis

7.  Lighter – sports cars, low centre of gravity,
fuel economy
 High strength to weight ratios
 Carbon fiber makes more economic sense for
electric cars, because lithium-ion batteries
are expensive. Less weight means a smaller
battery pack, a worthwhile trade-off.
 The carbon fiber body felt highly
maneuverable—with a remarkably quick
response - better driving experience

8.  Outer frame/body
 Shocks, steering tie rods even gears
 Chassis – monocoque cars
 Wear can be easily repaired

9.  The new BMW 7-series sedan, which starts at
about $80,000, as well as the similarly priced
Alfa Romeo 4C and Chevrolet Corvette Z06
sports cars, use carbon fiber elements.
 Pics!!!!

10.  Fitting pre-made carbon/glass fibre panels
 Injection moulding

11.  VARTM,SQVARTM
 Compression moulding
 Prepreg moulding
 All methods can be adapted to an assembly
line process

12.  Carbon fibre
 Glass fibre
 Epoxy resin for best strength and compatibility
 Graphite reinforced polymers
 Prepregs

13.  Honeycomb and closed cell cores
 Sandwich structure

14.  Quick cure epoxy resins with cure time of 3-4 minutes
 Low viscosity resins to aid injection and vacuum
moulding
 Prepregs – eliminate the need for resins as well
 Metal tools for
 New software completely dedicated to composites
analysis
 Woven fabrics to decrease unidirectional nature
 Different weaves for differently curved surfaces
 Adhesives – Epoxy/polyester, polyurethane or MMA
based

15.  A metal matrix composite (MMC) is
composite material one being a metal the
other material may be a different metal or
another material, such as a ceramic or
organic compound.

16.  Porsche is using MMCs for cylinder liners
having porous silicon preform into the cast
aluminum block
 Honda incorporates alumina and carbon
fibers in the bores of die cast aluminum

17.  Control arms or wheel hubs are made of
strong silicon carbide (SiC) reinforced
aluminum or aluminum nano-composites
 SiC-reinforced aluminum brake rotors

18.  Improves aluminum alloy designs by
improving strength characteristics similar to
cast iron
 Reduces cost
 Reduces quantity of metal used
 Weight reduction – fuel economy