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Plastics vs. Metals in Automobiles

Plastics vs. Metals in Automobiles. Greg Boehm Kendall Chapman Gordon Clarke II Gary Gomlak April 10, 2001. General Overview. History / Background General Design Characteristics Select Parts for Comparision Fuel Tanks Interior / Exterior Cooling and Air Intake Systems. History.

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Plastics vs. Metals in Automobiles

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  1. Plastics vs. Metals in Automobiles Greg Boehm Kendall Chapman Gordon Clarke II Gary Gomlak April 10, 2001

  2. General Overview • History / Background • General Design Characteristics • Select Parts for Comparision • Fuel Tanks • Interior / Exterior • Cooling and Air Intake Systems

  3. History • History • Polymers first use in vehicles • Tires. • Rubber in bumpers. (1940’s) • Electrical wiring. • Interior (late 60’s – 70’s) • Upholstery cushioning. • Dashboard / Instrument Panels. • Electronic components and housings.

  4. History • Exterior • Body panels – from composites (fiberglass) on the Corvette. • Bumper fascias on almost all models today. • Compression molded polyester body panels. • Highly sophisticated polymers, such as injection molded nylons, are now being developed for mechanical and operational systems.

  5. General Design Characteristics • Mechanical Strength • Weight • Temperature • Material Cost and Manufacturability • Coatings Applications • Recyclability

  6. Mechanical Strength • Temperature • Plastics making inroads to high temperature engine accessory applications. • Corrosion • Weight • Permeability • Issue in fuel and high pressure systems.

  7. Materials Cost • Biggest barrier to plastic in automobiles. • Raw material cost. • Basic polyethylene to specialty plastics. • Strength and weight to cost ratio. • Cost in manufacturing. • Challenge in high end parts. • Recyclability.

  8. Coatings Applications • Materials and manufacture. • Economical raw material costs. • Lower “tooling” costs. • Coating Process. • Greatest expense lies with paint materials and their adhesion difficulties with plastics.

  9. Introduction to Fuel Tanks • Terne-coated steel mainstay for automotive for automotive gas tanks. • Drivers for change include: • Legislation • Permeability • Weight • Safety • Cost

  10. Plastic Fuel Tanks • Since mid 1980’s plastic replacing steel fuel tanks. • HDPE is the resin of choice for plastic gas tanks. • Barrier technology enables plastic fuel tank manufacturers more stringent emission standards. • Some see multi-layer tank technology as the answer to stricter emission standards

  11. Steel Fuel Tanks • Currently a steel substrate coated with zinc-nickel or terne. • Stainless steel tested but are difficult to form without severe breakage. Also very expensive. • Testing painted galvanneal found it effective for resisting corrosion on both sides of the tank.

  12. Performance AttributesManufacturability • Terne plate holds a cost advantage over HDPE. • Cost not the only driver: reliability within the total fuel system. • Plastic tanks need to be chlorinated or fluorinated to retard permeation. Can be toxic if mishandled.

  13. Performance AttributesFeatures and Weight • Plastics have the ability to meet packaging constraints. • Design engineers have flexibility in the car design without worry of fitting the gas tank • Plastic tanks can boast of weight savings of up to 30%. New permeability requirements diminish weight savings.

  14. Performance AttributesSafety and Corrosion • Ability to meet crash requirements is the key. • Plastic considered safer because they are seamless. • Plastic are also not a source of sparks. Retard heat transfer to the fuel. • When deformed they have the ability to rebound. • Thermal properties are an issue in determining material.

  15. Interior • Polyurethane foam has long been used due to design and economic benefits. • ABS plastic instrument panels reduce production costs and weight of autos. • Seamless, single units are easier to assemble and install. • Steering wheels made from molded vinyl resins or pigmented urethanes.

  16. Interior • HVAC vents and control consoles produced from ABS and polypropylene resins. • Key parameters to all plastics in this area are: • Reduced weight. • Reduced noise and vibration. • Reduced manufacturing costs.

  17. Exterior • Materials and manufacture. • Cost effective. • Highly filled and cross-linked polyesters. • Premium mechanical Properties. • Compression molding process. • Coating process. • Unique problems to solve. • Adhesion problems with paints. • High cost of coatings and “off-line” preparation.

  18. Cooling and Intake Systems • Cooling Systems • Radiator end caps • Radiator fan • Water pump • Air / Fuel Intake Manifolds • Fuel injectors • Temperature resistance and cost drivers.

  19. Cooling • Radiator end caps injection molded Nylon • 30% weight savings. • Molded into complex shapes to save space. • High resistance to corrosion and temperatures. • Water pumps also made of Nylon. • Withstand high pressures. • Radiator fans from Nylon. • Mechanical strength to avoid warping. • Short molding cycle for Nylon.

  20. Air / Fuel Intake Systems • Air intake manifold • Nylons again used for its flexibility in design. • Smooth interior surfaces to allow for better flow of air into engine. • Fuel intakes now emerging with integrated injectors, filters and sensors. • Cost is still a barrier to widespread use.

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