PRESENTATION BYNAWAL KISHORE BABUL

100109034

Plastics vs. Metals Polymer Applications in Automobiles

- Instrument Panels- Engine- Windows- Tires- Body Panels

Compete with other materials based on:◦ Weight savings◦ Design flexibility◦ Parts consolidation◦ Ease of fabrication

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 ElastomericOlefin (TEO)

Tire Elastomers

Application Material Processing MethodLoad-Bearing- bumper beams

Glass-fiber reinforced polyester resins

Pressing of resincompounds

Moldings/covers- front apron- spoiler- wheel-well liners- radiator grill- hood- fenders- trunk

PolyurathanePolypropylenePolyethleneAcrylonitrile-butadiene- styrene (ABS)Polycarbonate

Injection Molding

ProtectiveMoldings

Polyvinyl chlorideEthylene-PropyleneTerpolymers

Injection Molding/Extrusion

EnergyAbsorbing Foam

Polyurethane Liquid ReactionFoaming

Polycarbonate/ABS resins Introduction of airbags in IP design Injection Molding vs. Blow Molding

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

Plastic Body Panels - Chevy Corvette since 1953

Sheet Steel - still most commonly used for vehicle

body structureAluminum - weighs less but costs morePlastics - increasingly used for metals parts

replacement

1. Cost2. Flexural Modulus3. Coefficient of Thermal Expansion4. Chemical Resistance5. Impact Resistance6. Heat Deflection Temperature (HDT)

• Better color match• Incorporate in existing facilities• Assembly line temperatures exceed 200oC

Alloys:Polyphenylene ether/polyamide ABS/PolyestersABS/Polycarbonates

• Larger choice in materials• Additional steps take time• More plastics will enter the market as assembly lines are redesigned

Advantage of plastics

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

• Growth of applications- Body panels on GM’s Lumina, TransPort, and Silhouette- Structural components - valve covers, grille- opening reinforcements, fascia supports, etc.

• 250 million lbs. of SMC was used in 1997

Bottom line benefits◦ Tooling for SMC hood was 23% of steel◦ Weight savings of 18%

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%

Toughened Safety Glass (TSG)- tempered glass

Laminated Safety Glass (LSG)- two panes of glass bonded together using polyvinylbutyral

SGL Group and car company BMW

JV by SGL Group and car company BMW carbon fiber-reinforced plastics (CFRP)  Costs around $100m

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