Plastics versus Metals in Automobiles .


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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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Slide 1

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

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

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History Polymers first use in vehicles Tires. Elastic in guards. (1940\'s) Electrical wiring. Inside (late 60\'s – 70\'s) Upholstery padding. Dashboard/Instrument Panels. Electronic segments and lodgings.

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History Exterior Body boards – from composites (fiberglass) on the Corvette. Guard sashes on all models today. Pressure formed polyester body boards. Profoundly refined polymers, for example, infusion shaped nylons, are presently being created for mechanical and operational frameworks.

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

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Mechanical Strength Temperature Plastics making advances to high temperature motor embellishment applications. Consumption Weight Permeability Issue in fuel and high weight frameworks.

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Materials Cost Biggest boundary to plastic in vehicles. Crude material cost. Essential polyethylene to claim to fame plastics. Quality and weight to cost proportion. Taken a toll in assembling. Challenge in top of the line parts. Recyclability.

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Coatings Applications Materials and make. Prudent crude material expenses. Bring down "tooling" costs. Covering Process. Most prominent cost lies with paint materials and their grip troubles with plastics.

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Introduction to Fuel Tanks Terne-covered steel backbone for car for car gas tanks. Drivers for change include: Legislation Permeability Weight Safety Cost

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Plastic Fuel Tanks Since mid 1980\'s plastic supplanting steel fuel tanks. HDPE is the sap of decision for plastic gas tanks. Obstruction innovation empowers plastic fuel tank makers more stringent emanation gauges. Some observe multi-layer tank innovation as the response to stricter emanation benchmarks

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Steel Fuel Tanks Currently a steel substrate covered with zinc-nickel or terne. Stainless steel tried however are hard to shape without serious breakage. Likewise exceptionally costly. Testing painted galvanneal thought that it was successful for opposing erosion on both sides of the tank.

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Performance Attributes Manufacturability Terne plate holds a cost advantage over HDPE. Taken a toll not by any means the only driver: dependability inside the aggregate fuel framework. Plastic tanks should be chlorinated or fluorinated to retard pervasion. Can be dangerous if misused.

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Performance Attributes Features and Weight Plastics can meet bundling imperatives. Plan engineers have adaptability in the auto outline without stress of fitting the gas tank Plastic tanks can brag of weight funds of up to 30%. New penetrability necessities lessen weight reserve funds.

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Performance Attributes Safety and Corrosion Ability to meet crash prerequisites is the key. Plastic considered more secure on the grounds that they are consistent. Plastic are likewise not a wellspring of flashes. Impede warm exchange to the fuel. At the point when disfigured they can bounce back. Warm properties are an issue in deciding material.

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Interior Polyurethane froth has for quite some time been utilized because of plan and monetary advantages. ABS plastic instrument boards decrease creation expenses and weight of cars. Consistent, single units are less demanding to amass and introduce. Controlling wheels produced using shaped vinyl tars or pigmented urethanes.

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Interior HVAC vents and control supports delivered from ABS and polypropylene tars. Key parameters to all plastics here are: Reduced weight. Lessened clamor and vibration. Decreased assembling costs.

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Exterior Materials and produce. Financially savvy. Very filled and cross-connected polyesters. Premium mechanical Properties. Pressure shaping procedure. Covering process. Interesting issues to fathom. Attachment issues with paints. High cost of coatings and "disconnected" readiness.

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

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Cooling Radiator end tops infusion shaped Nylon 30% weight reserve funds. Formed into complex shapes to spare space. High imperviousness to erosion and temperatures. Water pumps likewise made of Nylon. Withstand high weights. Radiator fans from Nylon. Mechanical quality to abstain from twisting. Short trim cycle for Nylon.

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Air/Fuel Intake Systems Air consumption complex Nylons again utilized for its adaptability as a part of outline. Smooth inside surfaces to consider better stream of air into motor. Fuel admissions now rising with incorporated injectors, channels and sensors. Cost is still a boundary to across the board utilize.

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