1. Abstract:
Over time, automobiles have changed dramatically from their first inception. The focusof this report was on the replacement of traditional metal parts with plastic parts. The reason for this change can be attributed to the gas shortage of the 70’s. Engineers knew that a lighter weight car was needed to gain more miles per gallon of gas. The bumper, for example, is a partthat has achieved weight reduction of 2.5 pounds while eliminating 13 metal parts. Another example would be the engine manifold where 5 pounds are now saved as well as increasing thehorsepower by 33%
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. There are many parts that have made the change but this paper will focusonly on the fuel tank, engine and interior/exterior of the automobile. In some cases plastic has become more prevalent than metal. Plastic frees engineers from the design constraints imposed by metal. There are environment benefits from the more fuel-efficient vehicle, due to plasticslighter weight. However, there are no cars made completely of plastic so metal has it’sownadvantages. Therefore the sections to follow will discuss each materials characteristics inmanufacturing application, and how industry and consumer both benefit.
2. Introduction:
Through history, cars were typically made completely from steel. However, over time,cars have evolved into a composite of materials. The reason for this evolution can be blamed onthe increase in the price of oil during the decade of the 70’s. Society looked for a more efficientcar in terms of mileage per gallon of gas. Engineers looked toward plastic due to its lightweight.Plastic provides an average weight savings of 400 pounds. With 15 million cars manufacturedeach year, this translates to energy savings of 5.25 million gallons of gas per year and 10.5 billion pounds less carbon dioxide in the air
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. The question then arose “Why not make a car completely out of plastic?” The answer is an easy one, toexpensive. Therefore a compromisehad to be made depending on the different characteristics of the materials. This leads to the factthat the automobile is now a composite of materials. Better gas mileage helps us manage our natural resources such as gasoline, while reducing emissions released into the atmosphere. Someareas where the use of plastics has become more proficient are exterior/interior, electrical, fuel,engine, chassis and power train. The first known use of plastic in an automobile, aside fromtires, was the bumper. Nowadays the majority of plastic bumpers are made of thermoplasticolefins, polyesters, polypropylene or blends of these compounds with glass fibers to increasestrength.
3. Uses of plastic in an Automobile:
3.1 Fuel Tank:
As changes in weight and cost savings drive the performance criteria for automotivematerials, equipment manufacturers are taking a hard look at the historically terne-coated steelused for gas tanks
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. Thus, we will compare steel and plastic for gas tank uses according tocompetitive analysis and performance attributes. Throughout history, terne-coated steel has beenused for automotive gas tanks. However, several issues must be met regarding the changing performance criteria. This exploration proves to be a threat to the application of steel products.Many characteristics can be taken into account for the material change such as permeability,weight, packaging, safety, and cost. Even though the use of plastic fuel tanks has increased in
the marketplace, a comparative analysis of the various plastic and steel alternatives indicates thatsteel remains a cost-effective material that meets all of the required performance criteria
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. 3.1.1 Plastic Fuel Tanks Plastic fuel tanks are made from high density polyethylene(HDPE), a strong, lightweightmaterial which has allowed manufacturers to substantially lower the net weight of theautomobile. Since the mid-1980s, automakers have been displacing coated-steel fuel tanks with plastic ones. During the early 1990’s, approximately 2.7-3 million cars and trucks built in NorthAmerica used nonmetallic tanks. At this time it represented 22-25% of the market, compared to16% in the late 1980’s. Experts dealing with automotive designs predict plastic tanks willcapture 60% of the North American market by the end of 2001. This can be considered as aworst-case scenario for the steel industry if it fails to provide a cost-effective steel alternative thatmeets all of the performance criteria. 3.1.2 Performance Attributes 3.1.2.a ManufacturabilityTerne-plate holds a materials cost advantage over high-density polyethylene. The cost of the material is not the only driving force. Consideration must also include the cost of the tank and its reliability within the fuel system of the vehicle. This system is composed of the tank,filler tube, and level control to name a few
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. All of these components must function properly asany unforeseen corrosion can easily contaminate the fuel delivery system and cause costlyrepairs. Metal tanks cost structure indicate a lower cost per piece versus plastic ones
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. 3.1.2.b Design FeaturesPlastic tanks have the ability to meet packaging constraints with complex shapes, anddesign engineers have greater flexibility in the car design and styling without having to worryabout fitting the gas tank. The average gas tank for a compact automobile can boast weightsavings of up to 30% versus a similar steel tank. However, the weight advantage of plastics hasdiminished due to new permeability requirements
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.3.1.2.c SafetyOne critical part of the performance criteria of the tank is its ability to meet crashrequirements. Generally, plastic tanks are considered safer in crashes because they are seamlessand, thus, not prone to failures in the seam areas. Also, plastic tanks deform and have someability to rebound back to shape. When steel tanks absorb energy and deform, the pressure withinthe tank is inversely related to the volume. As the pressure in the tank increases the volumedecreases. This makes them vulnerable at welded or clamped areas where failure can potentiallyoccur. At the same time, the tank must withstand extreme in-tank temperatures in NorthAmerica. The high point (79°C) temperature exceeds the boiling point of the alcohol fuels whilethe extreme cold introduces potential cracking problems
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. Plastic, with its insulating properties,slows heat transfer to the fuel when compared to a steel tank. Also, plastics cannot be considereda source for sparks
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. In the case of an under-car fire, plastic tanks will hold back the rise in fueltemperature. However, this is not a permanent solution as the tank will soften, sag, andeventually release the fuel. A steel tank does not sag in a fire; however, the fuel temperature mayrise rapidly, perhaps resulting in over pressurization and release of fuel through a mechanicalfitting.
3.1.2.d CorrosionCorrosion is a well-known concern on both the inside and outside surfaces of tanks. Theoutside surfaces and supporting structure are exposed to road chemicals, salt, mud, and gravel.The corrosion issue is critical with zinc-coated products that replace terne-coated plates becauseof their nature, which puts an even higher demand on the barrier film for both the inside andoutside surfaces. In contrast, the HDPE gas tanks are inert to the corrosive environments insideand outside the tank. 3.1.2.e RecyclabilityThis is the hardest obstacle to overcome for a plastic part. Despite progress in recycling,the propagation of plastics in automotive applications faces some problems, such as
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:
1)
1)
The absence of a plastics recycling infrastructure.
2)
2)
A typical passenger cars steel and iron parts are recoverable.
3)
3)
The molding process for plastic fuel tanks. This process results in 35% of plasticmaterial ending as waste.
4)
4)
The lack of technology that dismantlers can use to quickly collect various plastics.
5)
5)
Cost. Recycled plastics are not cost competitive with newer plastics.As a result, automotive-design engineers must not only meet customer, design, styling, cost,weight, and regulatory needs but also environmental criteria. All material suppliers must showthat their product is not only lighter and cost effective but also recyclable.3.1.3 Tank Materials and Manufacturers 3.1.3.a ManufacturersChrysler made the decision to outsource plastic tanks and they remain committed to thisdecision. The listed advantages of plastic, according to Chrysler, are lack of corrosion, easier packaging and lower weight.Ford called for a switch in 1997 to zinc-nickel-coated steel from terne-coated steel tanksin all models. In some models they will also switch from plastic to zinc-coated tanks. However,they will continue to use plastic tanks in certain models.General Motors at this time has an ongoing corrosion test program to see if Plastic would be better than metal in fuel tanks
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. 3.1.3.b Competitive AnalysisThere are two aspects to compare between steel and plastic fuel tanks; production volumeand the ability to recycle the material. Plastic is much cheaper when it comes to productionvolume while steel is cheaper to recycle. The difference in these characteristics will be thedriving influence in plastic versus metal fuel tanks.
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