APPLICATION OF

COMPOSITE MATERIALS IN
THE AUTOMOBILE
INDUSTRY
S U B M I T T E D BY:
M U S TA FA S I R A J
MEB18010
 CONTENTS
• Composite materials
• Properties of Composites
• Classification of Composites
• Composites in Automobile Industry
• History of Composites in Automobile Industry
• Application of composites in major segments of Automotive Industry
• Examples of applications of composites in Automobile Industry
• Trends in automotive composites
• Future of composites
• Conclusion

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 COMPOSITE MATERIAL
Composite material is essentially a combination of a matrix and a
reinforcing material having different chemical and physical
properties. They are combined to get desirable characteristics
from both in the final product for specific purpose. The matrix
material protects the material from the external damage while
the reinforcing material provides strength to the composite.

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 PROPERTIES OF COMPOSITES
• High tensile strength to weight ratio
• Better torsion and stiffness properties
• Light weight
• Corrosion resistance
• High fatigue endurance limit
• Produces less noise and vibration during operation

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 CLASSIFICATON OF COMPOSITES

Composite
Based on matrix Based on reinforcing material

Metal matrix Polymer matrix Ceramic matrix Fiber

Structural Laminated
composites composites composites reinforced
composite composite
(MMC) (PMC) (CMC) composite

Carbon fiber Glass fiber Natural fiber

Sandwich Laminated
reinforced reinforced reinforced
composite composite
polymer(CFRP) polymer(GFRP) polymer(NFRP)

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 COMPOSITES IN AUTOMOBILE INDUSTRY
With increase in demand of reduced cost, enhanced design and
aesthetics, improved safety, crashworthiness and fuel efficiency of
automobiles, the need to incur composite materials has become an
important factor in automobile industry. Unique features that composites
provide to automobile industry are:
• Low coefficient of thermal expansion
• Excellent dimensional stability
• Resistance to corrosion
• High impact strength
• Relatively lower weights
• Ability to meet class A surface requirements
• Ease of manufacturing

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 HISTORY OF COMPOSITES IN AUTOMOBILE INDUSTRY
• 1941- Ford Motor Co.’s Soybean car which used plastic
panels on tubular steel frame cutting 407 kg of a steel
car.

• 1957-1991- East German Trabant automobiles used

cotton reinforced plastics called Duroplast to make its
body.

• 1973-2004- Chevrolet Corvette used entirely sheet

molding compounds(SMC) body panels.

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• 1981-Present- McLaren MP4/1 was the first Formula One car to use
a monocoque chassis wholly manufactured from carbon
fiber composite, a concept which is now ubiquitous.

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APPLICATION OF COMPOSITES IN MAJOR SEGMENTS OF
AUTOMOTIVE INDUSTRY
Exterior Interior Powertrain Chassis

PARTS: Door modules Dash boards Engine Vehicle frame

Hood Floor Transmission
Trunk lid Steering Suspension
Bumpers etc. Seat etc.

MATERIALS: GFRP GFRP CFRP CFRP

CFRP CFRP Graphite fiber
NFRP Epoxy composites
Thermoplastics Polyurethane
NFRP

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 EXAMPLES OF APPLICATIONS OF COMPOSITES IN
AUTOMOBILES
• Exterior Components:
1. Roof cover, trunk lid of BMW M6 is made up of GFRP and CFRP.
2. Lamborghini Aventador LP700-4 produces its front and rear bumpers, body
aerodynamics kit of CFRP.
3. Wheel rims of Daimler Smart 3rd generation electric car is made using GFRP.
4. Bumpers and mudguards are produced of Alfa Romeo 4C using CF + PUR-RIM.
5. The Ford Shelby GT350 Mustang sports a carbon fiber composite grille-opening
reinforcement 2-piece injection molded box design.
• Interior Components:
1. Instrument panel, inner door modules developed by Land Rover using GFRP.
2. BMW i8 have its Passenger cell entirely made of CFRP.
3. Daimler-Benz has developed the dashboards and center armrest consoles along with
seat back panels using NFRPs in a large amount.

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• Structural and Powertrain components:
1. Suspension knuckle developed by Ford Motor Co. using SMC and Prepreg.
2. Advanced SMC steering knuckle developed by Marelli.
3. Carbon fiber epoxy suspension links press-formed over aluminum by Shape
Machining Ltd..
4. CFRP stabilizer bars by IFA Composite.
5. CFRP output shafts developed by Dynexa.
• Chassis Systems:
1. Chassis developed by Alfa Romeo 4C using Prepreg(CF, epoxy)
2. BMW pioneered the i3 which uses a carbon fiber-reinforced plastic for its chassis.
3. Chassis, bodywork of McLaren MP4-12C Spider CF by monocell, lightweight CF
body panels.

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 TRENDS IN AUTOMOTIVE COMPOSITES
• Thermoplastics in continuous fiber composites using overmolding are
used to produce seat backs, airbag housings, bumpers and floor
components.
• Unidirectional tapes are used to increase the loading strength of the
composites and the parts made from it.
• Pultrusion using polyurethane resin and glass, carbon or hybrid
reinforcements increases the crashworthiness of automobiles.
• Metal-Composite hybrids are also being used to provide extra
reinforcements at the desired locations to increase the strength.
• Natural fibers is being used beyond interior components to build body
panels and crash structures too

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 FUTURE OF AUTOMOTIVE COMPOSITES

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 CONCLUSION
Composite materials have been welcomed with open arms in the
automobile industry, providing benefits of cost savings, enhanced design
and aesthetics, improved safety and crashworthiness, improved fuel
efficiency and thus overall efficiency of automobile production. The
automotive composites industry has an undeniably bright future. In terms
of market demand, it is set for rapid growth due to the reasons outlined
above. In terms of applications, with the forthcoming improvements in
technology and manufacturing processes, composite materials can be
used in more and more components and parts that were previously the
domain of traditional lightweight materials such as steel and aluminum.

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THANK YOU

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