1.

What are the factors to be considered while choosing a material for a

component?
In manufacturing process selection of materials for the design of a machine is an essential step to
accomplish the reliable functionality of the machine. The selected material should satisfy both the
availability as well as the function and many other factors. Those are discussed in brief, there are
some factors need to be considered while selecting a material for a machine part.

Factors Effecting in the selection of Materials for Engineering purpose

 Mechanical Forces or Loads,

 Wear and tear
 Electrical insulation
 Thermal properties
 Availability & cost
 Recycling
 Safety

These are the factors need to consider in the selection of material for the engineering purpose. Let’s
go with one by one.

Mechanical Forces or Loads

There are the different type of mechanical forces can act on machine members and produces
different stress and strains. These following actions produce the different types of forces in the
machine parts.

Self-weight of the machine

Energy Transmitted

Change of temperature

Frictional resistance

The inertia of reciprocating parts

Unbalance of Moving parts.

Due to these actions, the following loads/Forces will produce.

Tensile Forces

Compressive Forces

Shear Forces

Bending Forces

Torsion Forces

Bearing Force

Due to these loads, different materials can be responds in a different way. These responses will
depend on the
Following are the different material properties available.

Elasticity

Plasticity

Ductility

Malleability

Stiffness

Brittleness

Hardness

Toughness

Understand the full details about the different material properties here.

With the help of these material properties, we can select the material for the suitable application.
The second factor in the list is Wear and Tear.

Wear and Tear

As the moving parts or sliding parts needed to withstand the wear and tear as they getting aged. So
this is also a factor that makes the difference in selecting a material for the machine parts.

Electrical Insulation

It is very important that whether the component should resist the electric current between the two
mated components, or it is not necessary to insulate the current. So there are some special materials
available to resist the electric current. PVC, glass and asbestos are the examples of Insulation
material. These insulating materials can be used in between the mating parts to resist the electrical
current.

Thermal Properties

Thermal properties of the materials, that are necessary to consider while picking a material for a
machine part. it might affect the mechanical properties of the materials due to the heat. In some
applications, it is necessary to insulate the thermal energy to flow between the mating parts.

Availability & cost

Finally, the most important factor is that the availability of the material resource. From the
economical point of view, the material should be easily available in nature. This availability decides
the cost of the material. So it is necessary to consider this factor as the major one in the selection of
materials for the engineering purpose.

By considering these factors, we can select a suitable material that can fulfil the designer
requirement from all perspectives such as the functionality, Cost, availability to build reliable
machines.

RECYCLING

There are Some guidelines in the European Union and Asian countries about this issue.
For example, in the UK, around a million vehicles reached the end of their life each year these
vehicles are considered hazardous waste until they have been fully treated.

If we count down to the smallest screws, a single car has about 30,000 different parts. Recycling a
car is therefore a little more complicated than an empty beans tin. It takes time, knowledge and
expertise to recycle, re-use or recover 95% of a car’s weight.

Here are some well-known car parts which can be recycled,

Engine oil

Windows and Windscreen

Scrap metal

Car batteries

Car tyres

Plastic components

oil filters

Car engines

Car mats and carpets

Starters & Alternators

SAFETY

The ability to absorb impact energy and be survivable for the passenger is called "crashworthiness"
of the structure in the vehicle.

At first two concepts in the automotive industry should be considered:

Crashworthiness

Penetration resistance.

Conclusion

These are the different factors that play an important role in the selection of materials for the design
of machine members. There are the different classification of materials are available for different
application in this Article: Classification of Materials.

2.Explain thermoset and thermoplastic materials in brief along with

examples.
Polymer Materials

When it comes to polymers, you have two basic types: thermoplastics and thermosets. When
machining plastic, it’s crucial to know which one you’re working with due to distinct differences
between how these two main polymer categories react to chemicals and temperature.
Thermoplastics soften when heated and become more fluid as additional heat is applied. The curing
process is completely reversible as no chemical bonding takes place. This characteristic allows
thermoplastics to be remolded and recycled without negatively affecting the material’s physical
properties.

Thermoplastics possess the following properties:

• Good Resistance to Creep

• Soluble in Certain Solvents

• Swell in Presence of Certain Solvents

• Allows for Plastic Deformation when Heated

Thus, you will find these materials used for plastic injection molding, extrusion, and thermoforming
processes. They generally tend to resist shrinking and offer good strength and elasticity. What’s
more, some thermoplastics common to manufacturers are:

• Acrylic

• Nylon

• Acetal Copolymer Polyoxymethylene

• Acetal Homopolymer Polyoxymethylene

• Polycarbonate (PC)

• Polyethylene (PE)

• Polystyrene (PS)

• Polypropylene (PP)

• Polyvinylchloride (PVC)

• Polyethylene terephthalate (PET)

• Teflon

Each of these thermoplastics has different properties, thus, their uses of these materials vary from
industry to industry.

Thermosets contain polymers that cross-link together during the curing process to form an
irreversible chemical bond. The cross-linking process eliminates the risk of the product re-melting
when heat is applied, making thermosets ideal for high-heat applications such as electronics and
appliances.

Thermosets possess the following properties:

• High Resistance to Creep

• Cannot Melt

• Insoluble

• Rarely Swell in Presence of Solvents

Thus, when you expose the materials to temperature regardless of the degree, melting will not take
place. This helps the material retain its shape after heating and forming specific shapes. However,
overheating may cause the materials to degrade while still in the solid phase.

Some thermosets common to manufacturers are:

• Phenolics

• Silicone

• Melamine

• Epoxy

• Polyvinylidene fluoride (PVDF)

• Polytetrafluoroethylene (PTFE)

• Polyurethane

• Polyimide

Phenolic, Bakelite, Vinyl Ester and Epoxy materials would be considered examples of a thermoset,
while ULTEM, PEEK, TORLON and Polycarbonate materials are examples of thermoplastics.

The thermoplastic category of polymers is further categorized into Amorphous and Crystalline
polymers per the figure below:

Most amorphous polymers are thermoform capable, translucent and easily bonded with adhesives
or solvents. One example of this would be TORLON.

Semi-crystalline polymers are difficult to bond or thermoform, but possess better chemical
resistances, electrical properties and a low coefficient of fiction. An example of a semi-crystalline
polymer would be PEEK.

It is also important to note that there is the possibility of a material to be thermoplastic and
thermoset. Polyester is a typical example. Additionally, the storage form of thermosets polymer is
liquid, and it is in a large container or tank.

The automotive, lighting, appliance, and energy industries also choose this polymer. This is because
they have higher structural integrity and resistance to impact and deformation.

What Are the Main Differences Between Thermoplastic vs Thermoset?

Although thermoplastics and Thermosets are similar plastic polymers in some cases, there is some
thermosetting and thermoplastic difference. We will discuss these differences under the following
headings:

3.What are the pros and cons of thermoset plastic material?

Pros and Cons of Thermoset
Pros Cons

Resist corrosion Inability to reshape or remold

Good electrical insulation properties Unrecyclable

Resist water  

Strong dimensional stability  

Resist heat at high temperatures  

Allows for flexible product designs  

Low thermal conductivity  

High strength-to-weight ratio  

4.What are the pros and cons of thermoplastic material?

Pros and Cons of Thermoplastics

Pros Cons

Not suited to all applications due to softening when

Resist corrosion
heated

It can be remolded and Typically more expensive than thermosetting

reshaped polymers

Can be recycled  

High-quality aesthetic finish  

High impact resistance  

Resist Chipping  

Superb electrical insulation  

Enhanced anti-slip properties  

5.Explain the manufacturing process in thermoset and thermoplastic
material? Thermoplastic and Thermoset Processing Methods
Manufacturing Process in Thermoset material:
types of manufacturing processes,

 Compression Moulding
 Sheet Moulding
 Bulk Moulding Component (BMC)
 Thermoset Injection Moulding
Thermoset products are made through liquid moulding processes. The polymers and other
agents are fed into tanks or barrels, where they are heated to a liquid state and mixed. Then
the liquid polymers and other agents are injected into a mould cavity. As the material cools
and hardens to the configuration of the cavity, it goes through a curing process where the
polymers cross-link together. That process forms an irreversible chemical bond that
prevents the risk of melting, softening or warping when or if the finished product is
subjected to high heat or corrosive environments. This makes thermosets perfect for high-
heat applications and outdoor use.
There are two primary liquid moulding processes used to produce thermoset plastics:
Reaction Injection Molding(RIM):

 
The RIM moulding process begins when two liquid agents an A-component (polyol) and B-
component are placed in separate tanks and heated to an elevated temperature. They are
then fed at high pressure into a mixed. Once combined, the mixed liquid flows into a mould
where the chemical reaction takes place, forming a polymer in the mould.
Resin Transfer Molding(RTM)
 

 
RTM is a closed-moulding process also known as liquid moulding. Resin formulations are
mixed with a hardener, or catalyst, and injected into a mould that contains dry fibres, such
as fibreglass, where the part is allowed to harden and form.
Compression Moulding:

This is how thermosets are formed. The reaction occurs in the mould as the granules are
heated and compressed. UF or urea-formaldehyde and MF melamine formaldehyde are
formed by this method.

Manufacturing Process in Thermoplastic material: 

There a many types of manufacturing processes of Thermoplastic:
 Injection Moulding
 Vacuum forming / Thermoforming
  Blow Moulding 
 Rotational Moulding / Roto MOulding 
 Extrusion
 Structural Foam
 RIM (Reaction Injection Moulding) 
Injection Moulding
The injection moulding process is the most commonly used manufacturing process for the
fabrication of plastic parts in the world. It is so popular because of its ability to create a wide
variety of items of differing sizes, shapes, and complexities. Most injection moulding
machines use the same process – thermoplastic conversion – to turn the plastic stock into
the final moulded parts, using these five basic steps:

 
This technique is widely used for forming thermoplastic materials. It is similar to the casting
technique used to form metal components. The plastic (in a powdered or granular form) is
put in a hopper. A screw thread turns to force the plastic material through a heater, melting
it. When all the materials have melted the screw thread then acts as a ram and forces the
plastic into the mould, where it cools and solidifies.
Injection moulding is a very common process used in the manufacture of the casing of many
electronic products such as TV's and radios.

 
 
Vacuum Forming of Thermoplastic:

Vacuum forming is used to make simple moulds using thin sheets of thermoplastic. High
impact polystyrene sheet is what is used in school (HIPS). PVC can also be used.
A mould is created from wood or epoxy resin and this is placed on the table (platten) of the
vacuum forming machine. The sheet plastic is heated until it becomes soft.
The table with your mould on is lifted into position and a vacuum is used to draw the plastic
over the mould. Vacuum forming only works with thin plastics and moulds with no
undercuts.
The plastic can then be trimmed to the required shape.
 
Extrusion Blow Moulding:

 
Blow moulding is used to manufacture bottles and containers with very thin walls. Blow
moulding first requires a tube of plastic to be extruded. The tube of molten plastic is
extruded between the two halves of a mould. Before the plastic cools the two halves of the
mould are brought together and the air is blown into the centre of the material through a
blow pin. This forces the plastic out forming the shape of the mould. The plastic can then be
cooled and removed. 
 
Extrusion Moulding of a Thermoplastic:
 

  
 This process is widely used to form metal and plastic components that have constant cross-
sectional shapes such as pipes, curtain rails etc.
The extrusion process is similar to injection moulding. Plastic granules are heated in a
hopper and a screw thread forces the material through a die. The material is then cooled.
Extrusion can only be used for simple shapes and the end product generally has a poor
quality finish

 
6. Materials classified as thermoplastic material? Self-learn on the above
topic and include as much material as possible
 Thermoplastic commonly employed for manufacturing include polyethene (PE), polyvinyl
chloride (PVC) and polystyrene (PS), which often is used for packaging. Other groups of
thermoplastics are acrylics, fluoropolymers, polyesters, polyimides, and nylons. All of these
types can be melted down repeatedly and re-shaped into different forms. For example, a
foam cup is a thermoplastic material man be re-melted and fabricated into a dish.
Some of the most common thermoplastic materials in use include:
 Polycarbonate
 Acetal Copolymer Polyoxymethylene
 Acetal Homopolymer Polyoxymethylene
 Acrylic
 Nylon
 Polyethene
 Polypropylene
 Polystyrene
 Polyvinyl chloride (PVC
 Teflon
      Material        Properties          Uses

 High Voltages(up to 30KW)

 They are wax-like in appearance, Odourless
applications 
 one of the lightest plastics
POLYETHYLENE OR POLYTHENE  Coaxial cables
 Flexible over a wide temperature range
 Packaging
 High resistivity and dielectric strength
 Fan and Blower casing 

 These are the Cheapest and most widely used

Plastic
 Cables jackets

 It becomes soft beyond 80°C.

 Fabric coating

POLYVINYLCHLORIDE (PVC)
 The rigid types have good dimensional
 Flooring and ceiling panels
stability and are water-resistant.
 Cladding
 The flexible types are strong, tear-resistant,
 Lead wire insulation
and have good ageing properties

POLYPROPYLENE (PP)  Its resistance to chemicals is better than that  Vacuum flasks
of polyethylene.
 Hairdryers
 It is attacked by strong acids
   Filaments and fibres

 Refrigerator parts

 They are brittle at low temperature,

 Electrical insulators
translucent and flammable.
 Films and sheets for packing

 Flashlight casings

 Automotive parts

 Piston rings
 It is a highly crystalline material and does not
soften at high temperatures (it retains its
 Bearing Bushes
strength up to +300 degrees celsius )
 Anti-corrosive seals
TEFLON OR
POLYTETRAFLUOROETHYLENE  it is non-flammable
 Moulding in aircraft
(PTFE)
 it is a good electrical insulator
 Seals
 It has a very low coefficient of friction and
 Gaskets
does not stick to other materials.
 Lining of chutes

 Lenses

 Instrument Panels
 It has good electrical properties and negligible
 Light Fittings
water absorption
 Automobile Dash blank
 Hard and brittle.
POLYSTYRENE  sheets and films for packaging
 Low dielectric constant.
 Refrigerator-cabinet compounds
 High resistivity.
 Office items like desk calendars,
 It is transparent.
pen stands, trays etc

 Housewares like water jugs,

mugs, tumblers, plates, trays etc

 It is hard, rigid and transparent; it possesses

high impact strength.
 Sanitary ware

 It is attacked by acetone, petrol etc., but it is

 Sheeting
ACRYLICS (Polymethyl resistant to household chemicals
 Display signs
Methacrylate PMMA)
 It has low abrasion resistance and low
 Roof light and domes
softening temperature.
 Lenses
 It is a good electrical insulator.

ABS (Acrylonitric Butadiene
Styrene)
 ABS materials are tough, hard and rigid  Extruded Sheets
 They possess hard surfaces, dimensional  Extruded pipes
stability, chemical resistance and heat
resistance.  Safety Helmets

 They have low water absorption and  Refrigerator Lines

resistance to creep or cold flow
  Electrical Parts

 Acid-resistant
 Seat covers
 Adequately tough
POLYVINYLIDENE CHLORIDE (PVC)  Bells and gaskets
 Non-flammable
 Acid-resistant tubing
 Solvent resistant

 All nylons possess good abrasion resistance.

 They are very tough and strong but flexible
too.
POLYAMIDES (Nylon)
 They possess high impact strength.
 They are resistant to most of the solvents and
chemicals
 The main use of nylon is in the
manufacture of fibre and yarn.
 The nylons are also used for
moulding gears, valves,
bearings, containers and
electrical equipment.

7. Materials classified as thermoset material? Self-learn on the above topic

and include as much material as possible

Thermosetting polymers are built from various types of material that serve key roles and
applications in the plastics fabrication industry. Thermal compounds are designed to form a
thermally conductive layer on a substrate, either between components or within a finished
electronic product. Thermoset purging compounds are used to clean moulding
machines between runs of different colours or compositions. Gap filling products are used
to fill in gaps or spaces between two surfaces to be bonded or sealed.
Specific types of thermoset materials that are in use within the plastics fabrication industry
include the following:
RIM Thermosetting Plastic:
 PDCPD (polydicyclopentadiene)
 Polyurethanes
 Polyureas
 Structural Foams
RTM Thermosetting Plastic (Fiberglass-reinforced):
 Polyester
 Vinyl Ester
 Polyimides
Other Types of Thermosets and Thermoset Resins:
  Epoxy (e.g., carbon fibre epoxy resin)
 Phenolics
 Bismaleimide (BMI)
 Fluoropolymers
 Polytetrafluoroethylene (PTFE)
 Polyvinylidene fluoride (PVDF)
 Melamine
 Silicone
 Urea Formaldehyde

8.Which material is used for transparent property and what are its other
properties?
Polycarbonate or “PC” is a highly useful engineering thermoplastic. It has desirable physical
properties such as transparency, high toughness, and very good heat resistance. The raw material of
polycarbonate allows similar levels of internal light transmission as those of glass. Polycarbonate
also has a high impact resistance and is very useful in applications which call for a tough material
that is also transparent. Examples for such applications include bullet-proof glass or protective eye
gear.

Polycarbonate can maintain its rigidity across a wide range of temperature: as low as -20oC and as
high as 140oC. It can be easily combined with flame retardant materials without major degradation.
Being a thermoplastic material, it has a melting point of 150oC. It can be heated to that
temperature, cooled, and then reheated again without any significant degradation. The ability of
polycarbonate to liquefy at 150oC makes it a good fit for injection molding.

Manufacturing of Polycarbonate

Polycarbonate is named so because it is a polymer which contains carbonate groups. It is produced

by reacting bisphenol A (BPA) and Phosgene. The bisphenol is produced by condensation of phenol
with acetone.

Polycarbonate is known to be very pliable. It can be formed at room temperature in a manner

similar to aluminum sheets, without breaking or cracking. Sheet metal techniques can be used to
process and form polycarbonate. This makes it an excellent material for making prototypes because
polycarbonate can be bent at room temperatures. It is not brittle like acrylic. It is also very useful in
making prototypes where transparency and non-conductivity are essential. Sheet metal cannot offer
both those properties.

Different Grades of Polycarbonate

Polycarbonate is available in different grades depending upon the application where it is to be used.
The method of preparation for each grade is different. Polycarbonate is available in grades such as
reinforced, flame retardant, film, crack-resistant, branched, etc. Certain blends of polycarbonate are
used in specific industries. The blends are made with ABS or polyester. Examples of various
processing methods for polycarbonate include:

• Extrusion

• Injection Molding

• Structural Foam Molding

• Blow Molding

• Vacuum Forming

Applications of Polycarbonate

Automotive: Polycarbonate is strong, lightweight, and durable. Hence, it is used to make sunroofs in
cars. It is also used to make dashboards, head lamp lenses, bumpers and various body panels.
Luxurious car interiors are made using polycarbonate.

Compact Storage: Polycarbonate is used to make CDs, DVDs, and Blue Ray discs via the injection
molding technique.

Electrical: Polycarbonate is a good insulator and heat resistant as well. It is used in

telecommunications hardware. It also serves as a dielectric in high-stability capacitors. Certain LED
screens are now being made with polycarbonate because it is lighter than glass.

Eyewear: Polycarbonate has high impact resistance and low scratch resistance (when coated). So, it
is used to make contact lenses and protective eyewear. A hard coating is applied to eyewear lenses
to make it scratch resistant.

ATM machines: The front panel of cash dispensing ATM machines are made with polycarbonate.
They are normally made using aluminum, but polycarbonate results in cost savings.

Mobile phones: The high impact resistance of polycarbonate makes it a great candidate for
producing mobile phone panels. Mobile phones must have a strong outer casing to prevent damage
from accidental drops. Polycarbonate offers the necessary solution.

Baby drinking bottles: BPA free polycarbonate is used to manufacture baby water and milk bottles.
High impact resistance makes these bottles unbreakable.

Police riot gear: Riot and protective gear used by law enforcement agencies is made from
polycarbonate due to the toughness and high impact resistance that it offers.

Swimming: Polycarbonate is used to make swimming goggles and SCUBA diving masks. This
polycarbonate is treated with anti-scratch coating for durability and high utility.

Properties and Specs

Property Type Detail

Scientific Name Polycarbonate (PC)
Resin Identification Code Other (7)
Chemical Formula C15H16 O2
 Tensile Strength 8500 PSI
Dielectric Constant 2.9
Specific Gravity 1.19
Melting Temperature 288oC – 316oC
Flexural Strength 93 MPa (13500 PSI)
Maximum Continuous Use Temperature 125oC
Shrink Rate 0.6 – 0.9% (0.006 – 0.009 in/in)
Izod Impact Strength 600 – 850 J/m
Elongation at break 80% – 150%
Rockwell Hardness M70
Poisson’s Ratio (v) 0.37
Heat Deflection Temperature 140oC at 66 PSI
Injection Mold Temperature (Typical) 82oC to 121oC

9.Which property of ABS is used in Automotive components?

ABS – What does it stand for?

ABS stands for Acrylonitrile Butadiene Styrene. ABS is an impact-resistant engineering thermoplastic
& amorphous polymer. ABS is made up of three monomers: acrylonitrile, butadiene and styrene:

 Acrylonitrile: It is a synthetic monomer produced from propylene and ammonia. This

component contributes to ABS chemical resistance & heat stability
 Butadiene: It is produced as a by-product of ethylene production from steam crackers. This
component delivers toughness & impact strength to ABS polymer
 Styrene: It is manufactured by dehydrogenation of ethyl benzene. It provides rigidity &
processability to ABS plastic

How ABS is Made?

ABS is produced by emulsion or continuous mass technique. The chemical formula of Acrylonitrile
Butadiene Styrene is (C8H8·C4H6·C3H3N)n. The natural material is an opaque ivory color and is
readily colored with pigments or dyes.

Molecular Structure of Acrylonitrile Butadiene Styrene

ABS is a strong & durable, chemically resistant resin but gets easily attacked by polar solvents. It
offers greater impact properties and slightly higher heat distortion temperature than HIPS.

Acrylonitrile Butadiene Styrene has a broad processing window and can be processed on most
standard machinery. It can be injection-molded, blow-molded, or extruded. It has a low melting
temperature making it particularly suitable for processing by 3D printing on an FDM machine.
ABS falls between standard resins (PVC, polyethylene, polystyrene, and so on) and engineering resins
(acrylic, nylon acetal…) and often meets the property requirements at a reasonable price-cost
effectiveness.

Key Properties of ABS

ABS is an ideal material of choice for various structural applications, thanks to its several physical
properties such as:

 High rigidity
 Good impact resistance, even at low temperatures
 Good insulating properties
 Good weldability
 Good abrasion and strain resistance
 High dimensional stability (Mechanically strong and stable over time)
 High surface brightness and excellent surface aspect

ABS shows excellent mechanical properties i.e. it is hard and tough in nature and thus delivers good
impact strength. Acrylonitrile Butadiene Styrene offers a high degree of surface quality. Apart from
these characteristics, Acrylonitrile Butadiene Styrene exhibits good electrical insulating properties.

Chemical Properties of ABS

 Very good resistance to diluted acid and alkalis

 Moderate resistance to aliphatic hydrocarbons
 Poor resistance to aromatic hydrocarbons, halogenated hydrocarbons and alcohols

Mechanical Properties of ABS

Elongation at Break 10 - 50 %
Elongation at Yield 1.7 - 6 %
Flexibility (Flexural Modulus) 1.6 - 2.4 GPa
Hardness Shore D 100
Stiffness (Flexural Modulus) 1.6 - 2.4 GPa
Strength at Break (Tensile) 29.8 - 43 MPa
Strength at Yield (Tensile) 29.6 - 48 MPa
Toughness (Notched Izod Impact at Room 200 - 215 J/m
Temperature)
Toughness at Low Temperature (Notched Izod 20 - 160 J/m
Impact at Low Temperature)
Young Modulus 1.79 - 3.2 GPa

Electrical Properties of ABS

Arc Resistance 60 - 120 sec

Dielectric Constant 2.7 - 3.2
Dielectric Strength 15.7 - 34 kV/mm
Dissipation Factor 50 - 190 x 10-4
Volume Resistivity 14 - 16 x 1015 Ohm.cm
ABS is readily modified both by the addition of additives and by variation of the ratio of the three
monomers Acrylonitrile, Butadiene and Styrene. Heat stabilizers, hydrolysis stabilizers, lubricants, UV
stabilizers etc. are being used in non-reinforced and reinforced grades to increase specific material
properties.

Hence, grades available include:

 High and medium impact

 High heat resistance, and
 Electroplatable

ABS/ PC BLEND

Polycarbonate/acrylonitrile butadiene styrene is most commonly used in the automotive and

electronic industries.

PC-ABS plastic is used to make:

 Glove boxes

 Overhead and middle consoles

 Knee bolsters

 Blow-moulded seatbacks

 Automotive interiors

PC-ABS plastic is one of the most widely used engineering thermoplastics in the world and is
commonly found in automotive interiors.

 Rear Lamp housing

ABS/PVC BLENDS

 Flame resistance

ABS/PVC used in 

 Automotive instrument panels

ABS/PVC used in Automotive instrumental panels 

10.What are the properties of nylon and its uses in Automotive components?
What is Nylon?
Nylon is the most useful synthetic material with applications varying from daily life activities
to industries. It is a plastic which can be drawn into fibres or moulded into daily products for
making amenities. We can live our entire life with nylon on our side. You hop across the
nylon carpet to the kitchen, eat your breakfast on a nylon bowl after cleaning your teeth
with a toothbrush whose bristles are made of nylon. A nylon umbrella over your head is
used to move out of the house in heavy sunlight or to keep out of the rain.
• The Science of Nylon
• Properties of Nylon
• Types of Nylon
• Uses of Nylon
The Science of Nylon
The term nylon points towards a polymer family known as linear polyamides. There are two
approaches to making nylon for fibre applications. In the first approach, the molecules that
consist of an acidic group (COOH) on every end react with molecules that contain amino
(NH2) groups at each end. The resulting nylon gets a name based on the number of carbon
atoms that separate two amines and two acidic groups. Hence, nylon 6,6 is widely used as
fibres made from adipic acid and hexamethylenediamine.

The salt which is formed by two compounds is known as nylon that has an exact ratio of 1:1
acid to base. This salt is dried and then heated under vacuum to remove water and form the
polymer.
In the other approach, a compound that contains an amine at one end and acid at the other
are polymerized to produce a chain with repeating units of (-NH-[CH2]n-CO-)x. The nylon is
referred to as nylon 6 if n = 5 which is another common form of this polymer. The
commercial production of nylon 6 starts with caprolactam that use an open-ring
polymerization.
In both the approaches, the polyamide is melt and drawn after cooling to obtain the desired
properties of every intended use.
Types of Nylon
Nylon 6 – It was developed by Paul Schlack. It is formed by ring-opening polymerization.
Nylon 510 – It is obtained from sebacic and pentamethylene diamine acid.
Nylon 1,6 – It is produced from dinitriles with the help of acid catalysis.
Nylon 66 – Wallace Carothers patented nylon 66 with the use of amide.
Properties of Nylon
• Lustrous
• Elastic
• Very strong
• Damage resistant to oil and many chemicals
• Resilient
• Does not absorb water
• Dries quickly

Properties of Nylon:
 All nylons possess good abrasion resistance.
 They are very tough and strong but flexible too.
 They possess high impact strength.
 They absorb water which causes a reduction in strength and impact properties.
 They are resistant to most of the solvents and chemicals.
  They have very high softening temperatures and thus moulding becomes difficult.

Uses In Automotive components:

 Nylon Plastic Injection Molded Gears

Plastic gearing has been increasing in usage as designers better understand its
benefits and limitations. These gears can be produced by hobbing or stamping or, for
large-volume runs, by injection moulding

 Bushings and Bearings

Nylon bushing and Bearings sleeve plastic flanged bushings used Automotive
  Push Clips

Nylon Plastic Push Clips for fastener in nuts and bolts.

11. What is a material blend? What are the blends used in the Automotive
industry?
Material Blend is the Multi-Channel, Full Material Equivalent of the atomic Blend Node. It
blends between two full materials (all possible channels) based on a grayscale mask, or
optionally based on one single colour from a Color ID mask.
Blends used in the Automotive industry:
 ABS Blends 
 PC/ABS Blends
 TPU/ABS Blends
 PVC/ABS Blends
 PPO/PS Blends
 

12. What are Fillers And Additives? Name some of them by explaining their
properties.
Additives and fillers are organic or inorganic compounds that are introduced into plastic to
change the properties of plastic. While most plastics in their original form are impact-
resistant and long-lasting, they are often brittle, hard, combustible, or too heavy for the
intended use.
ADDITIVES
A wide variety of additives and modifier ingredients can be used to expand the usefulness of
polymers, enhance their processability or extend product durability. Many additives are
used to modify and enhance resin properties that become a part of the polymer matrix.
These additives include
Physically, additives may be divided into four groups, solids, rubbers, liquids and gases, the
last of these being employed for making cellular polymers. In terms of function, there are
rather larger numbers of groups, of which the
Following are the most important:
(1) Fillers.
(2) Plasticisers and softeners.
(3) Lubricants and flow promoters.
(4) Anti-aging additives.
(5) Flame retarders.
(6) Colorants.
(7) Blowing agents.
(8) Cross-linking agents.
(9) Ultraviolet-degradable additives.
FILLERS
Filler materials are particles added to resin or binders that can improve specific properties,
make the product cheaper, or a mixture of both.
The top filler materials used are ground calcium carbonate (GCC), precipitated calcium
carbonate (PCC), kaolin, talc, and carbon black.
  

13. Name 10 Automotive interior components and the materials used? Also,
mention the property of the material which facilitates the use in the
Component.
 

Components  Materials Property of the Material

 Dash panels 
 High impact strength 
 Acrylonitrile-
Butadiene-Styrene  Toughness due to
(ABS),  rubber from
Polybutabiene
 polycarbonate alloys.
 Stiffness 

 Door Panels & Armrests  polyvinyl chloride  High Price

(PVC) 
 High flame retardancy
  ABS

 Sun Visor

 High heat resistance

 Polypropylene
 Low cost

 Steering Wheel

 High Impact strength

under low temperature

 Polyurethane(PU)  High-temperature
stiffness

 preventing heat sag

 Door Handle  All nylons possess good

abrasion resistance.

 They are very tough

 Nylon and strong but flexible
too.

 They possess high

impact strength.

 Interior Trim  It can easily be formed

into almost any shape.

 It has excellent
 Polypropylene chemical and heat
resistance.

 It was generally
resistant to impact.

 Seat Belt  Nylon Filament Yarns   It is smooth and

 comfortable to touch 

 Polyester Filament  It does not leave rough

Yarns ends of fibres.

 Headliner

 UV-resistant
 Polyurethane 
 It is smooth and
 Polyester fabric 
comfortable to touch.

 Glove or Storage Compartment

 High flame retardancy

 PVC
 Acid-resistant
 Acrylic
 Adequately tough

14. Name 10 Automotive exterior components and the materials used? Also,
mention the property of the material which facilitates the use in the
Component.
Components  Material Properties of a Material

 Bumpers   Polycarbonate(PC)  Polycarbonates

are strong, stiff,
 Acrylonitrile
hard, tough.  
Butadiene
Styrene(ABS)  Thermoplastics
that can maintain
rigidity up to
 140°C.

 Toughness down
to -20°C or special
grades even lower.

 Fenders 

 High rigidity.

 ABS   Good impact

resistance, even at
low temperatures.

 Doors

 Stable in cryogenic
environments.
 Polypropylene  Good impact
 polyvinyl chloride resistance.
(PVC)  Polypropylene has
a high flexural
strength 

 Tailgates Trunk Lids

 High yield
rephosforized steel  Polycarbonates
with the outer plastic are strong, stiff,
panel as hard, tough.
Polycarbonate.

 Spoiler  ABS  ABS materials are

tough, hard and
rigid

 They possess hard

surfaces,
dimensional
 stability, chemical
resistance and
heat resistance.

 They have low

water absorption
and resistance to
creep or cold flow

 Grilles

 ABS materials are

tough, hard and
 ABS rigid

 ABS has a low
melting point

 Semi-rigid.

 Translucent.
 Hood
 Good chemical
resistance.

 Tough.
 Polypropylene
 Good fatigue
resistance.

 Integral hinge
property.

 Good heat
resistance.

 Panoramic Roof  Polycarbonate(PC)  70 - 80 N/mm²

Notched Impact
Strength.

 60 - 80 Kj/m²
Thermal
Coefficient of
expansion.

 65 x 10-6. Max
Cont Use Temp.
  125 °C. Density.

 Extremely impact-
  Head Lights
resistant

 Very light
  polycarbonate resin
 Smaller production
 ABS tolerances are
possible

 Much more design

freedom

 Door Handle
 High Abrasion
Resistance  

 Good Thermal
 polyamide(PA) Resistance of nylon
can have a melting
 ABS/PC point of almost
300°C.

 Good Fatigue
Resistance 

15. Explain 5 types of thermoplastic moulding with an automotive example?

These types are already explained in Q5, The Thermoplastic moulding is,

1. Injection Moulding

2. Extrusion Blow Moulding

3. Extrusion Moulding

4. Vacuum Forming 

5. Compression Moulding

INJECTION MOULDING 
 This technique is widely used for forming thermoplastic materials. It is similar to the casting
technique used to form metal components. The plastic (in a powdered or granular form) is put in a
hopper. A screw thread turns to force the plastic material through a heater, melting it. When all the
materials have melted the screw thread then acts as a ram and forces the plastic into the mould,
where it cools and solidifies.

Example:- Front and Rear Bumper

Automotive plastic front and rear bumpers are both safety and decorative parts. Bumper
Molding’s structural design is not only closely related to the safety of the vehicle but also affects the
texture. With the development of society, cars play an increasingly important role in the lives of
modern people. Auto bumper mouldings also have been on the road of innovation, which is
integrated into aesthetics, energy absorption, lightweight and low cost, high performance and fuel.

EXTRUSION BLOW MOULDING

 
Blow moulding is used to manufacture bottles and containers with very thin walls. Blow moulding
first requires a tube of plastic to be extruded. The tube of molten plastic is extruded between the
two halves of a mould. Before the plastic cools the two halves of the mould are brought together
and the air is blown into the centre of the material through a blow pin. This forces the plastic out
forming the shape of the mould. The plastic can then be cooled and removed.

Example:- HVAC Duct 

To minimize wall thickness in the design phase, Regency Plastics uses a blow moulding process
simulator throughout development to measure and optimize localized wall thickness. This bypasses
the need for prototype tooling, cuts mould cost, reduces delivery time, and decreases product
development time by up to 40%.

EXTRUSION MOULDING

The extrusion process is similar to injection moulding. Plastic granules are heated in a hopper and a
screw thread forces the material through a die. The material is then cooled. Extrusion can only be
used for simple shapes and the end product generally has a poor quality finish

Example:- Automotive Car Door and Window Seal Strips

automotive car door window seal strips are installed on the auto door and windows to protect
against weather damages, they are made of durable PVC plastic trim combined with EPDM sponge
rubber bulb seal, weather seals are made up of the extrusion moulding.

VACUUM FORMING 
Vacuum forming is used to make simple moulds using thin sheets of thermoplastic. High impact
polystyrene sheet is what is used in school (HIPS). PVC can also be used.

A mould is created from wood or epoxy resin and this is placed on the table (platten) of the vacuum
forming machine. The sheet plastic is heated until it becomes soft.

The table with your mould on is lifted into position and a vacuum is used to draw the plastic over the
mould. Vacuum forming only works with thin plastics and moulds with no undercuts.

The plastic can then be trimmed to the required shape.

Example:- Cars doors, Dashboard are made from Vacuum Formed.

In this process, the parts are formed by heating acrylic to a suitable temperature. Place the acrylic
sheet on the mould surface and fixed using a clamping unit. Heat it until it becomes soft and then
quickly apply the vacuum. Using a surge tank, quickly pull the air out from between the mould and
the sheet. This will trigger the formation of a cavity on the mould. The heated sheet will then
conform to the shape of the mould cavity, cool and be ejected from the cavity.
 

COMPRESSION MOULDING

This is how thermosets are formed. The reaction occurs in the mould as the granules are heated and
compressed. UF or urea-formaldehyde and MF melamine formaldehyde are formed by this method. 

Example

The compression moulding process is frequently chosen for high-volume composite parts that are
produced with BMC and SMC materials. This closed mould process creates high strength complex
parts of various sizes. Once the matching metal dies are mounted into a hydraulic moulding press
and heated, the material charge is placed into the mould, the two haves are closed, and up to 2,000
psi of pressure is applied, depending on the material type and part thickness.