CARBON

COMPOSITES FOR
AUTOMOTIVE
Shubham Patil
 Abstract

Carbon composites are widely used in automobiles in modern times due to their
properties of being shockproof, high tensile strength, high melting temperatures and
more. The development of these carbon composites is dependent on the use of PAN
(Polyacrylonitrile) which is heated at high temperatures for carbonation. The
developments were found to require high energy but contribute to significant positive
impacts on automobile operations. Their ability of shock resistance not only helps to
prevent accidents but also helps to protect internal components. This study presents a
detailed view of the factors involved in carbon composite development and their impacts
on automobiles. Moreover, discussions have been provided regarding the effectiveness
of carbon composites, their properties and comparison in regards to the use of steel or
other similar metals. Furthermore, the study also presents the contribution of suppliers
in Carbon composite development and the recommended actions that can be taken to
improve carbon composite manufacturing within organizations for improvements in
automobiles and their operations.

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 Table of Contents

1. Introduction 3
1.1 Brief Introduction 3
1.2 Background 4
1.3 Aims and Objectives 5
1.4 Research Questions 5
1.5 Research Rationale and Problems Stated 6
1.6 Methodologies Selected 7
2. Analysis and Findings 8
2.1 Concept of Carbon Composite 8
2.2 Manufacturing Methods for Carbon Composites 10
Carbon Fibre Manufacturing 10
Composite Manufacturing 13
2.3 Strength and Weaknesses of Different Manufacturing Processes for Carbon
Composites 15
2.4 Importance of Carbon Composite in Automotive Industry 16
2.5 Properties of Carbon Composites 17
2.6 Comparison between the use of Carbon Composites in Automobiles as opposed
to Steel and other metals 18
2.7 Carbon Composite Implementation in Automotive 19
2.8 Market research 20
Contribution of Suppliers in Carbon Composite Manufacturing Processes 20
2.9 Summary of Findings 23
3. Recommendations 24
4. Conclusion 25
References 26

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1. Introduction

1.1 Brief Introduction

Carbon Composite has been a very effective unidirectional fibre. They are made by
mixing different kinds of matters like resin and carbon elements. The main aim of using
this method is to reduce the amount of carbon emission in the environment, per
kilometre. Carbon Composite is a thermoplastic fibre that is used to resolve carbon
emission problems. For various reasons, the production of this unidirectional fibre is not
as high as other products (Jacob, 2014). The global automotive process highly suggests
this process should be used more often. They are mainly obtained in ribbon-like pieces
which are consolidated composites. On the flip side, sometimes these components
become very costly due to lesser mass production. Although, efforts like the flow of raw
materials, local fibre orientation and others are being made to create better accessibility
of the technique.
Carbon fibres changed the working radically the working dynamics of various industries.
Carbon fibre reinforced polymers (CFRP), due to their high strength-to-weight ratio and
stiffness, have proved to be portable and more practical than other alternate metal
composites. It has large demand in aerospace, automotive and the manufacture of
sports equipment. Methods that are being adopted to make the products are mainly
environment-friendly techniques. They can also adopt cost-effective methods for the
application of carbon composites. The entrepreneurs demand advancements in
technologies that would enable better performances. This study will present a detailed
view of carbon composites, their importance in automobiles, manufacturing processes
as well as recommended actions for improved development and implementation.

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1.2 Background

A carbon composite is a porous structure made of carbon with reinforces of both carbon
fibres and carbon matrix. Carbon composite is a strong, stiff, lightweight material that is
popularly used in specialized, high-performance products like aircraft, race cars and
sporting equipment. Within the automotive industry, carmakers are forever on the
lookout for advanced technology that enables better performance coupled with cost-
effectiveness and increased production, to meet the ever-growing demands of
consumers and such technology is Carbon Composites.
Carbon fibres were discovered way before it was used. They were around for over 150
years and only through special manufacturing processes in the last century their
excellent strength-to-weight ratio was achieved. Modern advances in the last couple of
decades have helped in the decrease of manufacturing costs and the composites of
carbon fibres became a popular material for their usage in the greatest technological
advances of recent times (Krasova, 2018). The improvement in the manufacturing
processes of carbon fibres have increased the elasticity and firmness of the material
and led the engineers to finally understand the true potential of carbon fibres.
Over the recent years, societal emphasis on environmentally friendly practices
considers carbon because it's so lightweight. Vehicles do not need to burn as much fuel,
which is eco-friendly. For example, Mercedes-Benz SLR McLaren, the first car with an
entire body made from composite carbon fibre. Initially, high-end cars, supercars and
expensive racing models were the ones that incorporated carbon fibre in smaller
components to gain speed advantages with automakers incorporating a carbon fibre
hood, roof panels, rocker panels and air splitters. Even wheels are made, as it
contributes towards faster acceleration and better control. The major advantage is to
build lightweight cars to gain fuel efficiency and a 10% reduction in weight for saving up
to 6-8% of fuel in automobiles (Khalil, 2017). With the benefit of quick accelerations and
higher top speeds, the material adds a smoother and sleeker touch to the appearances
of automobiles.

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1.3 Aims and Objectives

The study aims to evaluate the efficiency of manufacturing processes in the automotive
industry and the assessment of innovativeness of implementing Carbon Composite for
Automotive manufacturing and developing processes.
The objectives of the study are as follows:
● To identify various methods by which manufacturing processes of carbon
composites are conducted within Automotive brands
● To evaluate the efficiency of Carbon Composites proper operations of
automotive.
● To recommend methods to improve manufacturing processes of Carbon
Composites for utilization in Automotive.

1.4 Research Questions

The research questions involved in the study can be stated as follows:

● What are the methods by which the manufacturing processes of carbon
composites are conducted in the Automotive industry?
● How does the Carbon Composite contribute to the efficiency and operations of
automobiles?
● What recommended actions can be taken to further improve the manufacturing
processes of Carbon Composites?

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1.5 Research Rationale and Problems Stated

The major problems that have been discussed are the demand for a fuel-effective
vehicle. The economy or the amount of money spent behind the fuel of the vehicles or
the "fuel economy" is determined by so. The lesser amount of fuel will determine how
much the vehicle will travel per unit. A fuel effective vehicle will determine spending on a
lesser amount of gas to a given distance.
Product complexity challenge arrives at any point in time. The demand for innovative
products and a steady trend of increasing variant products is expanding. Dedicated
engineers must communicate with the demands, otherwise, there will be a huge
communication gap. The industries must get familiar with the use of the Carbon
Composite in automotive, otherwise, the sudden appearance of the technique might
create huge confusions within the company. The abrupt and sudden appearance of
technology would create chaos within the company and worldwide. Carbon composites
were suddenly used because of their first and foremost utility that is, it is eco-friendly.
We already know how polluted the world is due to pollution. The introduction of carbon
composites will help to reduce the amount of it. Valid and reliable information should be
provided to maintain the workflow.
Carbon fibres are more than 4 times firmer than glass reinforced plastics, almost 20
times more than pine and 2.5 times more than aluminium. It must be taken into account
that carbon composites have electrical conductivity and can facilitate Galvanic
Corrosion but with careful installation, this problem can be reduced (Delic and Eyers,
2020). Carbon fibres possess the quality of high resistance to fatigue and have good
tensile strength. Their properties of fire resistance and non-flammability make them a
more suitable choice for engineers. Therefore, these properties of carbon composite are
the reasons why they are an ideal material used in various industries (Khalil, 2017).

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1.6 Methodologies Selected

The positivism philosophy has been selected within this study due to its ability to use
logical thinking (Marsonet, 2019). It can help to collect information regarding the
importance of carbon composites within automotive and can present logical thinking
regarding the best method for its use. Similarly, the research approach involved within
this study is selected as the deductive approach. It is mainly based and formed on an
existing hypothesis and then experiments are done to test that existing hypothesis. It
has been selected as no new concept or prototype is not involved within this paper.
Some principles are often maintained for the success of the work. Math, power,
psychology and validity are also embedded within such a structure.
Explanatory Design is mainly applied for the research design within this study. This
design has been selected to be able to logically explain the deductions made from the
collected information and to provide a detailed result that is not based on probabilistic
views (Rahi, 2017). A means to produce composite structures with increased has been
investigated with the help of trajectorial fibre steering of composite tows. This process
includes strategic designs involving the alignment of fibres with major stress vectors and
the recent concept of the load paths. Such laminated designs involve the use of logical
thinking for proper operations and utilization and thus the explanatory design is efficient
in dealing with the issue. Application of these methods include specimens with pin-
loaded holes that help increase 62-85% of the strength (Jiang, 2020). The Qualitative
method has also been applied as it involves observations, textual references and more.
The collected data is presented and analysed in textual form within this method thus
leading to easier understanding. This method has been selected as carbon composite
developments are critical tasks that are only conducted by skilled specialists within an
organization. The use of surveys or interviews of these specific group of specialists
require a high time-frame and budget and thus have not been selected for this study.

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2. Analysis and Findings

2.1 Concept of Carbon Composite

A family of materials consisting of a carbon matrix that is reinforced with carbon or

graphite fibres can be termed carbon composite. It ranges from simple unidirectional
fibre secured structures to complex three-dimensional entwined structures.

(Easy Composites) (Easy Composites)

Carbon fibre is a very strong material with a low weight. It is often five times more
effective than steel, thus it is an ideal material for manufacture. Composites of carbon
are formed by collaborating resin and carbon fibre reinforced plastic that has properties
of strength-to-mass ratio and rigidity. Some of the qualities of composites of carbon are
high stiffness, tensile strength, lightweight, high chemical resistance, tolerance towards
high temperatures and low thermal expansion (Klunder, et al, 2019). The use of carbon
fibres goes way back to 1879 when Thomas Edison parched cotton threads or bamboo
silvers in high temperatures that resulted in the carbonization into a fibre filament.
Highly operative carbon fibres were invented by the year 1958. A new manufacturing
process was established at a British research centre in 1963 where the true potential of
carbon fibres was realized and put to use. The steps required for the formation of
composites from polyacrylonitrile are spinning, stabilizing, carbonizing, treating the
surface and sizing (Zhao et al. 2017).

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Carbon fibre comprises carbon atoms which are bonded forming chains, therefore
providing stiffness to composites made from fibres. Carbon fibre has high modulus and
temperature resistance. It can repel corrosion, fatigue and creep and inherits high
electrical conductivity. Despite several useful properties, carbon fibre does have certain
disadvantages, they often break or shatter when compressed beyond its limited strength
or exposed to high impact. Carbon fibres are generally eco-friendly; thus, they do not
cause any severe damage to the environment. The weight of carbon fibre material is
equivalent to that of plastic and possesses more properties than conventional metal
materials hence rendering them more useful for aerospace engineering, nautical
engineering, civil engineering, automobile engineering, military services and
motorsports along with many other competitive fields.

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2.2 Manufacturing Methods for Carbon Composites

Carbon Fibre Manufacturing

1.Raw material – Percussor is a raw material for manufacturing Carbon fibre. PAN,
Acrylic, Pitch are the main precursors. These yarns should be fully drawn yarns.
(Gudiyawar, Lecture)
The prime precursor to the development of Carbon Composites involves the use of PAN
(Polyacrylonitrile) such as Dralon X or Dralon L fibres (Ruiz et al. 2018). The first step of
development involves the collection of propylene, ammonia and air as the primary
oxidizer. The SOHIO process is used to pass the collected propylene, ammonia and air
through a fluidized bed reactor. The fluidized bed reactor includes a catalyst that is
heated at around 400-510 degree Celsius. The reactants are dipped in aqueous
sulphuric acid before they are passed through the reactor. However, it leads to excess
development of propylene, carbon monoxide, carbon dioxide and dinitrogen (Szepcsik
and Pukánszky, 2019). These excess substances do not dissolve and thus is either
vented to the atmosphere or are incinerated. In large industrial plants, the incineration
process is less prevalent due to its contribution to the release of Carbon Monoxide and
Carbon Dioxide. As incinerating these substances can contribute to higher levels of
pollution and global warming, these processes can lead to the infraction of
environmental laws. Venting contributes to a low level of carbon dioxide and carbon
monoxide release which can have lower impacts than incinerating which increases the
CO2 and CO released. However, methods to collect CO and CO2 may be used for use
in future carbonization processes.
The remaining aqueous solution includes substances such as acrylonitrile, acetonitrile,
hydrocyanic acid and ammonium sulphate. The ammonium sulphate content, however,
is produced only in case of the inclusion of excess ammonia for the reaction. A recovery
column is used to remove the majority of water involved in the solution while the
acrylonitrile is collected via the use of distillation processes (Dickson et al. 2017). The
acrylonitrile is then polymerized with other monomers which mainly include dyeing
additives. This process leads to the development of PAN (Polyacronitrile) powder which
is further processed for carbon composite development. The PAN powder is dried and

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stirred into dimethylformamide (DMF) which is heated until the powder dissolves. Dry
spinning processes are used further to ensure the evaporation of the DMF from the
solution with the use of hot air during spinning processes. The spinning material is then
washed, dried and lubricated. Additionally, staple fibre or tow is provided to these
materials for providing proper tenacity, elongation, titre, volume and more for proper
development of the Dralon X PAN resins. Dimethylacetamide (DMAC) is used instead of
DMF to ensure proper development of the Dralon L resins.
Most Carbon Fibres are developed using PAN while about 10% are industrially
developed from rayon or petroleum pitch. The Carbon Fibre development process
includes part chemical and part mechanical operations. This includes the Dralon X or L
resins being developed into fibres and then heated at significantly high temperatures
while preventing its access to air or oxygen. Oxidation can lead to the burning of the
fibre which can affect the development of carbon fibres negatively (Trogen et al. 2021).
The lack of oxidation ensures that the high temperature helps to vibrate the atoms
within the fibre to act violently and expel all the non-carbon atoms within the fibre. This
method ensures efficient carbonization and helps to develop long chains of carbon
atoms within the fibre held together by only a few non-carbon atoms remaining within
the fibre. The entire process involves the five following steps for Carbon Fibre
development:
2. Stabilization: This step is conducted before the carbonization of the Dralon X or L
fibres and involves chemical alteration processes for changing the linear atomic bonding
process into a stable ladder bonding method. This is ensured by heating the fibres in
the air for about 200 to 300 degree Celsius (Byrne et al. 2018). This process should be
done in an oxygen atmosphere. The CO and CO2 that can be collected after conducting
the SOHIO process may be used at this stage along with the air used for heating. The
oxygen molecules are picked up from the air and helps in rearranging the atomic
bonding pattern within the carbon composites. The passing of Dralon X or L fibres over
hot rollers or through beds of loose materials that are held in suspension via the use of
hot airflow to achieve this goal and ensure stabilization.

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3.Carbonization: The stabilized fibres are heated to temperatures of around 1000 to
3000 degree Celsius for a few minutes within a furnace filled with a gas mixture. This
gas mixture does not contain Oxygen has this high amount of heat can damage the
PAN fibres and the gas pressure in the furnace is kept higher than that of outside
pressure. Further, the points where the fibres enter and exit the furnace are seal for
preventing oxygen from entering. Due to the heating process, non-carbon atoms are
expelled and the carbon atoms latch onto the heated fibre resins from the air mixture
within the furnace. In this stage, we get pure carbon fibre. The carbonization stage is
done in a Nitrogen atmosphere

4.Surface Treatment: The surface is usually uneven after the carbonization process
which is managed within this stage. The surface is slightly oxidized to ensure better
bonding properties of the carbon atoms with the Acrylonitrile resins (Hung et al. 2018).
Carbon Dioxide, Ozone, Sodium Hypochlorite, Nitric acid and more are used to achieve
the oxidation process. This treatment process includes taking proper care that the fibres
do not have tiny surface defects such as pits which may lead to failure of the fibre when
utilized within automobiles.

5.Sizing: This process involves the coating of fibres to prevent them from damage
during winding or weaving after the proper surface treatment of the carbon fibres.
Materials such as epoxy, nylon, urethane, polyester and more can be used to achieve
this goal. Further, these coated fibres are shaped into cylindrical structures known as
bobbin which are loaded into spinning machines thus allowing the fibres to be twisted
into yarns of different sizes as per need.

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Composite Manufacturing

Wet spray-up mould (Composites UK)

Vacuum infusion (Composites UK) Filament winding (Composites UK)

Continuos process (Composites UK)

The above image is some main types of the composite manufacturing process. There
are different types of composite manufacturing techniques as per the end product. For

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automotive parts following moulding techniques are used to produce composites,
Additive manufacturing, Compression moulding, Curing, Filament winding, Infusion,
Continuous process Injection and over moulding. For manufacturing the composite, we
need carbon fabric and resin for applying on the surface of the fabric. Mainly 5 different
types of resins are used for the automotive industry for manufacturing carbon
composites. Mostly for the automotive industry using epoxy and thermoplastic resins for
car body and Phenolic and BMI cyanate resin for engine, engine compartment and
gearbox. In the below image we can see in any shape we can mould carbon composite
easily. Manufacturing complicated shape by composite using the moulding process is
very easy than giving shape to steel and metal. (Gudiyawar, Lecture)
• Types of Resins
Epoxy – High quality, Standard applications
Phenolic – Fire resistant resin
BMI Cyanate – High temperature
Polyester – Low-cost substitution
Thermoplastic – High impact resistance. (Gudiyawar, Lecture)

(TRUMPF)

(GommeBlog.it: Car & Performance 2019) (Jacob 2011)

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2.3 Strength and Weaknesses of Different Manufacturing Processes for
Carbon Composites

Manufacturing Strengths Weaknesses

Process

Creation of Carbon • Does not include the • Needs to be heated at

Composite with the use of specialized extremely high
use of PAN systems and equipment temperatures which can
for the development of lead to damage to the
PAN. fibres.
• Allows efficient • Requires a high-time
carbonization and frame as well as cost for
surface treatment development of the PAN-
processes for easy use based carbon
in automobiles. composites.

Creation of Carbon • Highly cost-friendly due • Involves the use of a

Composite with the to the use of low-cost lightweight and volatile
use of Rayon or raw materials for the materials which can lead
Petroleum pitch development of Carbon to unexpected fires and
Composites damage to the equipment
• Lower heat as well as materials.
requirements for • Requires additional
Carbon composite graphitization processes
development thus for the development of
saving energy as well high-quality carbon
as decreasing possible composites that can be
damage to the fibres. used in automobiles (Zou
et al. 2020).

Table 1: Comparison Amongst Different Manufacturing Processes.

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2.4 Importance of Carbon Composite in Automotive Industry

Composite materials have certain advantages over steel in automobile manufacturing

industries. They are considered to make safer, lighter and more fuel-efficient vehicles.
They provide enhanced properties compared to individual materials as the composites
consist of high-performing fibres, such as carbon. Composites are often preferred over
other materials because they do not rust or corrode like steel or aluminium. Carbon
composites are important in the automotive industry because they significantly increase
vehicle fuel economy and reduce vehicle weight up to nearly 60% as recommended by
Oak Ridge National Laboratory. The rigidity of the composites of carbons provides
extreme stability that helps the cars to be able to absorb large quantities of impact
energy, thus ensuring the safety of the vehicles. The composites of carbons used in
automotive applications offer a cost reduction, mass reduction and recyclability (Ramli
et al. 2018). They provide many structural and weight advantages over other materials
like the traditional steel and injection moulded automotive parts.

(Vibin P Vijay 2018)

In the above image, it seen that Excellent crash performance is obtained with the use of
thermoplastic composites compared to steel. Thermoset composites allow absorbing
energy twice as that of steel and thermoplastics can absorb seven to eight times the
energy of steel. According to the European directives and standards, the automobile
manufacturing industry addresses some issues such as environment-friendly

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dismantling, recycling of vehicles, increase in the reuse, recovery of cars and their
components, production of new cars with improved recyclability and lastly contributing
abundant perspective for application of thermoplastic composites in the automotive
arcades (Jaeger and Frohs, 2021). Composite materials are quite impressive when it
comes to durability. They can withstand challenges that would generally extinguish the
steel if it is used. They can resist harm from certain corrosive chemicals such as acid
rain which destroys some alternate metals.
With the help of moulding, composites can be transformed into different complex
shapes without involving high-pressure tools, therefore making them stronger and
providing resistance to bending. They have also been helpful when it comes to boosting
the fuel efficiency of the cars. The use of composites materials helps the automotive
industries to expand into the eco-friendlier territory by reduction of cost and
improvement of product quality (Delic and Eyers, 2020). Using composite material tools
can cost as little as 20% of the cost that involves usage of comparable metal parts and
can be 20-40% lighter thus helping reduce the net weight of the vehicle. These are the
reasons why composites have been welcomed with open arms in the automotive sector.

2.5 Properties of Carbon Composites

Carbon-Carbon Composites (C/C) are composed of a carbon fibre-infused carbon

matrix that upholds unique mechanical and thermal properties. C/Cs incorporate
significant technological and physical properties including high stiffness, high tensile
strength, high chemical resistance, low weight, low thermal expansion and high-
temperature tolerance properties. Such unique physical properties have made C/Cs
popular in the automotive industry to improve vehicle architecture and automobiles.
Lightweight carbon-fibre-reinforced carbon matrix can sustain a variety of structures
including oriented, lamellar, columnal and mosaic which have advanced applications in
the vehicles including interior and exterior designs and body parts.
Carbon composites are manufactured with diversified reinforcement mechanisms that
allow improving the maximum level of mechanical properties. Moreover, fabrication of
carbon composites can be completed by Liquid Phage Infiltration Process or Chemical
Vapour Deposition Process for preparation of Carbon matrices for desired structure.

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Carbon Composite has a high modulus of elasticity up to 200 GPa and Tensile strength
of 200 to 500 MPa. Fabrication processes result in a higher modulus of elasticity and
mechanical strength. C/Cs also upholds compressive strength of 150 to 200 MPa and
fracture toughness of 5 to 10 MPa alongside excellent thermal resistance, low
coefficient of thermal expansion and high electrical connectivity (Kumar et al. 2018).
C/Cs can retain excellent heat resistance at temperatures up to 3000°C and a low
density of 114 lb/ft³. High thermal conductivity up to 700 BTU and low coefficient friction
has increased its mechanical and engineering capabilities. However, the main
disadvantage of carbon composites is their low oxidation resistance as it reacts with
oxygen at a temperature above 482°C. For oxidation protection of carbon composites
various coating methods. including ceramic coating with carbides, nitrides and oxides,
impregnation of oxidation inhibitors including halogen compounds, phosphates, boron
oxides and silicate glasses (Zhao et al. 2017). Based on heat treatment temperature
carbon composites can be classified into three types. Type I is a high heat treatment
carbon matrix (HTT) that can sustain higher temperatures of 2000°C and above. Type II
carbon composites can sustain up to 1500° C and 1000°C by Type III carbon
composites. Such mechanical and physical properties have made lightweight carbon
composites significantly effective and efficient in providing excellent shielding
performance in portable electronics and multifunctional.

2.6 Comparison between the use of Carbon Composites in Automobiles as

opposed to Steel and other metals

The fibres of carbon offer high stiffness and strength at a very low density which helps
to lower the mass. Therefore, it can be concluded that they are lighter than aluminium
and steel which makes them practically beneficial and provides easy transportability.
Carbon fibres possess two to five times more rigidity than metals like aluminium or
steel. Carbon composites made from the fibres of carbon are way safer than steel
making them environment friendly. They possess high durability than most metal
polymers. High dimensional stability helps them to sustain their shape even in places
with extreme temperature differences. Hence carbon composite is better than any other
metal components or steel. In recent years, composites are snapping at the heels of the

18
incumbents. Despite the abundance of steel and aluminium or any other metals, the
manufacturers prefer carbon fibre composites because of their high strength-to-weight
ratio (Francois et al. 2017). They possess high malleability and ductility hence used as
binding agents. Properties such as low weight, tensile strength, compressive strength,
adherence to standards, corrosive resistance and low thermal conductivity and high
tolerance towards temperature extremities make the composites of carbon fibre more
efficient and practical for their usage in the above-mentioned industries. Corrosion-
resistant carbon composites triumph over steel and they are proved to be 30% lighter
than aluminium with incredibly high firmness. The biggest benefit of composite materials
is their ability to mould into different complicated shapes without the need for high-
pressure tools (García, 2019). Carbon composite materials have an exceedingly long
life span and combining with their low maintenance requirements make them an ideal
material of choice for the application host and is used in abundance in various industrial
enterprises.

2.7 Carbon Composite Implementation in Automotive

Carbon fibre and composites including carbon fibre-reinforced plastics (CFRPs) are
creating comprehensive opportunities for automotive companies to adapt structural
engineering transformation towards sustainability and affordability (Krishnan et al.
2020). Steel and other metals have been widely used in the automobile industry for a
long time. However, metal and alloys are still critical to automotive design and vehicle
foundation.

Seat Placing - (Jacob 2011) Chassis - (Bhargav 2017)

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Engine - (LIFE BEYOND SPORT) Gearbox- (LIFE BEYOND SPORT)
In the above images, we can see that carbon composites can be used in various distinct
parts such as doors, lift gates, seat, Chassis, Engine, Gearbox and interior designs to
enable car bodyweight reduction up to 25 to 60% compared with metallic mouldings.
Moreover, instruments, under-tray, body parts and accessories can be made of carbon
composites (Song and Zhao, 2017). The development of these carbon composites
contributes to increased shock resistance of automobiles and are beneficial in
protecting internal components. In the case of the use of carbon composites for car
hoods, it can help to prevent issues involving head-on accidents. Even if these
accidents occur, the shock resistance of Carbon composites can help to keep the
internal components protected, thus preventing possible busting of the battery or
problems with electrical damage.

2.8 Market research

Contribution of Suppliers in Carbon Composite Manufacturing Processes

Suppliers are playing a fundamental role in uplifting industry standards and value
proposition activities and proactive supplier management practices are significantly
becoming an integral property manufacturing processes within organisations. CFRPs
are expected to comprise a $35 billion market by 2022 which require large-scale
mainstream production and supplies to sustain the usability of CFRPs (Hadigheh et al.
2021). Automotive companies are incorporating relationship-driven partnership

20
programs with carbon Composite producers, joining consortia and conducting
brainstorming sessions and mutual R&D pipelines. Suppliers are concentrating on
recycling programs and large-scale production of CFRPs at a faster pace, more efficient
equipment and resins. Leveraging upstream partnership, transaction-specific
investment and low-cost operational methods are critical for carbon composites usage
in the automotive industry.

(Grand view Research 2020)

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 (Grand View Research 2020)

(Grand View Research 2020

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2.9 Summary of Findings

The industrial revolution and globalization attributes have created the global automotive
industry as one of the world's largest manufacturing industries while considering techno-
capitalism perspectives and technology-driven innovations and usage of cutting-edge
carbon fibres have largely influenced MNCs for leveraging cost-effective production
methods. Key manufacturers including BMW, Ford, General Motors and Toyota have
leveraged customised manufacturing practices, multi-domestic expansion policies, JDA
alliance between OME and composite material suppliers and venture development
programs to produce truck, vehicles equipped with CFRPs (Szász et al. 2021). Mutually
conducting R&D pipelines, aerodynamically advanced vehicle design, usage of carbon
composites and electrical engineering principles are effective for the betterment of
safety and quality of the public.
A high increase in the use of carbon fibre composite materials has effectively resulted in
the displacement of steel or metal composites like aluminium in automotive and
aerospace applications. Carbon fibre composites can be used as an additive to asphalt
making electrically conductive asphalt concrete. Their qualities of high strength, high
modulus, resistance to temperature extremities, corrosion resistance, fatigue and creep
resistance, electrical conductivity and low thermal expansion make them an ideal choice
for their application in many industries. They are used in abundance in the automotive
industry because the rigidity of the composites provides extreme stability that helps the
cars to be able to absorb large quantities of impact energy, thus ensuring the safety of
the vehicles. The carbon fibres are environment friendly, has a high strength-to-weight
ratio and excellent stiffness, hence with the appropriate amalgamation of reinforcement
and material matrix, the producers can render them into an ideal choice of composite
material that can resist heat and temperature extremities which fills the requirements of
almost every industrial purposes.
The applications in the defence-related aerospace industry were the main reason
behind the usage of carbon fibre composites due to their excellently crafted structure
and binding capability. Despite being an ideal material of choice, carbon composite
materials are still not used in every single application. It could be mainly because they
are cost-prohibitive in many industries and keeping in mind the recent marketing tactics,

23
the quality of fibre used in the aerospace industry and commercial grade may vary
drastically. But these current problems can be fixed with technological advancements
involving innovative ways of manufacturing more cost-effective products. Composites
are responsible for the reduction of passenger car weight by 50% and improvement in
fuel efficiency by nearly 35% without any compromise in the safety and performance of
the vehicle.

3. Recommendations

The recommended actions that can be taken for the improved manufacturing of Carbon
Composites are as follows:
• The Carbon Monoxide (CO) and Dioxide (CO2) produced during the
development of PAN (Polyacrylonitrile) can be stored via the use of Bio-energy
with Carbon Capture and Storage (BECCS). This can allow the use of CO or
CO2 during the carbonization or surface treatment processes for easier
development of the Carbon Composites.
• The use of modernized technologies such as the MIS and Artificial Intelligence
(AI) can help to ensure more efficient planning processes. The use of proper
planning can ensure the development of carbon composites are more efficient
and large-scale developments can be done with ease.
• To develop the carbon composites, a temperature of around 1000-3000 degree
Celsius is required. This contributes to a high level of energy loss during product
development which can be managed efficiently by using a variety of materials
like ammonia, methane and more. These gases can lead to a decrease in the
overall heat requirements for the carbon composite development thus decreasing
the energy loss.

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4. Conclusion

Based on the study, it can be concluded that the use of Carbon composites has a
positive impact on automobile operations. Carbon composites are highly shock resistant
and can sustain significantly high temperatures which contribute to their utilization in
cars and automobiles. Other materials such as steel and similar metals are good
conductors of electricity and heat energy which can contribute to major damage to other
components of the car. Therefore, the use of carbon composites is highly efficient in this
regard. Similarly, the use of Carbon Composites for the car hoods or the battery holder
can be highly efficient as its shockproof abilities can help to keep damage to internal
components of the car at bay in case of major accidents. This is beneficial in saving
lives and also ensure continued sustenance of the car or automobile.
The Carbon composites are manufactured from Polyacrylonitrile at high temperatures to
ensure proper carbonation for structural development and oxidation for surface
treatments. However, the use of gases such as ammonia and methane instead of the
regular heated gas mixture can be efficient in decreasing the temperature required for
conducting the development process. This can ensure better energy savings and can
help organizations to meet demands in regards to Carbon composite developments.

25
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