MATERIAL SCIENCE FINAL REPORT

MATERIAL SELECTION
FOR AUTOMOTIVE BODIES
SUBMITTED BY:
ABHINAV SAHU
JAGDISH PRASAD MEENA
Outlines of content
Steel’s
usage
Need of change
Options we can choose
Aluminum's usage
Composites/FRP
FRP constituents
Steel : It has been conventional?
>Steel has been the material of choice for
automobile structures since Henry Ford’s
introduction of mass production in 1913.
>In 2004, the average light vehicle
produced in North America contained
2233 pounds of steel (55% of the vehicle
weight) and 331 pounds (8%), of iron.
Why change of material ?
Major factors which compel change of material:
1.Constraints on energy consumption
2. Environmental issues have influenced vehicle
development for last four decades.
3.Rises in oil prices due to increasing demand and
4.The increased prominence of global warming in
the popular press, technological advances to
improve vehicle efficiency are becoming
increasingly important
5.The competition of global automobile market
“Fat men cannot run as fast as thin
men, but we build most of our
vehicles as though deadweight fat
increased speed…. I cannot imagine
where the delusion that weight
means strength came from….”
Henry Ford
INCREASING EFFICIENCY ???

TWO IMPORTANT POINTS:

1:Architectural development
2:Material substitution
OPTIONS TO SUBSTITUTE STEEL
Requirements of main properties of
Material:
1) Strong
2) Light
3) Cheaper
Suitable Materials Available
1) Aluminium and its alloys
2) Polymers
Aluminum and its alloys
Over the years there have been many attempts to
introduce aluminum and aluminum sheet alloys for
automobile bodies.

Aluminum has, for example, been used for a

variety of Land Rover applications since 1948, and
the latest Land
Rover Discovery V8i features aluminium side
panels.
PROPERTIES OF
ALUMINIUM
Although the modulus of aluminium is
approximately one-third that of mild steel.
The important parameter for maximum
stiffness at minimum mass for a flat plate
loaded in bending is E1/3/ρ.
And density of aluminium is less in
comparison of steel.
So the value of above
parameter for aluminium is
approximately twice that of
mild steel, so for equal
stiffness, in aluminium a panel
will weigh 50% less than in
mild steel.
Polymer composites
Polymers have a wide range of
properties and we can modify their
properties according to
requirement or sometimes we can
manufacture new polymers.
POLYMERS IN PAST IN
AUTOMOTIVES
The use of polymer composites for
automobile body components is by no
means new, as instanced by the various
Scimitar sports saloon models (Reliant
Motor PLC, U.K.) which used such
materials for the application over many
years in association with a steel structural
frame.
 What are composites/ FRP ?
A combination of:
1. a polymer (plastic) matrix (either a thermoplastic or
thermoset resin, such as polyester, isopolyester, vinyl
ester, epoxy, phenolic)
2. a reinforcing agent such as glass, carbon, aramid or
other reinforcing material

Such that there is a sufficient aspect ratio (length to

thickness) to provide a discernable reinforcing
function in one or more directions.
Cont..
To modify and enhance the final product, it
may contain:
1: Fillers
2: additives core materials

The constituent elements in a composite retain their

identities (they do not dissolve or merge completely into
each other) while acting in concert to provide a host of
benefits ideal for structural applications.
Components of FRP?
Its depends on properties required, yet
common categories are
 Resins
 Reinforcement
 Fillers
 Additives and modifiers
 Gel coats, adhesive and Core material
Resins: The primary functions of the resin
are to transfer stress between the reinforcing
fibers, act as a glue to hold the fibers together,
and protect the fibers from mechanical and
environmental damage. Resins are divided
into two major groups 1.thermoset
2.thermoplastic.
The most common thermosetting resins used
in the composites industry are unsaturated
polyesters, epoxies, vinyl esters and phenolics.
Reinforcements: The primary function of
fibers or reinforcements is to carry load along
the length of the fiber to provide strength and
stiffness in one direction.

Most commercial reinforcements is glass fiber.

Other e.g. carbon, aramid, UHMW (ultra high

molecular weight) polyethylene,
polypropylene, polyester and nylon
Fillers: Use of inorganic fillers in
composites is increasing. Fillers not
only reduce the cost of composites, but
also frequently impart performance
improvements.
Calcium carbonate, Kaolin (hydrous
aluminum silicate), Alumina trihydrate,
Mica, Feldspar etc are common fillers.
Additives and Modifiers: A wide
variety of additives are used in
composites to modify materials properties
and tailor the laminate's performance.

Other components of composits are

gel coats, Adhesives and Core Materials
for Sandwich Structures.
Pro and Cons of Composites?
Problems related to FRCs Body
High cost
Non recyclable
sophisticated designing process

The polymer composite industry’s developments

in process and design have, from a production
perspective, maintained composites technology
as an economically credible alternative for
vehicle body applications.
We are here…

Lamborghini Gallardo LP 570-4

Spyder Performante enjoys carbon fiber with weighing solely 3274 lbs however with a 570hp
with a prime speed of 201mph( ~320 km/h).
Queries?

THANK YOU!