COMPOSITE MATERIALS IN THE AUTOMOTIVE INDUSTRY

ABSTRACT

This article examines the growing role of polymer and composite materials in the automotive industry. In recent years, polymers have increasingly been used to manufacture both small complex components and large load-bearing structures in vehicles. Composite materials, especially carbon fiber, provide significant advantages such as low density, high strength, corrosion resistance, and the ability to create structures with predetermined properties. Their use helps reduce vehicle weight, improve fuel efficiency, and enhance performance. The study also discusses technological developments in manufacturing composite parts and analyzes current trends in their application in modern and electric vehicles. Despite higher production costs and technological challenges, the demand for polymer composites continues to grow. The research concludes that further development of automated production technologies, reduction of manufacturing costs, and improvement of material properties will expand the use of composite materials in future automotive design and engineering.

АННОТАЦИЯ

 В этой статье рассматривается растущая роль полимерных и композиционных материалов в автомобильной промышленности. В последние годы полимеры все чаще используются для изготовления как небольших сложных компонентов, так и крупных несущих конструкций транспортных средств. Композитные материалы, особенно углеродное волокно, обладают значительными преимуществами, такими как низкая плотность, высокая прочность, устойчивость к коррозии и возможность создания конструкций с заданными свойствами. Их использование помогает снизить вес автомобиля, повысить топливную экономичность и улучшить эксплуатационные характеристики. В исследовании также рассматриваются технологические разработки в области производства деталей из композитных материалов и анализируются современные тенденции в их применении в современных автомобилях и электромобилях с электроприводом. Несмотря на более высокие производственные затраты и технологические проблемы, спрос на полимерные композиты продолжает расти. В исследовании делается вывод о том, что дальнейшее развитие автоматизированных производственных технологий, снижение производственных затрат и улучшение свойств материалов позволят расширить использование композитных материалов в будущем автомобильном дизайне и машиностроении.

Keywords: polymer composite materials (PCM), prepregs, carbon fiber plastics, fiberglass, automotive industry, automobiles, polymer composite materials (PCM), prepreg, carbon plastic, fiberglass, automotive industry, cars.

Ключевые слова: полимерные композиционные материалы (ПКМ), препреги, углепластики, стеклопластики, автомобильная промышленность, автомобили, polymer composite materials (PCM), prepreg, carbon plastic, fiberglass, automotive industry, cars.

Introduction

In recent years, the functions of polymer materials in any industry have changed somewhat. Polymers began to be used for more and more critical parts. Thus, they are used to produce more and more relatively small, but structurally complex and responsible parts of machines and mechanisms, at the same time, polymers are increasingly used to manufacture large-sized body parts bearing significant loads.

Currently, polymer composite materials (PCM) have become one of the main structural materials – the list of car parts that are made of polymers in certain models would take more than one page: bodies and cabins, tools and electrical insulation, interior trim and bumpers, radiators and armrests, hoses, seats, doors, hood. Moreover, several different companies abroad have already announced the start of production of all-plastic cars.

Composite materials are primarily carbon fiber products, which have been used, for example, in the automotive industry for many years, and every year the volume of use of such materials is growing. The most important advantage of carbon fiber is its low density and high strength. Carbon fiber is 5 times lighter than steel and 1.8 times lighter than aluminum. The use of composites in the automotive industry makes it possible to reduce the weight of a vehicle by 20-25%, thereby significantly increasing the efficiency of the engine and reducing fuel consumption. Carbon fibers are made from synthetic and natural polymer-based fibers. Depending on the processing mode and the feedstock, materials of different structures and with different properties are obtained. This is the main advantage of composite materials, which can be created with initially set properties for specific purposes. The first thing that designers and developers borrowed from light–engine aviation is the ability to form body panels from composites of almost any shape and size. A significant reduction in body weight (almost by half) gave considerable advantages, but record figures had to be paid for by a significant increase in cost and complexity of manufacturing technology. The fiberglass or carbon fiber body had to be molded almost manually, with constant and continuous control of all technological operations. Marriage was not allowed, each of the panels was a piece product, it is no longer possible to restore or fix anything after molding. Conveyor assembly, even of the most elite models, was the basis of any automobile plant, otherwise production costs would not be covered by income from the sale of cars. Even such undeniable advantages as fuel economy, improved dynamic properties of cars, and a 50-year corrosion-free guarantee were not so attractive in the eyes of buyers to pay double the price for a novelty.

Objects and methods of research. Analysis and testing of fiberglass–reinforced composite power elements unexpectedly showed that in the role of load-bearing structural elements designed to absorb the main impact energy, composites are significantly inferior to metal - at least 2 times. It could be summed up – the introduction of plastics and plastics into the design of the car did not bring the desired effect and left the main dominant positions for high-quality steel and light alloys. The return of developers to the use of composite materials was noted by experts quite recently and coincided with the appearance of hybrid cars and "clean" electric vehicles on the market. An electric drive in most promising models implies the presence of a significant additional mass of electric batteries or fuel cells. The resource, mileage and dynamic qualities of electric vehicles strictly depend on the weight of the car. At the same time, models designed for operation in urban conditions are made with a high center of gravity and a small distance between the axes. The small dimensions of the car make it easy to find a parking spot and squeeze through traffic jams. A high center of gravity leads to a tendency for the car to overturn. Composite materials reduce the weight of the structure by almost 30%, and heavy batteries located in the lowest possible position shift the position of the center of gravity of the machine to a guaranteed safe one. In this case, the use of composite materials gives a tangible economic effect.

Figure 1. Forecast of the use of carbon composites until 2030

The technology of manufacturing composite parts has also changed. Currently, they are manufactured (as well as metal assemblies) on robotic lines. To simplify installation, metal fasteners are pressed at the interface points with other parts when forming the assembly. This method allows the use of welding, bolted and riveted connections. Any fluctuations and alternating loads are perceived by such products (as well as metal ones) without the risk of fatigue cracks and panel delamination.

Results and its discussion. Observing the technical progress in the field of development and application of composite materials, we can confidently state that in the near future there will be production cars with a fully composite body and many components and assemblies. IHS experts predict that the use of polymers in the automotive industry will grow (Fig. 1).

Currently, the average car contains ~ 200 kg of one or another type of plastic mass, but by 2020 this figure will exceed 350 kg. Such data is provided by the analytical company IHS. But even greater progress is expected in the carbon fiber segment – their use will grow 3 times by 2030 – from 3.4 to 9.8 thousand tons.

IHS specialists also note that the automotive industry is a fast-growing and very attractive industry for the chemical industry. If in 2003 car production amounted to 56.9 million cars per year, by 2020 this figure will grow to 104.1 million.

Figure 2. Materials used in the automotive industry

The use of parts and assemblies produced on the basis of polymer and composite materials in the automotive industry is expanding every year. Currently, in the structure of raw materials for automotive components, the share of polymers (in % of the cost of an average car) is in third place after metals (Fig. 2).

The use of plastics in the production of technical products provides: reducing the weight of the structure with its high strength; a high level of safety in terms of electrical strength – tracking resistance and arc resistance; a high level of resistance to UV radiation; the possibility of using dyes to create a color range of products. Using a PCM in a car allows you to reduce its weight by 15-30%, and reducing the weight by 100 kg leads to a decrease in fuel consumption by 0.5 liters for every 100 km. Of course, high-tech structural polymers are not more economical than steel or aluminum alloy and the process of forming polymer parts is longer than stamping steel sheet, but they do not require corrosion protection. Compared with American car manufacturers, whose share of polymers in the total weight of an average passenger car is 11-13%, in Russian-made passenger cars this figure is only 4-9% (Fig. 3).

According to experts, this circumstance is due to two main factors. On the one hand, the low proportion of polymer components in relatively modern models of domestic brands (Lada Kalina, Lada Priora) can be explained by a rather conservative approach in the development of these models. When developing new domestic cars, designers and engineers have to take into account both the real state of the local automotive components market and the technical capabilities of existing car factories: it is not recommended to include in the design of a new large-scale car the use of parts and materials that cannot be manufactured even in the future.

Figure 3. The weight content of polymers in various car models

Thus, a small proportion of polymers in domestic models is indirectly affected by the low technological level of development of the plastic automotive components industry. On the other hand, it is unprofitable for manufacturers of automotive components to take certain polymer parts into mass production if the batch of such parts is below a certain economically justified minimum, i.e. the industry of local automotive components does not receive the proper incentive for development, including because the domestic automotive industry does not produce enough cars. Compared to employees of the domestic automotive industry, foreign colleagues feel more confident in this area.

BMW has invested $533 million. in the development of industrial production of an electric car model. The body of the new BMW electric car is largely made of carbon fiber, which made it possible to increase the mass of the electric battery by 250-350 kg. In fact, the body is made of synthetic material reinforced with carbon fiber. The body made of such material is 50% lighter than steel and 30% lighter than aluminum. Structural elements made of the new material can be easily combined with aluminum body panels or metallized (Fig. 4).

The first positive results have already been reflected in the Ford GT model. Experts note the improved handling and rapid acceleration of the car, which is difficult to achieve without giving individual components increased flexibility and rigidity. The body is made of carbon fiber. The wheels are made of special aluminum alloys. This made it possible to reduce the weight of the car by 12%. In total, the concern intends to reduce the weight of large-sized crossovers by 300 kg. Nanomaterials are used in car paint, which prevents damage to the surface from scratches and small chips.

Figure. 4. BMW car

Carbon fiber is also used by the Mercedes concern, parts from which are being introduced to replace steel components. Motor housings and a load-bearing system of a girder structure are made of them. In the updated series of the SL65 Black Series, thanks to innovations, the weight of the car decreased by ~ 170 kg, which allowed to increase the efficiency of the car as a whole. Currently, new structural materials are being tested in detail for medium-sized sedans, but soon they are supposed to be used to produce springs for heavy trucks operating under high loads. Such materials need special strength, elasticity and rigidity. This task can be accomplished with the help of twisted glass fibers reinforced with epoxy resin and other components. Springs made of complex high-tech PCM, unlike steel ones, are not subject to corrosion, are neutral to reagents and chemicals used in car washes. In addition, such springs are more economical to manufacture, since the process is less energy-intensive. Their production does not require large capacities with steelmaking furnaces, but rather small workshops. For example, one such detail is a high-pressure cylinder for cars running on gas fuel. There are six such cylinders on each car, they are used in the braking system. Currently, the main problem with the use of steel specimens is that they rust, and parts made of composites will be essentially "eternal". In Russia, multi-axle wheeled vehicles of high cross-country capability are produced, such as the ZIL-BAZ-135 with a cabin, engine compartment and lining made of composite materials and the ZIL-1E5P floating wheeled vehicle with a load-bearing (frameless) composite body. The experience of creating numerous parts from PCM: housings, bodies, frames, cabins, springs, fuel tanks, wheel rims, etc. – proves the wide possibilities of using composites in wheeled vehicles.

Figure 5. Composite materials in the automotive industry

The materials are intended for use in the structures of the high-speed helicopter carrier system, and can also be used to manufacture loaded car parts (body, body, frames, springs).

Table 1.

The share of PCM in domestic cars

Conclusion.

Composite materials are the most intensively developing segment in the materials market. Increased strength, ductility, heat resistance, low density – these advantages allow composites to increasingly displace classical materials – wood, metals, stone. Composites are intensively entering the familiar world of every person, their use in the automotive industry, aircraft industry and other sectors of the economy is increasing every year.Thus, it can be concluded that in order to continue the further successful implementation of composite materials in the automotive industry, several tasks need to be solved. Firstly, to reduce the manufacturing cycle of parts to a few minutes, which will allow for their mass production and reduce the amount of necessary equipment. Secondly, to ensure their acceptable market value, which is associated with both solving the first task and reducing the cost of raw materials. Finally, it is necessary to create modern automated production facilities, which will employ specialists in the design and development of modern technological processes, as well as in the maintenance of structures made of polymer composites throughout the entire life cycle – up to disposal.

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