{"id":16642,"date":"2015-09-01T05:15:48","date_gmt":"2015-09-01T09:15:48","guid":{"rendered":"https:\/\/acmanet.org\/?p=16642"},"modified":"2025-02-04T16:17:26","modified_gmt":"2025-02-04T21:17:26","slug":"automotive-industry-meets-lightweighting-demands-with-composites","status":"publish","type":"post","link":"https:\/\/acmanet.org\/automotive-industry-meets-lightweighting-demands-with-composites\/","title":{"rendered":"Composites in the Fast Lane"},"content":{"rendered":"
The industry is evolving quickly to meet automotive lightweighting demands.<\/strong><\/p>\n Deadlines are looming for CAFE fuel efficiency standards in the U.S. (54.5 mpg fleet average by 2025) and for Europe\u2019s required reductions in CO2 emissions (40 percent decrease for fleets from 2007 to 2021). In response, automakers and OEMs are working more closely than ever with the composites industry to produce lighter, more efficient vehicles to meet the new requirements.<\/p>\n According to the U.S. Department of Energy (DOE) a 10 percent reduction in vehicle weight can improve fuel efficiency by 6 to 8 percent or increase the range of a battery-electric vehicle by up to 10 percent. Compared with steel, composites can offer a mass reduction ranging of 25 to 30 percent for glass fiber systems and 60 to 70 percent for carbon fiber systems. So it\u2019s not surprising that Persistence Market Research predicts the global composites automotive market will more than double in size in the coming years, going from $3.06 million in 2014 to $7.01 million in 2022.<\/p>\n \u201cThe CAFE standards are really what\u2019s been driving the growth of composites,\u201d says Laura K. Gigas, senior product manager, Ashland Performance Materials. \u201cComposites are lighter than steel, and they have other qualities like corrosion resistance and the ability to consolidate multiple steel parts into one composite part.\u201d<\/p>\n Lightweight and cost effective<\/strong><\/p>\n Although carbon fiber has grabbed much of the attention in the automotive world, OEMs today are using a wide range of composites in their vehicles.\u00a0<\/strong><\/p>\n Sogefi, working with Owens Corning, unveiled the first composite material coil springs for automotive suspension systems last fall. Audi will use the GFRP coil for its mass-produced A6 Avant 2.0 TDI ultra. The composite coils weigh 40 to 70 percent less than traditional springs made of steel and will reduce the weight of the vehicle by approximately 9.7 pounds. They also will reduce noise and decrease CO2 emissions up to 1.1 pounds per 0.62 miles.<\/p>\n Chevrolet will use Continental Structural Plastics\u2019 TCA Ultra Lite SMC, a polyester-based Class A SMC with a specific gravity of 1.2, in 21 body panel assemblies in the 2016 Corvette. Components include doors, deck lids, quarter panels and fenders. The use of composites will save money, since tooling costs for composites for production volumes under 150,000 can be as much as 50 to 70 percent less than those for stamping steel or aluminum.<\/p>\n Ford researchers have been experimenting with both injection molding and compression molding for composite components made from chopped fibers. \u201cThe properties look very, very good for future applications,\u201d says Matt Zaluzec, global materials & manufacturing research \u2013 VES Technical Advisory Board, Research & Advanced Engineering at Ford.<\/p>\n But random fiber composites provide less predictable, less reproducible results than composites made with continuous fiber. That\u2019s not an issue in body panels, but it is essential in structural, safety-critical components. Ashland is working with resins and processes such as prepregs and high pressure resin transfer molding (HP-RTM) to improve the structural stability of both glass and carbon continuous fiber composites.<\/p>\n <\/p>\n Hyundai: Using a CFRP Frame<\/strong><\/p>\n Automakers like CFRP because of its weight (70 percent lighter than steel and 40 percent lighter than aluminium), high strength-to-weight ratio, stiffness and corrosion resistance. For its new Intrado crossover, Hyundai is using a rigid CFRP structure in combination with lightweight steel.<\/p>\n At the core of the Intrado\u2019s frame are CFRP sections that begin life as beams containing overbraided carbon fiber and flexible foam cores. Hyundai says the composition makes laying-up and bending into shape easy \u2013 no pre-forming steps are necessary – while the enclosed foam reduces frame mass and cost. A vacuum-assisted RTM process is used to create the final material.<\/p>\n Precisely-shaped, continuous loops made from CFRP form self-contained modular frames for the roof, hood and door aperture on either side of the car. Hyundai bonded the carbon loops along their lengths, rather than at cross-sections, to make the frames stronger and reduce torsional stresses.<\/p>\n The seals of opening panels shut directly against these frames, further reducing weight and showcasing the CFRP whenever the doors, hood or trunk are opened. Body panels are made from advanced, super lightweight steel, but the strength and rigidity of the central CFRP frame structure means Hyundai could make them from any material.<\/p>\n A \u201cfloating\u201d center console beam, also made of CFRP, runs the length of the Intrado. This beam provides the vehicle with its unique strength, connects the passenger areas and powertrain to the CFRP frame and serves as a mounting point for essential controls and protective padding.<\/p>\n Hyundai says the unique qualities of the Intrado make it more repairable than typical CFRP structures, as damaged sections or parts can be replaced without the use of expensive tooling or ovens. The Intrado\u2019s minimalistic, self-supporting skeleton-like frame structure is highly stable and extremely lightweight, saving 70 percent weight compared to a conventional chassis and around 30 percent on the overall vehicle weight without compromising safety attributes, according to the company.<\/p>\n Ford: Bonding Composites with Aluminum<\/strong><\/p>\n A CFRP passenger cell will anchor Ford\u2019s new GT high-performance, limited-run supercar, scheduled for production in late 2016. The vehicle will include aluminum front and rear subframes encapsulated in structural CFRP body panels. The CFRP in the GT\u2019s chassis tub and bodywork will be hand laid.<\/p>\n <\/p>\n Ford also will use CFRP in a mass-produced car, offering CFRP wheels as a standard feature on its Shelby GT350R Mustang. The one-piece wheel is half the weight of an equivalent aluminum wheel (18 pounds versus 33 pounds). Australia\u2019s Carbon Revolution worked with Ford to develop the wheel, which includes a thermal barrier coating and a special durability coating to resist corrosion. The team also developed several new processes to produce the wheels\u2019 high-gloss black finish.<\/p>\n