Materials In Automotive Industry Research Articles

Exploring mechanical properties of eco-friendly hybrid epoxy composites reinforced with sisal, hemp, and glass fibers

It is now widely accepted that various subsets of hybrid fiber composites reinforced with combined natural and synthetic fibers can significantly expand the applicability of composite-based materials in design and technology practice. The already existing unnatural circumstances on the planet put natural fibers far ahead of traditions in the field of materials thanks to their biodegradability characteristics, availability and over-term endurance and corrosion resistance. At the same time, composites are rapidly taking their place in many industries and sectors of the economy as metals in as much as it is economically and energetically justified. This study evaluates the mechanical properties of hybrid composites reinforced with glass, hemp, and sisal fibers. Using a hand lay-up method with epoxy resin, composite laminates were fabricated and tested for tensile, flexural, impact strengths and hardness test in accordance with ASTM standards. The experimental results revealed that glass-sisal fiber composites achieved the highest tensile strength of 69.1 MPa, while glass-hemp-sisal fiber composites exhibited superior flexural strength of 15.22 MPa and impact strength of 137.45 kJ/m2 while best hardness value was 24.73 HV for glass-sisal fibre composite. These findings underscore the potential of glass-sisal-hemp fiber-reinforced epoxy composites as viable alternatives to traditional synthetic fiber-reinforced materials in automotive industry where there are no structural loadings i.e. automobile interiors; offering enhanced mechanical performance and sustainability.

Solidification paths of Al-Cu-Sn alloys: Comparison of thermodynamic analyses and solidification experiments using in situ X-radiography

The increasing importance of Al-Cu-Sn alloys as materials for producing self-lubricating bearing materials in automotive industries requires the development of uniform microstructures with improved performance, which could be achieved by a precise control of solidification processes. Adding Sn to Al-Cu binary alloy could dramatically alters the solidification path, generating liquid phase separation and monotectic reaction. In this paper, Al-10 wt% Cu-X wt% Sn (with X = 0; 5; 10 and 20) alloys have their solidification paths investigated by three different complementary approaches. Firstly, the solidification paths were calculated by using the CALPHAD method through Thermo-Calc software revealing the sequence of transformations that could occur during the solidification of these alloys, from the formation of the initial α-Al dendrites to the final eutectic reaction. Secondly, experimental thermal analysis was carried out by DSC (Differential Scanning Calorimetry), which reveals the successive events that occur during the controlled melting and cooling of these alloys. Thirdly, directional solidification was performed on all alloys, with in situ and real-time observations achieved through the utilization of X-radiography. The comparison between the various approaches showed a suitable correspondence between the history of the alloy solidifications computed by Thermo-Calc and those obtained experimentally (DSC and directional solidification experiments). Additional information about the dynamics of each reaction was obtained during the directional solidification experiments in terms of microstructures, segregation, and the genesis of the liquid phase separation that occurred for high Sn-content alloys.

Critical Materials in Automotive Industry: A Brief Review

Critical Materials in Automotive Industry: A Brief Review

Hybrid multiwalled‐carbon nanotube/nanosilica/polypropylene nanocomposites: Morphology, rheology, and mechanical properties

AbstractPolymer composite are very interesting materials in automotive industry. Nanocomposites play a crucial role in the automotive parts and cars weight reduction fields. Hybridization of polymer nanocomposites is appeared as a process of choice in obtaining the required property/weight ration. Simple and hybrid nanocomposites of polypropylene (PP) blend with carbon nanotubes (CNTs) having different aspect ratios and nanosilica at different nanosilica contents were prepared in molten state in an internal mixer. Scanning electron microscopic images along with rheological and tensile properties revealed that only 0.2 wt% CNT is high enough to finely disperse nanosilica particles in PP matrix in the absence of any chemical compatibilizer. Differential scanning calorimetric thermograms showed that none of nanoparticles has any effect on crystallinity of PP. Mechanical characterizations showed that hybrid composites are superior to PP‐S3 composite. Due to its more intensive hydrodynamic motions it was also observed that the longer CNT showed a higher ability to disintegrate nanosilica particles aggregates. Transmission electron microscopic images well portrayed the nanosilica particles in the vicinity of CNTs' surfaces which accounts for electrostatic adsorption of fine nanosilica particles. At such a low CNT content (say 0.2 wt%) in the absence of any chemical compatibilizer, elongation at break of the tensiled nanocomposites raised from 13.23% to 35.41% and fracture energy was mounted from 1253 to 2750 J. This divulges the effectiveness of CNTs to disperse nanosilica in PP matrix but a poor adhesion between the particles and PP matrix is an overwhelming drawback yet. Under these conditions a maleic anhydride grafted PP (PP‐g‐MA) was added to the composite in molten state. The tensile strength of these chemically compatibilized nanocomposites increased with respect of that of their counterpart physically mixed nanocomposites. For example, in the presence of this chemical compatibilizer, the tensile strength of PP‐S3 nanocomposite raised from 21 to 28 MPa.

Correlating topographical characteristics of relaxed layer to tribology in Cu-Gr-TiC composite system

The copper graphite composites are often being applied as bearing materials in various industries. In present investigation, the correlation between the topographical characteristics of relaxed layer to tribology in Cu-Gr-TiC composite system has been investigated. For this purpose, the flake powder metallurgy approach was used to fabricate Cu-Gr-TiC composites and the tribology of these composites was studied under lubricating (synthetic SAE 20W40 motor oil) condition. Variable loads of 10 N–70 N, sliding velocities of 0.75 m s−1–3 m s−1, and sliding distances of 2000 m–8000 m were the test parameters for sliding wear of composites under lubricating conditions. The worn surfaces were examined using SEM and EDS while topographical parameters were studied by AFM. The other properties like mechanical and physical properties were also studied for the sintered samples to better correlate the overall results of surface topography and tribology. The tests depict the successful fabrication of the composites. The composite having 4.5 wt% TiC particles exhibit maximum hardness and least wear and CoF under lubricating environment. The results of sliding wear test conducted under lubrications revealed that rise in the concentration of nano TiC particles in the matrix improves the composite’s tribological performance. The mechanism of wear for pure copper sample is abrasion whereas for TiC particle reinforced composite is smooth ploughing and delamination. The surface topographical parameters that are average surface roughness, area peak to valley height and skewness depicted less roughness values and better load bearing capacity for 4.5 wt% TiC reinforced Cu-Gr sample. The fabricated TiC reinforced copper graphite composites could be utilized as bearing materials in automotive industries.

RETRACTED: The Review of Carbon Fiber Materials in Automotive Industry

In present scenario, light weighting becomes a main issue for energy efficiency in automotive industry. The emission of gases and fuel efficiency of vehicles are two important issues. The best way to improve the fuel efficiency is to decrease the weight of vehicle parts. Research and development played an important role in lightweight materials for decreasing cost, increasing ability to be recycled, enabling their integration into vehicles, and maximizing their fuel economy efficacy. There arises a need for developing a novel generation of materials that will combine both weight reduction and safety issues. The application of carbon fibre reinforced plastic material offers the best lightweight potential to realize lightweight concepts. Carbon fibre reinforced plastic has outstanding specific stiffness, specific strength, and fatigue properties compared to commonly used metals. In automotive industry, the advantages of carbon fibre reinforced plastic are reduction in weight, part integration and reduction, crashworthiness, durability, toughness, and aesthetic appealing. Carbon fibre reinforced plastic is a composite material that has been used extensively in various applications such as aerospace industry, sports equipment, oil and gas industry, and automotive industry. Keeping in view the aforementioned advantages of carbon fibre reinforced plastic, the authors have presented a brief review on carbon fibre for automotive industrial applications.

RETRACTED: The Review of Carbon Fiber Materials in Automotive Industry

This paper was retracted by The Electrochemical Society (ECS) on June 21, 2023 following an investigation that revealed that the work was not original to the authors. ECS is investigating why this was not identified during the submission and peer review process by the conference. As a member of the Committee for Publication Ethics (COPE) this has been investigated in accordance with COPE guidelines and it was agreed the article should be retracted. The corresponding author agreed with this retraction. Retraction published: June 21, 2023

Design and Analysis of Robotic Arm for Serving Material in Automotive Industry

The Robotic arm plays an important role in industries for performing tasks which are dangerous for humans, high precision work and carrying heavy load. This work is related to design and analysis of a robotic arm that might be used for pick and place operations for carrying heavy weight. Solidworks was used for model. ANSYS software was used to simulate the CAD models of structures, electronics, or machine components for analysing strength, elasticity, toughness, and temperature distribution. Importing a CAD model into the ANSYS software helps in examining a robotic arm under loading condition. After the completion of the design, the stress variation and deformation of the robotic arm by using different materials and under provided loading condition were obtained.

Artificial intelligence and advanced materials in automotive industry: Potential applications and perspectives

The first part of this paper presents a literature review-based study of the most emerging technology of the century, artificial intelligence (AI) and its various applications in the automobile sector. In this era of the fourth Industrial Revolution (Industry 4.0), industries have become all the more sophisticated owing to the intelligent technologies employed to maximize production, quality, and profits; and minimize wastage, time and cost of production. This paper studies various aspects of AI and related tools and techniques and aims to employ them in the automobile industry to make modern vehicles smart, safe and reliable. Simultaneously, it strives to automate the drives, thereby reducing manual labor, increasing efficiency and relieving humans of performing mundane, repetitive tasks. This paper explores different areas of the automotive industry like the vehicle itself, the designing and manufacturing sectors, the after-sales services. It provides solutions to make each of them ‘Intelligent’. The second part briefs us about advanced materials like polymer composites, carbon fiber, and high-strength steel. It discusses the various factors that make these intelligent materials feasible in the automobile industry and discusses the methods and areas of applications of these advanced materials in the automobile industry.

Investigation of structure-morphology-function relationship of plastomers used to produce low mold shrinkage thermoplastic olefins

Thermoplastic Polyolefins (TPOs) are one of the most commonly used polymeric materials in automotive industry due to their better elastomeric properties compare to commercial polyolefins. Thermoplastic polyolefin (TPO), or olefinic thermoplastic elastomers are prepared by mixing a polyolefin usually copolymer polypropylene and a plastomer in certain fraction in order to improve elastomeric properties. One of the most challenging problems in automotive industry during the production of these materials is to control the mold shrinkage of TPOs since the parts having very high aspect ratio such as bumper, exterior trims, glass run channel are produced by those materials. Therefore, this paper intends to produce TPO formulations with minimum mold shrinkage by focusing on to optimize the mechanical properties. For that purpose, TPO formulations were prepared by melt blending of plastomers having different physical/mechanical properties into a polyolefin phase. The relationship between structure of plastomer and the function of final product TPO was tried to be explained by structural characterization and molecular dynamic (MD) simulations. In terms of mold shrinkage values and mechanical properties the optimum TPO compound is found to be “sample A” containing 70% plastomer with medium crystallinity and 30% copolymer PP. It shows low mold shrinkage values in parallel (0,19%) and perpendicular (0,2%) to flow direction and optimum tensile strength (13,4 MPa), tear strength (74,4N/mm) and elongation at break (815%) results. Findings of this study is useful in understanding the micro-events taking place during compound process of PP with plastomers, and to explain the necessary PP-plastomer ratio with desired mechanical traits.

Static investigation of almond shell particulate reinforced aquilaria agallocha roxb blended epoxy hybrid matrix composite

Nowadays, the use of recyclable, eco-friendly materials in automotive industries are growing due to the environmental concerns in place of synthetic polymers. Natural filler materials are increasingly used to reduce the usage of the polymer matrix and to improve the mechanical, thermal properties of the composite materials. Natural fiber and filler incorporated hybrid composite materials are used in places where the load requirements are low. This study focuses on the use of Almond shell as a particulate reinforcement in the Aquilaria agallocha Roxb reinforced Epoxy composite with different volume fractions. The specimens were fabricated using hand layup process and the mechanical properties were investigated. The results had shown that the composite with 20% v/v Almond shell particulate reinforced composite had shown better mechanical properties. While the Visco elastic properties had shown minor improvement due to the incorporation of natural filler in the hybrid composite material.

Microstructure, Tensile and Fatigue Behaviour of Resistance Spot Welded Zinc Coated Dual Phase and Interstitial Free Steel

Galvannealed (hot dip galvanized and annealed) dual phase (DP600) steel and interstitial free (IF) steel are two of the widely used materials in automotive industries owing to their high specific strength, toughness, formability and corrosion resistance. This inevitably requires their joining to form larger components. Resistance spot welding has emerged as the predominant welding technique for joining of sheet metals in automotive industries. There are complexities regarding microstructural variation of the fusion zone and across heat affected zones during spot welding of fundamentally dissimilar steels. This is further aggravated by the prospect of zinc redistribution during the welding process. Current study presents the evolution of microstructure in different zones of welding in IF and DP600 steel. Micro-hardness profiles and electron back scattered diffraction studies were performed. Furthermore, redistribution of elements in different welding zones is studied using electron probe micro analysis. The effect of welding current and time on the nugget size and the strength of the weld during tensile–shear is determined. It was observed that there was an increase in nugget diameter and maximum load bearing capacity of the joint with an increase in heat input, until the occurrence of expulsion. Furthermore, critical nugget diameter for pull-out failure was determined and existing empirical models were verified for the applicability in this case. None of the existing empirical models could predict the critical nugget diameter correctly and thus a new empirical relationship between sheet thickness and critical nugget diameter for zinc coated dissimilar steels has been proposed. Failure behaviour of the spot-welded sheets were studied under tensile–shear configuration under quasi-static and fatigue mode of loading and it showed substantial difference in location of crack initiation and fractographic features. Tensile–shear specimen at optimum welding parameter failed from the base metal of the IF steel side with dimples on the fracture surface, whereas fatigue specimen failed from the heat affected zone of the IF steel side with transgranular striations on the fracture surface.

Hybridization Effect on Crashworthiness Parameters of Natural Composite

The use of metallic materials in automotive industry leads to increasing fuel consumption and cost, so trends are starting to use lighter and cheaper materials. In automotive applications, fibers are used in composites because they are stronger, stiffer, and lighter than bulk materials, and they can achieve higher energy absorbing compared to metallic materials. The purpose of this work is to study the potential utilization of natural fibers in the crash energy absorbing applications. The experimental procedures (the principle of a combination of manual layup and vacuum bladder technique) were applied to search the influence of utilizing jute fiber mat on crashworthiness parameters of composite materials with other kinds of fibers such as woven glass fiber reinforced epoxy composites. The study involved corrugated composite tubes with three layers of jute and hybrid glass-jute/epoxy material have been tested in uniaxial quasi-static crush conditions at the speed 10 mm/min. The results exhibit that the tube of jute fiber was somewhat lower than synthetic fibers, but the substitution of one layer of jute fiber with one layer of glass fiber resulted in an improvement in the crashworthiness parameters. As hybrid jute-glass was used, the best result was obtained, where energy absorption and specific energy absorption are improved by 17.75% and 25.122%, respectively.

Mechanical characterization and comparison of glass fibre and glass fibre reinforced with aluminium alloy (GFRAA) for automotive application

Over the past ten decades, the application of composite materials has been continuously increasing from traditional application areas such as military aircraft, commercial aircraft to various engineering fields including automobiles, robotic arms, and even architecture. Due to its superior properties and reduced cost, composites have been one of the materials used for repairing the existing structures. The work aims to provide an alternative for metal structures with composite materials in Automotive Industries, which would subsequently reduce the production cost. The present work is to investigate the Glass fibre composites with epoxy resin, Aluminium alloy and improve their mechanical properties like Tensile, Compression, and Impact strength by conducting a series of tests so that the behaviour of these composites can be studied. The most essential factor in the manufacturing of these composites is the adhesive bonding between aluminium and FRP layers which in turn increases the strength of the components manufactured in the automotive industry.

Sustainable Sandwich Composites Manufactured from Recycled Carbon Fibers, Flax Fibers/PP Skins, and Recycled PET Core

European union end of life vehicle directive mandates the use of more sustainable/recyclable materials in automotive industries. Thermoplastics matrix-based composites allow recyclability of composites at the end of life; however, their processing technology is more challenging than thermoset composites. Manufacturing process and mechanical testing of sustainable sandwich composite made from sustainable materials: flax, recycled carbon fiber, polypropylene, and recycled PET foam are presented in this article. High pressure compression molding with adhesive thermoplastic polymer film was used for manufacturing sandwich composite skin. The recycled PET foam core was integrated/joined with the skin using a thermoplastics adhesive film. A three-point bending test was conducted to compare the flexural properties. The results show that such sustainable sandwich composites will be an excellent material for truck side panel to operate in adverse wind/storm conditions. The sustainable sandwich composite can potentially be an excellent candidate for the fabrication of light-duty, lightweight, and low-cost engineering structures in automotive industry to meet the EU end of life requirements.

A review of carbon fiber materials in automotive industry

In present scenario, light weighting becomes a main issue for energy efficiency in automotive industry. The emission of gases and fuel efficiency of vehicles are two important issues. The best way to improve the fuel efficiency is to decrease the weight of vehicle parts. Research and development played an important role in lightweight materials for decreasing cost, increasing ability to be recycled, enabling their integration into vehicles, and maximizing their fuel economy efficacy. There arises a need for developing a novel generation of materials that will combine both weight reduction and safety issues. The application of carbon fibre reinforced plastic material offers the best lightweight potential to realize lightweight concepts. Carbon fibre reinforced plastic has outstanding specific stiffness, specific strength, and fatigue properties compared to commonly used metals. In automotive industry, the advantages of carbon fibre reinforced plastic are reduction in weight, part integration and reduction, crashworthiness, durability, toughness, and aesthetic appealing. Carbon fibre reinforced plastic is a composite material that has been used extensively in various applications such as aerospace industry, sports equipment, oil and gas industry, and automotive industry. Keeping in view the aforementioned advantages of carbon fibre reinforced plastic, the authors have presented a brief review on carbon fibre for automotive industrial applications.

Problems and Perspectives of Implementation of Metalmatrix Composition Materials in Automotive Industry

In this paper we studied possible problems and perspectives of deployment of aluminum-based composite alloys in automotive industry.Aluminum-based composite alloys thanks to their high elastic strength combined with a relatively low mass density, good casting and tribological properties with respect to conventional alloys were implemented in automotive industry over 20 years ago already.These alloys successfully substitute steel, cast iron and titanium alloys in engine, suspension, braking units. However high final cost of auto-components made of strengthened aluminum alloys limits its applications in the industry.In this work we presented the examples of aluminum-based composite alloy technology that reduces the production costs of final product.

Problems and Perspectives of Implementation of Metalmatrix Composition Materials in Automotive Industry

In this paper we studied possible problems and perspectives of deployment of aluminum-based composite alloys in automotive industry.Aluminum-based composite alloys thanks to their high elastic strength combined with a relatively low mass density, good casting and tribological properties with respect to conventional alloys were implemented in automotive industry over 20 years ago already.These alloys successfully substitute steel, cast iron and titanium alloys in engine, suspension, braking units. However high final cost of auto-components made of strengthened aluminum alloys limits its applications in the industry.In this work we presented the examples of aluminum-based composite alloy technology that reduces the production costs of final product.

Parametric analysis of tribological for gear materials behaviour and mechanical study of cobalt metal powder filled Al-7075 alloy composites

The research article presents the results obtained from the tribological behavior and mechanical characterization of Co metal powder (0–2 wt%) reinforced Al7075 alloys composites for gear materials fabricated via high vacuum casting method. The wear experiments are conducted on the multi specimen tester in lubrication condition. The specimen of fabricated composite is used as new developed material in automotive industry for fabricating of gear. Important variation in behaviour of these materials is possible as a result of cobalt particulate filler introduction. The hardness (151.2–196 HV), flexural strength (341–498.2 MPa), compressive strength (290–490 MPa), tensile strength (235–394 MPa) and impact strength (20–65.5 J) of particulate reinforced alloy composites are showing improved in mechanical characteristics with the increased in cobalt metal powder from 0 wt% to 2.0 wt% respectively. The result of experiment that the cobalt metal powder particulate composites exhibited a minimum the wear rate compared to base alloy and the wear resistance of composite improves it. Finally, the results were investigated that the analysis of microstructure, mechanical and wear behaviour of cobalt metal powder filled Al7075 alloy composite.

Fatigue Process in Materials for Automotive Industry

Structural parts of automobiles in operation are exposed to the influence of temperature and vibration. The overwhelming majority of metal destruction cases is caused by metal fatigue. It results in economic losses and often leads to accident-induced human casualties. This is why one of the most relevant tasks for the modern automotive industry is to ensure the operability of automobile parts and components. Thus, it is necessary to know the behavioral patterns of metal materials obtained by different technologies and exposed to vibration. The destruction of metal structure directly affects the behavior of sample deflection that reflects the competition between hardening and softening as two mutually opposite phenomena. They directly affect the structural damageability of metals. This article is about the study of the kinetics of fatigue failures of materials for the automotive industry by the calibration of structural damage to their surface with the behavior of the curves of changes in current deflection at alternating loads. The paper considers automotive materials (20KhI3, 14Kh17N2, 35KhGSA steel grades) and model metals and alloys (M1 copper, L63T brass, V95pchT2 aluminum alloy) in various structural states under cyclic loads at low, room, and elevated temperatures, including the registration of the samples deflection and the related structural damage. The article also reveals the possibility to study the fatigue failure kinetics of the sample materials by deflection curves that provide an integral characteristic of destructive processes observed at alternating loads. These processes can be used to monitor the phases of fatigue damage to metal materials, including structural damage in the initial phase, occurrence of a microscopic crack and its subsequent propagation to the complete separation of the structural material. These phases can be used to find out the correlation between the period before the fatigue crack nucleation and the subsequent crack propagation, and also determine the average rate with which the fatigue crack spreads across the metal sample body. It is also important that deflection curves can be used to evaluate the destruction kinetics of materials when the structural state of sample surfaces cannot be examined directly, for example, at cryogenic and elevated temperatures or in corrosive media. Deflection curves used together with fractographic and metallographic analysis of fatigue allow evaluating destruction phases of materials and using this evaluation to choose the latter for structural automobile parts, considering vehicle operation conditions, and optimizing the parts fabrication technology to enhance the service life of automobiles and improve their repairability.