Plastics & Fiber Reinforced Plastics

For
Modern Automobiles
Special Presentation for 4TH Plasto 2006
Avinash Arankalle
Sr.Assistant Director,
The Automotive Research Association of India, Pune

Automotive Plastics

Thermosets

Semi-crystalline

Thermoplastics

Amorphous

Fiber Reinforced Plastics

Thermosets

Thermoplastics

Fibers

Semi-crystalline Vs Amorphous Plastics

Semi-crystalline Plastics

Amorphous Plastics

Sharp Melting Point

Broad Softening Range

Usually Opaque

Usually Transparent

High Shrinkage

Low Shrinkage

Solvent Resistant

Solvent Sensitive

Fatigue / Wear Resistant

Poor Fatigue / Wear

Examples of Thermoplastics
Semi-crystalline Plastics

Amorphous Plastics

Acetal (POM)

Acrylonitrile-butadiene-Styrene
(ABS)

Polyester (PETP, PBTP)

Acrylic(PMMA)

Polyamide(Nylon)(PA)

Polycarbonate (PC)

Fluorocarbons(PTFE)

Modified Polyphenylene Oxide

(PPO)

Polyethylene (PE)

Polystyrene (PS)

Polypropylene (PP)

Polyvinyl Chloride (PVC)

PE, PP,PS and PVC are known as Commodity Plastics, while

all others are known as Engineering Plastics.

Global Demand for Major Plastics

Per Capita Polymer Consumption

Low per Capita Polymer Consumption a pointer to promising demand growth in

Future.
Per Capita Consumption of FR is 0.2kg whcih very low and expected to grow at 20%
growth rate in India

Materials Usage in Avg. Vehicle

Steel sheets: 41%

Plain Steels: 18%

Cast iron: 6.4%

Aluminium: 8%

Non-ferrous: 2%

Plastics: 9.3%

Rubber: 5.6%

Adhesives: 3.0%

Glass: 2.9%

Textiles: 0.9%

Fluids:0.9%

Misc.: 2%

Plastics In Car

Bumpers: 9.5%

Dashboard: 14.2%

Interior Trim: 19%

Upholstery: 8%

Seats: 12.3%
Others: 37%

History of Automotive Plastics

In 2000 : More than 1.8 Million Tones of Various

Types of Plastics were used in Automotive in about
1000 different parts.

Use of Plastics in Automobiles

Use of Light
Weight
Materials :
International
Scenario

Top 10 Plastics in Automotives

Plastics in Automotive
Material

1980

1985

1990

PVC

12.5

11.0

8.0

PU

11.2

15.0

20.0

PP

8.0

11.0

15.4

ABS

6.4

6.4

6.5

Nylon

2.75

3.5

5.8

Polyesters

1.5

5.5

11.0

Phenolics

7.0

5.0

3.5

PE

2.5

4.0

11.6

PC

0.3

3.0

5.3

Mod. PPO

0.3

3.0

4.1

Acetal

0.8

2.0

5.85

RIM PU

--

1.2

2.4

PBT

--

0.5

1.0

Cellulose

0.2

0.15

--

Acrylics

1.2

1.0

0.7

Others

0.02

2.5

3.6

TOTAL

54.8

74.25

104.35

Why Plastics so Important to the

Automotive Industry ?

Light Weight
Functional Design
Economics
Integrated Systems
Styling Potential
New Effects
Recyclability

Improved Safety
Reduced Noise & Vibrations
Reduced aerodynamic drag
coefficient
Legislative Requirements
Corrosion & Chemical
Resistance
Resource Efficiency

Weight Reduction

In the USA the legislation of Fuel Economy

was brought in force in 1985, which is
known comonly as Corporate Average Fuel
Economy (CAF). According to this
legislative requirement, every car sold in the
market by the vehicle manufacturer should
have average 29 miles to the US gallon
(m.p.g.) of petrol (11km/lit.)

Weight Reduction

Weight reduction of 30% improves fuel economy

by 6 m.p.g. or 2.1 km/lit.
It is estimated that, on average, 100kg of plastics
replaces 200 300 kg of conventional material,
reducing the fuel consumption by 750 liters over
the life span of 1,50,000 km running of a car.
Globally, this would save over 21 million barrels
of petrol per year.
Additional calculations suggest that it would
reduce CO2 emissions by 50 million tones per year

Functionality

Design Freedom
Component consolidation
Balance Mechanical Properties along with
rigidity, impact strength and ductility, tactile
properties such as soft touch
Innovative Polymers play roles e.g. Fule Tank,
Tailgate, engine manifold, etc.

Economy
Total number of parts
Cost of sub assembly
Assembly line cost

Tailgate in
Steel, kg

Tailgate in Polypropylene
Double Skirt Single Skirt
Part
Part

Finished part
weight, Kg

6.42

4.3

2.6

Total Cost in
Rs.

725

1060

535

Styling potential

Plastics possess unlimited shaping potential &

aesthetic appearance to provide various
aerodynamic shapes desired by the modern
vehicles integrated along with the functional
requirements e.g. door mounted mirror,
exterior panels, bumpers, etc.

New Effects

It includes wide range of characteristics such

as sound dampening, thermal and electrical
insulation, energy absorption, colour, gloss,
texture etc. The safety standards of the modern
vehicle, with improvements designed for
passenger protection derive from these
characteristics of plastics. So does the level of
comfort and passenger-friendliness of car
interiors

Corrosion resistance

The traditional sheet steel used require corrosion protection,

however, none of the plastics is susceptible to factors like acid
rain, sea spray and road salt. The corrosion resistance provided
by plastics ways out to extensive automotive applications. Due
to distinctive chemical nature owned by each polymer,
selection of engineering plastics should be critically accessed
for each application. This because, some of the plastics get
affected by fuels and lubricants, others are attacked by battery
acid and all are affected to some degree by weathering

Development of Markets for Plastics in

Automotive

Main Application Areas

Interior

Seats, Door Panels,

Upholstery, Instrument
Panels, Steering Wheels,
Roof-liners, Interior
Trim, Climatic Control /
Air Ducts, Air Bags,
Seat Belts, Pedals.

Exterior

Bumpers & Fascia System,

Body Panels, Exterior Trim,
Weather Strip Seals, Head
lamps, Tail lamps &
Reflectors, Window Glasses,
Door sill panels

Electricals
Component Housings,
Switches & Sockets,
Connectors, Lighting
Systems, Circuit Boards &
Wiring Harnesses, Battery
Boxes, Ignition, etc.

Main Application Areas

Power-train

Engine
Air Intake Systems,
Fuel Intake Systems,
Engine Components,
Cooling Systems

Transmissions,
Driveshaft, Bearings,
Flywheels, CV Joints
& U Joints

Chassis

Structures, Supports,
Suspension, Brakes

Fuels

Fuel Tanks, Fuel

Lines, Vapour
Recovery System,
Fuel Filter Pipes, Fuel
pumps, Fuel Modules,
Fuel Rails

Automotive Applications of Plastics

Component

Main Plastics Type

Weight in Kg /
Avg. Car

Bumper

PP, ABS, PC, RIM PU

10.0

Seats

PUR, PP, PVC, ABS, PA

13.0

Dashboard

PP, ABS, PA, PC, PE

15.0

Fuel Systems

PE, POM, PA, PP

7.0

Body (including body panels0 PP,PPE, UP

6.0

Under the Bonet Components

PA, PP, PBT

9.0

Interior trim

PP,ABS, PET, POM, PVC

20.0

Electrical Components

PP,PE, PBT, PA, PVC

7.0

Exterior Frame

ABS, PA, PBT, ASA, PP

4.0

Lighting

PP,PC, ABS, PMMA, UP

5.0

Upholstery

PVC, PUR, PP, PE

8.0

Reservoirs

PP,PE,PA

1.0

TOTAL

105.0

Exterior Plastic Body Panels

New Construction
Principles
New Manufacturing
Processes
New Production Sites

Exterior Plastic Body Panels

Example :
Conductive Fender

Design Flexibility
Functionality
Hybrid Construction
Light Weight

Exterior Competitive Automotive

Markets Foster Flexibility

One Brand delivers numerous products and

models which differ in car type, equipment,
colour, etc.

Same Parts concepts

Modular Construction
Platform Strategy
Small Edition

Plastic provide cost

efficient solutions

Exterior Light Weight and Cost

Cars will stay a multi material application but

Plastics Body Panels can provide:

Weight Reduction
Reduction of Fuel
Consumption (CO2 emissions)
Design Freedom
Cost Efficient Production for Small Editions
Integration of various functions

Exterior Applications

Automotive Bumpers
Moulded from RIP-PU or or elastomer
modified thermoplastic PBT.
Withstands impact test at -200C and
temperatures as high as 1800C
Polymer pigment coatings on surfaces
improves
gloss
finish,
aesthetic
appearance and colour stability, weather
resistance and resistance to yellowing &
chalking.

Headlamps &
Reflectors
Made up from PC resins weigh far less
than glass lenses. Offers greater
freedom of design. Withstands
temperatures as high as 2050C.
Provides Optimum optical properties.

Exterior Applications

Door handle

Radiator Grill

Door Panel

Air Ducts

Interior Applications

Instrument Panel
Made up of ABS, ABS / PC alloys, PC, PP,
modified PPE and SMA resins.
Complex design possible in items such as
airbag housings, center stacks for the
instrument panels, and large integrated
instrument panel pieces.
Helps to eliminate need for a steel support
beams, and allows manufacturers to save cost
and weight.

Automotive Seats
Materials used are RIM-PU, PC-ABS,
PA-6.
Provides comfort and safety to drivers
and passengers. Ensures ergonomical
designs, good vibration dampening
properties.
Foaming material yiel automatically
correct seat positioning improving
lateral stability to support drivers in all
positions

Under the Hood - Integration

Example : Engine

Design Flexibility
Functionality
Hybrid Construction
Light weight

Under the Hood Thermal Resistance

Example : Air Intake

Manifold

Thermal Properties
Mechanical
Properties
Process Cost
Fuel Efficiency

Engine Applications

Engine Manifold

Throttle Body

Cooling System

Fuel Tank

Under the Hood Compatibility with

Electronics

Example : Gear Box

Control

Durability (1400C)
Comfort
Fuel Efficiency
Hybrid Electronics /
Plastics

Automotive Plastics and Safety

Federal Motor Safety Standards (FMVSS)

provide the Challenges and Opportunities for
Plastics e.g.

Plastic Fuel Tank

Bumpers
Automotive Seats

:
:
:

Flammability Test :

Regulations
ECE R34, FMVSS 301
ECR R42, EEC 74 / 483
ECE R17, R21, & 25
FMVSS 201, 202, 207
FMVSS 302, ISO 3795

Safety Active Devices

Example : Anti
Blocking System
(ABS), Electronic
Stabilization Program
(ESP)

Hybrid Engineering
Electrical / Electronic /
Magnetic Properties

Safety Plastic Connectors

Plastic connects
various materials and
devices

Hybrid Systems
Electrical Systems
Glass Fiber Systems

Threats to Plastics in Automotive

Aluminium Alloys
High Strength Low Alloy Steels (HSLA)
Magnesium Alloys
Engineering Ceramics
Plastic Scrap & Recycling

Bus Body Applications

WHY FOR CITY

TRANSPORT BUSES?

Consumption of diesel for over 6.0 lakhs of

registered buses in the country is more than
25,00,000 kiloliters and fuel bills are roaring
over10,000 million rupees. Any attempt to
improve fuel efficiency and conserve the
depleting fuel resources & energy is the need of
tomorrow.
Bus Code Practice as per AIS 052 shall be in
force from 2006 which will mandate bus
builders to meet specifications.

WHY FOR CITY

TRANSPORT BUSES?

Better riding comforts, reduced noise

& vibration levels, ergonomic seats and
aesthetic appearance are needs of bus
passengers traveling from city to city.

Mandates on End of Life of Vehicles (ELV)

leading to issues of recycling of materials
are expected in future

What Are the possible

Advantages to use for Buses?

Weight reduction to 35-40% leads to 10%

improvement in fuel efficiency
Composite sandwich structures possess better
dampening coefficient and shall reduce noise
& vibration levels when used for floor, roof
and side panels
Aerodynamic designs shall improve drag
coefficient to make fuel efficient vehicle

International Scenario & Technology Gaps

In India use of Plastics & composites in Auto industry is less than 4%.
Use of Plastics & Composites in the developed countries is increasing
in the automotive sector to achieve fuel economy, safety and comforts
The material of construction is dictated in India perticularly by the
collaborators.
The existing standards and regulations like CAFE standards, limits on
gvw, crashworthiness, NVH are not enforce and restrict technology of
use of light weight materials.
Lack in Joint venture and collaborative programs between various
sectors as seen elsewhere e.g.

Intercity Bus Weight Reduction Program between Transport

Development Center; Martec Ltd; Prvost Car; Virtual Prototype
Technologies Inc; Canada
North American Bus Industries (NABI) and TPI Composites; USA
Advance Technology Transit Bus (ATTB) Program with Los
Angeles County
Metropolitan Transportation Authority
(LACMTA) and Metropolitan Transportation Authority of Harris
County, Texas (Houston Metro); USA
GKN Composites; UK

International Scenario : Light Weight Bus Models

Scania Irizar PB Coach:2004

MAN Lions International Coach:2004

Marcopolos 49 Passenger,
12.9 meter, Three-axle
Scolaris Vacanza 13
two-axle Andare

13 meter, two-axle Van

Hool 916TL

International Scenario : Light Weight Bus Body

Components

Computer Aided Engineering and aerodynamic design of Bus

Interiors, Dashboard and Luggage Compartment of Bus

International Scenario : Light Weight Bus

PHASE II Components

Engine
Manifold

FRP Leaf Spring

& Propeller
shaft

New Innovative Technology

in Applications of Plastics
and
Composites
in
Automotives

Automotive Applications
of
Nano-composites

Definitions

Flame-retardant Polyolefins

Definitions

Applications of Non-woven Jute Fibers

Applications of Non-woven Jute Fibers

Jute Fiber
Applications

Jute Fiber
Applications

Conclusions

For the future generation of vehicles Automotive

Plastics are emerging materials due to economics,
functionality, fuel economy & safety legislations
NVH requirements also may find potential
applications for the plastics
Sustainable Developments is foreseen in the Plastics
for the future of automotives
One of the need for its penetration in market is
overcome Scrap & Recycling problem

Thank You . . .