Composite materials in the automotive industry

[handbrake]

Hi all

I'm currently in my third year of university studying mechanical engineering and am fortunate enough to be allowed to write my research project on the use of composites within the automotive industry. I am currently considering the following points :

A study into the current demands of carbon fibre within the automotive industry
I intend to be able to quantify the past and current demands for composite materials and from this make predictions of the future demands

A study of energy intensity for the production of composite materials and a comparison of these values to those of aluminium and steel
With this I'd like to determine the net impact on energy use (and co2 emissions) over a vehicles lifetime

The technical side of the project will (hopefully) come from determining the volume (thickness) of carbon fibre which is required to replace a thickness of steel (considering failure modes and accounting for lack of fatigue prediction).

What I'd like, hopefully, is some feedback from you on other areas which could be of interest. I know if is a bit vague, but I'm finding it easy to get stuck in a rut with ideas and spend hours gathering unimportant data, some fresh thinking would be greatly appreciated!

Thanks

[Matt UK]

How about composite materials in engines?

Here's something I was reading the other day.
http://www.slideshare.net/sicchiuricciu/composite-...

[handbrake]

Wow, thanks. Have been trawling the internet for weeks and hadn't heard that mentioned anywhere!

[Matt UK]

No probs chap. Good luck.

[Tim1989]

Have you thought about looking at the working life of carbon fibre in an automotive capacity? Rust is often the killer of old cars currently, with the increased use of carbon fibre bodyshells could vehicles working lives be increased/ decreased as a result?

[carl_w]

handbrake said:

Wow, thanks. Have been trawling the internet for weeks and hadn't heard that mentioned anywhere!

Have you considered going to your university library rather than trawling the internet?

[161BMW]

Which uni are u at :-) ?

[handbrake]

Great point, thank you. I have been looking at this and there are two (interesting) sides to the argument, unfortunately detailed technical information on end of life (recycling etc) energy requirements are lacking but: as you say, composites tend to be very chemically resistant so typical degradation does not occur - no rust. There is, however there is a pretty big issue with recycling composite materials as energy requirements tend to be high, and the resulting 'recycled' materials aren't really good for much. Thermoplastics are obviously easier

Yes thanks carl_w.

[161BMW]

Agree CFRP the effect on vehicle life cycles as most vehicles rust
How is used in engines ? I know can be used for airboxes etc in engines but what else ?
How difficult or easy is it to repair following crash ?
Mainly reserved for supercars
Increasingly getting mainstream
Eg BMWs
Debut in E46 M3 CSL
Then more common on E9X M3, E63 M6
Now i3!
McLaren CFRP monocoque tub
McLaren F1 obviously I think they were the first to use maybe or maybe not ?
Also catches fire easily or not ?

[b0rk]

handbrake said:

I have been looking at this and there are two (interesting) sides to the argument, unfortunately detailed technical information on end of life (recycling etc) energy requirements are lacking but:

In terms of end of life this a critical matter for large scale adoption if a OEM wishes to demonstrate compliance with 2000/53/EC and not be left with costs for disposal, if you stick "End-of Life 2000/53/EC" in to your uni's electronic journal catalogue it should throw up a wealth of papers on the subject including energy analysis for various forms of re-use. Long term the EC intends that end of life composites should be recycled not landfilled.

If comparing against metals something your probably not aware is that high yield strength steels have very high virgin content due to process control difficulties when using recycled content. Recycled content is fine for making unspecified strength strip/coil for the food and white goods industries.