Materials for automobiles

Lec 17

Plastics
Adhesives
Material Costs

Plastics : Thermoplastics
Thermoplastics
Thermoplastics have the simplest molecular structure, with chemically
independent macromolecules
By heating, they are softened or melted, then shaped, formed , welded, and
solidified when cooled.
Multiple cycles of heating and cooling can be repeated without severe damage,
allowing reprocessing and recycling.
Often some additives or fillers are added to the thermoplastic to improve
specific properties such as thermal or chemical stability, UV resistance, etc.
Composites are obtained by using short, long or continuous fibres.
Alloys of compatible thermoplastics allow applications to benefit from the
attractive properties of each polymer while masking their defects.
Some thermoplastics are crosslinkable and are used industrially in their two
forms, thermoplastic and thermoset; for example, the polyethylenes or the
vinylacetate-ethylene copolymers (VAE) (the links created between the chains
limit their mobility and possibilities of relative displacement).

Thermoplastic consumption is roughly 80% or more of the total plastic

consumption.

Plastics : Thermoplastics
Thermoplastics :Advantages / Disadvantages
Advantages

The softening or melting by heating allows welding and

thermoforming.
The processing cycles are very short because of the absence of the
chemical reaction of crosslinking.
Processing is easier to monitor, because there is only a physical
transformation.
Thermoplastics dont release gases or water vapour if they are
correctly dried before processing.
The wastes are partially reusable as virgin matter because of the
reversibility of the physical softening or melting.

Disadvantages

When the temperature rises, the modulus retention decreases, due to

the absence of chemical links between macromolecules.
For the same reason, the creep and relaxation behaviours are not as
good as for the thermosets.
During a fire, fusibility favours dripping and annihilates final residual
physical cohesion.

Plastics : Thermoplastics

PE, PP, PVC, PS

ABS, SAN
PA, PC, PMMA, POM, PPE,
PET, PBT
PSU, PEI, PPS
ETFE, PEEK
LCP, PTFE, PFA, FEP, PI
PBI

commodity thermoplastics
copolymers with more specific applications
engineering thermoplastics
engineering thermoplastics with more specific performances
high-tech uses, limited consumption
high-tech uses, more limited consumption
highly targeted uses and very restricted consumption.

Plastics : Thermoplastic Elastomers

Thermoplastic elastomers (TPEs)
TPEs are copolymers or compounds of thermoplastics and rubber.
The elasticity of TPEs comes:
either from the structure of the macromolecules with alternating soft and hard
segments, the latter gathering together to constitute the nodes of a physical lattice;
or
from a dispersed phase of soft elastomer, vulcanized or not, forming microscopic
droplets in a continuous phase of a hard thermoplastic. This structure allows
processing in accordance with thermoplastic techniques. The rubber provides
elasticity.
TPEs account for roughly 1% of total plastic consumption.
They lead to a combination of interesting properties:
elasticity in a limited range of temperatures
ease of thermoplastic processing without curing and, often, without a mixing step
ease of recycling as for all the thermoplastics.
On the other hand, their mechanical properties decrease as the temperature rises
because of their thermoplasticity.

(Exterior)

Exterior

Interior

Interior

Plastics Thermosets
Thermosets
Thermosets before hardening, like thermoplastics, are independent
macromolecules. But in their final state, after hardening, they have a threedimensional structure obtained by chemical crosslinking produced after
(spray-up moulding or filament winding) or during the processing
(compression or injection moulding, for example).
Thermoset consumption is roughly 1220% of the total plastic consumption.
Advantages

Infusibility: thermosets are degraded by heat without passing through the

liquid state. This improves some aspects of fire behaviour: except for
particular cases, they do not drip during a fire
When the temperature increases the modulus retention is better,
Better general creep behaviour,

Disadvantag The chemical reaction of crosslinking takes a considerable time that

es
lengthens the production cycles and, often, requires heating
The processing is often more difficult to monitor,
Certain polymers release gases, in particular water vapour
The wastes are not reusable as virgin matter because of the irreversibility
of the hardening reaction. At best, they can be used like fillers after grinding.
The infusibility prevents assembly by welding.

PROPERTY MODIFICATIONS
By using bulk fillers, reinforced fillers, additives and blends.
BULK FILLERS: Mica, talc, calcium carbonate, asbestos, metallic
powders, graphite, molybdenum disulphide
REINFORCING FILLERS: Glass fibres, carbon fibres, aramid fibres,
boron fibres and synthetic fibres.

Properties of Modified Plastics

Better dimensional stability reduction in warping shrinkage and

creep
Low co-efficient of thermal expansion
Re-tension of mechanical properties over a much wider temperature
range
Low co-efficient of friction and therefore improvement in wear
resistant property
Higher stiffness and rigidity
Higher impact strength at higher & lower temperatures
Improvement in flexural strength and modulus
Higher heat distortion temperature
Imparting electrical and thermal conductivity

FIVE MAJOR GROUPS OF

ENGINEERING PLASTICS
Crystalline materials

Polyamides
Polyesters
Acetals

Amorphous materials

Polycarbonates
Modified Phenylene

Polyamides (Nylons)

The Polyamides (nylons) were the first materials to be recognized

as engineering thermoplastics.

Polyamides are polymers characterized by the amide group

(CONH) as a part of the main polymer chain.

Chemically the polyamides are divided into two types:

Based on diamines and dibasic acids
Based on amino acids or lactams.

Aliphatic polyamides such as nylons 66, 6, 10 and 11 are linear

polymers and thus thermoplastic.

Structure of Polyamides
Polyamide 6

-[ HN (CH2)6 CO ]-n

Polyamide 6,6

-[ HN (CH2)6 NH-CO (CH2)4 CO]-n

Polyamide 11

-[ HN (CH2)10 CO ]-n

Polyamide 12

-[ HN (CH2)11 CO ]-n

PROPERTIES

Good combination of mechanical properties like

Fatigue creep strength, stiffness, toughness and
resilience
Good abrasion resistance
Self lubricating characteristics
Suitable for prolonged, service temperature from 400C to 1200C
Good electrical insulator, but the electrical properties
are influenced by moisture content
Resistance to fuels, oils, fats, most solvents and
chemicals
Low permeability to gas and vapours
Non-toxic
Easy processable by conventional processing
techniques like injection,
rotational moulding.

extrusion,

blow

and

APPLICATIONS OF POLYAMIDES

Automobile Industry

Radiator fan
Radiator grill
Instrument housings
Speedometer gears
Fuel, oil filter housing
Electrical junction box
Head/Tail lamp housing
Front fork bush
Steering column bush

BLENDS OF POLYAMIDES
PA Blends

Applications

PA/ABS BLENDS

Impact and abrasion resistance

Chemical and heat resistance

Low moisture absorption

Good processability and surface finish

Automotive, chemical, electrical,

consumer and
sport industries.

PA/ELASTOMER (EPDM/EPR) BLENDS

Low temperature impact strength

Good processability

The moulded articles can suppress vibration

even at subzero temperature

Automotive, home appliances,

sport, business equipments
and consumer products.

PA/PP BLENDS

Shows good processability

Reduced water absorption

Low density (ie. Low cost per volume

Improvement in paintability

Automotive, building, furniture &

industrial

POLYACETALS

Acetalpolymers are properly called polyoxymethylene

(POM).
These resins are linear unbranched molecular chains
derived from the monomer formaldehyde.
The
structure of homopolymer and copolymer are as
follows:
---- CH2 - O - CH2 - O - CH2 - O - CH2 -----Polyacetal homopolymer
---- CH2 - O - CH2 - CH2 - O - CH2 -----Polyacetal Copolymer

PROPERTIES

Excellent combination of toughness, rigidity, fatigue,

strength and yield strength (spring like qualities)
Good wear resistance
Low co-efficient of friction
Service Temperature Range 90 - 1200 .C
Good dimensional stability over wide temperature 400.C to 650 .C
Good moisture and chemical resistance
Good electrical insulation
Easy processable with conventional technique
Excellent dimensional accuracy and post moulding
stability

APPLICATIONS OF POLYACETALS

Gears
Bearing boxes and bushes
Switch relays, terminal blocks and coil formers
Blower fans, ventilation fans and pump parts
Parts for office machines, house hold appliances and
bathroom fittings
Hinges
Springs, snap fittings, screw
Curtain rail runners
Aerosol nozzles
Nuclear engineering applications
Plumbing fittings and components for pneumatic systems
Automobile components such as radiator heater tapes,
water filter bodies, fuel contact applications
In irrigation system used in the areas of compression
fittings, jets and sprayers
Clock and watch parts

POLYACETAL BLENDS
POM/TPU BLENDS

High impact strength

High fatigue, flexural and tensile strength
Low water absorbency
Good resistance to oils, greases and many
chemicals
Most blends contain 10-30 wt. % of TPU
Blends have co-continuous morphology for
good performance

POLYCARBONATE
Polycarbonate is a linear polyester of carbonic acid in
Which dihydric phenols are lined through carbonate
groups. The commercial grades of polycarbonate is
manufactured from bisphenol-A and phosgene. The
structure of polycarbonate is:
O
ll
-[ C - O -

CH3
l
-Cl
CH3

- O ]-n

POLYCARBONATE BLENDS
Blend

APPLICATIONS

PC/ABS BLENDS
Moulding characteristics
High impact strength at low temperature
PC/ASA BLENDS
Rigidity and dimensional stability
Outstanding resistance to high temperature
ageing
Good resistance to UV radiation
PC/SMA BLENDS
Superior toughness
Heat resistance
Outstanding processability

Automotive, medical and

electronic

POLYPHENYLENE OXIDE - PPO

The chemical formulation is based on the oxidative
coupling of substituted phenols and the elimination of a
molecule of water. The full chemical name of PPO is
poly [1, 4 (2, 6-dimethyl phenyl) ether].
CH3
-[ -

- O - ]-n

CH3
PPO is used in blends with other Polymers. The neat
Polymer is not suitable for injection moulding because
of its high melt viscosity.

PPO
Properties

Blends of
Polyphenylene
Oxide

Applications

High Heat Resistance

Excellent Impact Strength
Exceptional dielectric and dissipation characteristics
Flame Retardancy
Exceptional low moisture absorption
PPO/PS blends,
PPO/PA blends
Polyphenylene Oxide is completely miscible with
Polystyrene in all proportions.
Automotive:

Fenders, dash- boards,

Head lamp systems,
Instrument and Control Panels,
Mud-guards,
Wheel Covers &
Fuse Blocks etc.

PROPERTIES

ACRYLONITRILE BUTADIENE STYRENE (ABS)

- CH2 CH
CN

CH2 CH = CH CH2
x

PROPERTIES
Good combination of mechanical,
thermal and chemical properties
Low cost of all engineering
thermoplastics
High impact strength
Low continuous use temperature
High thermal expansion
Limited weather resistance
Poor solvent resistance
Low water absorption
Easy processable by injection,
extrusion and vacuum forming
Electroplatable

- CH2- CH

APPLICATIONS
Telephone casings
Housing for domestic appliances eg.
Vaccum cleaners, TV cabinets, etc.
Luggage cases
Safety helmets
Car fascia and instrument panels
Toys
Furniture
Food mixture housings
Automobile radiator grills
Refrigerator door and tank liners
Automotive front and assembly

POLYTETRA FLUOROETHYLENE (PTFE)

-CCF
Properties

Inert to all chemicals

Excellent weatherability and not attacked by
bio-organisms
Anti-stick and low friction
Stable at high temperature (upto 250 Deg.C)
Tough at low temperature (down to 160
Dec.C.)
Self extinguishing
Stable electrical properties and non-tracking
Difficult to process by conventional methods
Processed by sintering technique
Easy machinable

n
Applications

High and low temperature

electrical and electronic
insulation
Bearings
Wear resistant, low friction
surfaces
Chemical process
equipments
Valves
Pump impellers
Gaskets
Non-stick cockwares

MECHANICAL PROPERTIES OF UNFILLED

AND FILLED PLASTICS
Elongation
(%)

Flexural
modulus
(psi x
105)

Izod
Impact
Strength
(ft.lb.in1)

11800
31000
40000

60
23
34

4.1
16.0
34.0

0.9
2.9
1.6

0
30
30

10200
18000
19000

50 100
3
2-3

3.9
12.0
25.5

1.3
1.8
1.1

Polypropylene

None
GF

0
30

5000
9800

200 700
23

2.0
8.0

0.5
1.6

4.

Polycarbonate

None
GF

0
30

9500
16000

90
46

3.4
12.0

2.7
3.7

5.

Polyphenylene
oxid

None
GF

0
30

9500
18500

60
34

3.6
11.5

1.2
1.7

S.No.

1.

2.

3.

Polymer

Polyamide 66

Polysulphone

Wt
%

Tensile
strength
(psi)

None
GF
CF

0
40
40

None
GF
CF

Nature
of fiber

HDT FOR UNFILLED AND FILLED

PLASTICS
S.No

Polymer

Heat Distortion Temperature C

(at 264 psi)
Unfilled

30% GF filled

55 60

146

Polybutylene terephthalate

55

200 212

3.

Polyethylene terephthalate

68

221

4.

Polycarbonate

140

149

5.

Polysulphone

174

185

6.

Polyphenylene oxide

130

155

7.

Polyamide 6

70

215

8.

Polyamide 6,6

104

255

9.

Polyphenylene sulphide

135

260

10.

Polyether ether ketone

160

315

1.

Polypropylene

2.

CO-EFFICIENT OF LINEAR THERMAL EXPANISON FOR

UNFILLED AND FILLED PLASTICS

S.No.

Polymer

Co-efficient of Linear
Thermal Expansion
(in-1 F-1 x 10-5)
Unfilled

30% GF
filled

1.

Polypropylene

3.8

2.0

2.

4.6

1.2 5.4

3.

Polybutylene
terephthalate
Polycarbonate

3.73

1.25

4.

Polysulphone

3.1

1.4

5.

Polyamide 6

4.6

1.7

DIELECTRIC STRENGTH AND ARC RESISTANCE FOR

UNFILLED AND FILLED PLASTICS
S.No.

Polymer

Nature of
Fibre

Wt.%

Dielectric
strength
(Vmil-1)

Arc
Resistance
(S)

1.

Polyphenylene
sulphide

None
GF

0
30

400 500
550 600

70 80
100 120

2.

Polycarbonate

None
GF

0
30

390 410
450 480

110 120
110 120

3.

Polyamide 6

None
GF

0
30

360 370
400 480

130 140
125 135

MOULD SHRINKAGE

FOR UNFILLED AND FILLED PLASTICS

Mould Shrinkage (mm/mm)
S.No.

Polymer
Unfilled

30% GF filled

0.01 0.025

0.002 0.008

0.017 0.023

0.002 0.006

0.007

0.0025

Polysulphone

0.007 0.008

0.002 0.003

5.

Polyphenylene oxide

0.005 0.007

0.002 0.004

6.

Polyamide 6

0.016

0.0045

1.

Polypropylene

2.

Polybutylene
terephthalate

3.

Polycarbonate

4.

Adhesives : Types ( Thread locking)

Adhesives : Types ( Thread locking)

Adhesives : Types ( Thread locking)

Adhesives : Types ( Thread locking)

Adhesives : Types ( Thread locking)

Adhesives : Types ( porosity sealant)

Adhesives : Types ( Auto Exteriors)

Adhesives : Types ( Auto Interiors)

Adhesives : Types ( Gaskets FIP)

MATERIALS COST
Material

Cost : Rs./Kg

BSK 46

41

SG iron

65

Gray CI

55

En8(bright bar)
Black Bar

52
Less Rs. 4/kg

En 19
Black Bar

73/
Less Rs. 4/ kg

En353

68 (black bar

20 Mn Cr5

48 (black bar)

Spring steel En45A conversion of

Spring leafs

44
Rs. 9/ kg

Harden & Temper SQF

Other

20/kg
15/kg

GCF Carburizing

25/ kg

Iso anneal

6/ kg

MATERIALS COST : FERROUS (RS/ KG)

MATERIAL COST NON FERROUS (RS/KG)

MATERIAL COST: NON METALLIC (RS/ KG)