Materials Used in Vehicle Bodies-2

M.Tech.
Automotive Engg II sem

PESIT -2009 Body and Chassis Engg
Prepared by RAVISHANKAR.V.K
Mob:9449600854 Email: korgal_r@yahoo.com
Chapter 4B
Materials Used in
Vehicle Bodies
M.Tech.Automotive Engg II sem
Plastics
Thermoplastic Thermo set.
Thermoplastics, if exposed to
heat, will melt in two to seven
minutes.
Thermo sets will keep their shape
until they are a charred, smoking
mess
Examples: grocery bags, piano
keys and some automobile parts
Examples :
kid's Toy, dinner sets.
Soften when heated.
No chemical change.
When cooled- back to normal
Soften only once
chemical change takes place
Burns only with smoke.
Plastic Classification based on the reaction to Heat
Ex:
Polyethylene. Polypropylene,
Polystyrene.
Ex:
Phonolic. Epoxy resins.
Unsaturated Plastics, Amino resins.
Mechanical Properties
Tensile strength
Elongation
Compressive
strength
Creep
Shear strength
Flexural strength
Torsional strength
Modulus
Impact strength
Specific gravity
Water absorbtion
Coefficient of Friction
(COF)
Tensile
Strength
Mechanical Properties
Elongation
Compressive
Strength
Measured in
pounds per
square inch (PSI)
Higher PSI =
harder to
compress
Creep
Associated with compressive strength
Creep at room temperature is called
cold flow
Shear
Strength
Flexural
Strength
Torsional
Strength
Modulus
Also referred to as stiffness
Used in conjunction with strengths (flexural modulus, tensile
modulus, etc.)
Higher modulus = stiffer material
Measured in PSI
Impact Strength
Izod Impact Tensile Impact Gardner Impact
Specific Gravity
Related to the density of material
Can be used to determine the weight
of material
Specific gravity of less than 1.0 will
float in water
Water Absorption
Measured by the percentage of swell
Think of a sponge as having high
percentage absorption
Coefficient of Friction (COF)
Resistance to sliding (slickness)
Low COF = more slippery (think of
wet ice as having lowest COF)
Thermal Properties
Coefficient of thermal expansion
Heat deflection temperature
Continuous service temperature
Melting point
Thermal conductivity
Coefficient of Thermal Expansion
(CTE)
Change in size as temperature
changes
Lower value = less change with
temperature
Heat Deflection Temperature
(HDT)
Temperature up to which a material can
perform, under load, without distorting
Used most widely to predict
performance
Continuous Service Temperature
(CST)
Highest temperature a material can
withstand and still retain at least 50% of
its properties
Measured in degrees Fahrenheit, in air
In high temperatures, both CST and
HDT must be considered
Melting Point
Temperature at which a crystalline
thermoplastic
changes from solid to liquid
Thermal Conductivity
How much heat a material will conduct
Most plastics are good insulators (do
not conduct heat well)
Higher value = more heat conducted
Thermal conductivity of plastics is 300 to
2,500 times less than most metals
Electrical Properties
Volume resistivity
Surface resistivity
Flammability
Volume Resistivity
Ability of electricity to flow through a
material
Measured in ohms/cm
Lower value = more easily current flows
Higher value = better resistor or
insulator
Surface Resistivity
Ability of electricity to flow over the
surface of a material
Same measurements as volume
resistivity
Most favorable ratings are given to
materials that extinguish themselves
rapidly, and do not drip flaming
particles
Flammability
Types of
Thermoplastics
Amorphous plastics (shapeless)
High performance
Engineering
Commodity
Amorphous Commodity
Thermoplastics
Key Characteristics
Low cost, temperature resistance and strength
Good dimensional stability
Bonds well
Excellent transparency (Polycarbonate only)
High stiffness.
Excellent dimensional stability.
Good surface finish.
Flame retardance.
Semi-Crystalline Commodity
Thermoplastics
Key Characteristics
Low cost, temperature resistance
and strength
Excellent chemical resistance
Low COF
Near zero moisture absorption
Very good electrical properties
Good toughness
Semi-crystalline plastics
High performance
Engineering
Commodity
Semi crystalline Plastics
Polyamide 6 and 66:
Properties: High rigidity.
Hardness.
High heat resistance.
Impact resistance.
Abrasion/chemical/stress crack resistance.
Applications 1. Under bonnet components.
2. Mechanical applications
3.Bumper.
4.Body embellishment (Wheel rims, Handles)
5.Lighting, Head lamp reflectors, Mirrors.
Blended Plastics:
Blended Plastics are used in large area Body Panels.
Which require following properties.
Temperature resistance
Low temperature impact resistance.
Toughness.
Petrol resistance.
Stiffness.
Applications : Large Body panels.
Injection moulded bumper.
Other facts and applications of plastics in vehicle bodies.
Plastics with
Vacuum metalising.
Electroplating.
It is used in
Mirror Housing.
Control Knobs.
Winder handler.
Decorative metallic trim.
Plastic thin parts property requirements for plastics;
1. Tough and resistant to occasional impact.
2. Impervious to attack by weather, road salts and extremes of
temperatures.
3. Low tensile strength No Heavy stresses.
4. Cheap and capable of being formed into highly individual and complex
shapes.
The main plastics types in this category are Thermoplastics and
Thermosetting resins.
These can be pressed, stamped, blow moulded, vacuum formed, injection
moulded any decorative shape.
Acrylic plastics:
Tensile strength. 35-75 N/m2
Modulus of elasticity 1550-3250 N/m2
Inert to most chemicals.
Complete stability against petroleum products.
Acetal resins:
Used in cams, sprockets, small leaf springs.
Housing cover plates, knobs and Lever.
Highest fatigue endurance limits.
Reduced friction and noise
Other things:
Plastic can be self colored Painting cost will be reduced
But large scale panels Painting is necessary to obtain the uniformity.
Plastics can be chrome plated.
Chrome plating avoids corroding the base body.
For joining thermoplastics adhesives are used
But now they can be welded also
Hot gas welding
Ultrasonic and vibrations methods .
Induction, resistance and microwave process.
Plastics Obtained with additional polymerization have wide application in
the construction of vehicle bodies.
Ploythene and polystyrene are used in many types of films and battery
cases where metal is not suitable.
Very economical because of their weight volume ratio
Range of density up to 1.00gm/cm3.
Expanded polystyrene can be used as thermo or acoustic insulating
boards with densities as low as 0.05 gm/cm3.
Another product is polyvinyl chloride (PVC).
It is used in covering, upholstery, roofing in case of convertibles.
Specific gravity of PVC is 1.20- 1.60
Ploythene and polystyrene
GLASSES
INTRODUCTION:
More and more glass being used in car.
Pillars are becoming slimmer and glass areas are increasing as
manufactures approach the ideal of almost complete all round vision in
the virtual elimination of blind spots.
Windscreens have becomes wider and deeper.
GLASSES:
The glass used in vehicle body has specific gravity of 3.5.
Safety glass must be used in vehicle body.
This is toughened so that it disintegrates into small pieces with blunt edges.
Toughened glass can not be worked out after the process of toughening.
This can not be cut or drilled.
CLASSIFICATION
TOUGHENED GLASS:
Uniformly toughened glass is produced by completely
Different process, involving heating of the glass followed by rapid cooling.
Usually toughened glass is produced by heating the glass in furnace to just below
Its softening point. At this temperature it is withdrawn from the furnace and chilled
By blasts of cold air. The rapid cooling hardens and shrinks the outside of the
glass; the inside cools more slowly
LAMINATED GLASS:
Plastic coated laminated safety glass in an ordinary laminated glass which has
soft elastic polyurethane films bonded on to the inner surface to provide
Improved passenger protection. if fragmentation occurs.
In some cases the adhesive namely gelatine is used to hold the together.
Definitions of glass types as per ARAI
Uniformly Toughened Safety Glass: A glass plane consisting a single layer
of glass, which has been subjected to special treatment to increase its
mechanical strength and to condition its fragmentation after shattering.
Laminated Safety Glass: Laminated Safety Glass means two or more pieces
of glass held together by an intervening layer or layers of plastic materials. The
laminated safety glass will crack and break under sufficient impact, but the
pieces of the glass tend to adhere to the plastic material and do not fly, and if a
hole is produced, the edges will be less jagged than they would be in the case
of an ordinary glass.
GLASSES : Other Facts.
Britaish standards: BS 857, ECER43,
Most Laminated wind screens used are 4.4 mm,5mm,5.8mm, or 6.8 mm in overall
Thickness, with a 0.76 mm PVB interlayer.
Large coaches and lorry wind screens are 7.8 mm thick
( 4.8 mm thick glass + 0.76 mm interlayer + 3mm Glass)
THE END

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M.Tech.

Automotive Engg II sem

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