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Research and development of composite materials
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(1) carbon fiber reinforced plastics (CFRP). Carbon fiber by fiber and polyacrylonitrile by heating processing manufacturing and become, with high heat resistance, the proportion is smaller than aluminum and glass fiber and plastic composite strength can match with the steel and aluminum. But the cost of GFRP and CFRP (glass fiber reinforced plastics), far higher than a lot, mostly limited to the scope of the use of aerospace and sporting goods.
In 1979, the Ford Motor Company in the United States published using GFRP manufacture light the car of new ideas (see Figure 1), the use of CFRP about 300kg, burning fee can be decreased by 35%. The experimental car is mainly used in the body of the CFRP material panel, the other is the drive shaft and the plate spring and other functional parts, while also trying to the engine block and connecting rod, piston and other parts of the application. CFRP material light weight, stiffness and strength are also high, due to the anisotropy of the material, the design can be in the desired direction to maintain its strength and rigidity. The elastic modulus of CFRP is 4~9 times of GFRP, which is 3~4 times of metal material. If the mass production, the cost will be further reduced, so it will be a very high expectation of the composite material.
(2) fiber reinforced metal (FRM). CFRP and GFRP have all kinds of superior mechanical properties, but their base is plastic, and the heat resistance is poor compared with the metal. Therefore, the use of FRM as a high temperature strength material is very popular, and opened up the possibility of using it in the car. Reinforced fibers are: carbon, silicon carbide, boron, aluminum oxide, etc.. Base, beginning with aluminum, copper and nickel, and after the various purposes with the various purposes of titanium, magnesium, zinc and tin, etc.. The combination of fiber and various metals will produce a variety of properties of FRM. The research on the application of FRM to the piston, connecting rod and some other sliding parts is carried out. Because of the high price of the fiber and the size of the mass production, it is a good material for high temperature strength, and its use value is very high.
3) metal plastic laminated material. The combination of high strength steel plate and aluminum, plastic and so on is a kind of ideal light material, and it is also a kind of laminated material. Because it is the two sides of the plastic core bond on the thin steel plate or aluminum, with superior insulation and sound insulation properties. Laminated material, it is called to play with the steel plate to match the rigidity of good characteristics, it is the plastic core of both sides of the metal plate under bending stress, the plastic core material to bear the shear stress. Under the same rigidity, the laminated plate and the general steel, the quality is its 30%~-70%, if there are certain restrictions on the quality of the laminate board, can be changed by the core of the metal plate and the thickness of the core plate to solve. Laminated material cost is generally 1 to 3 times the plate, but it still exist some problems need to be solved, such as: the use of in the body panel, and the panel to bond split; in the surface of metal plate corrosion and stiffness will reduce. However, with the development of the research and development of laminated materials, it will be a great possibility to make it practical.
Vehicle glass fiber reinforced composite material 4. Due to the many varieties of reinforced materials and filling materials, so the use of glass fiber as the material to enhance the material called GFRR. Because of the addition of glass fiber greatly improves the physical and mechanical properties of the plastic, and can also be used as engineering material through the enhancement of plastics. Currently on the use of glass fiber reinforced plastics mainly glass fiber reinforced PP, glass fiber reinforced PA66 or PA6, as well as a small amount of PBT and PPO materials. Auto Application of glass fiber reinforced composite materials including glass fiber reinforced thermoplastic materials, glass fiber mat reinforced thermoplastic materials (GMT), sheet molding material (SMC), resin transfer molding (RTM) materials and hand lay up of FRP products.
Reinforced PP is mainly used for manufacture of engine cooling fan blade and just toothed belt under cover etc. products, but some products are appearance quality is not good, warp lacking, and therefore non functional parts by talc Filled PP replaced gradually. Strengthen the PA material in passenger cars, vans and trucks have been adopted and are generally used to make some small functional pieces, such as: the lock protecting cover, insurance wedge block, Block Nut loaded, throttle pedal and a shift under the cradle - door cover and opening handle etc.. GMT is currently the extremely active composite developed varieties, which is kind of thermal plastic resin as the matrix and the glass fiber for reinforced skeleton of the novel, energy-saving and lightweight composite materials, the general can produce sheet of semi-finished products, then directly processed into the desired shape of the product, the fiber can is short cut glass fibre or continuous glass fiber mat.
SMC is one of the more important and widely used products of molded composites. Compared with the steel automobile parts, short production cycle of SC, convenient vehicle retrofit, good investment benefits; lightweight, fuel saving; free design; parts of the whole, the number of parts less; durability and heat insulation. But SMC can not recovery, environmental pollution; while the price performance is better, but one-time investment tended to be higher than corresponding to the steel parts, such as the Ford Taurus and Mercury Sable car front around the radiator bracket, the original steel is 22 parts, and SMC only 2, quality is greatly reduced, the cost is reduced by 14%.
Although many auto plants in the production of automotive have switched from glass fiber reinforced materials to replace the relatively heavy metal, but glass fiber is by molten glass pull into a fiber, it after the high temperature melting is very easy to re solidification, to the scrap car recycling processing brought great difficulties. To this end, the French national scientific research center is studying a kind of cannabis and polyurethane as raw material