An Introduction to Automotive Composites

Composites are being used more and more in the automotive industry, because of their strength, weight, quality and cost advantages. In 1998-1999, to further knowledge of composites, the Rover Group in conjunction with the Warwick Manufacturing Group devised a Composite Awareness course. This book is an updated and expanded version of the course notes. This book is intended to give readers an appreciation of composites, materials properties, manufacturing technologies and the wider implications of using composites in the automotive sector. It will be useful for those already working with composites in automotive applications and for those who are considering using them in the future. Chapter Titles...1. What are Composites? This chapter deals with the properties of composites, the types of composite commonly used for automotive applications and reinforcement with fibres. 2. Polymer Chemistry and Physics. This chapter explains how polymers are formed and how the structure affects the physical and chemical properties of the resulting composite. 3. Composite Ingredients. The differences between thermoplastics and thermosets are discussed. 4. General Properties of Composites. explained and how these properties influence what sort of composite is obtained. Test methods and manufacturing methods are also covered. 5. How can we use Composites in Car Manufacture? The reasons for using composites are discussed. Examples are given of the use of composites in specific automotive examples. 6. Manufacturing with Thermoset Composites. This chapter covers manufacturing methods, such as resin infusion, pre-pregging, resin transfer moulding, structural reaction injection moulding, filament winding and pultrusion. 7. Manufacturing with Thermoplastic Composites. This chapter discusses manufacturing methods such as log fibre GMT and short fibre injection moulding. 8. Economics of Composites Manufacture. Covers cost analysis, comparison of materials costs and parts integration and modules. 9. What to do with Composites at the end of Vehicle Life. Mechanical and chemical recycling, thermal conversion and energy recovery are all covered in this chapter. 10. The Future of Composites. gives examples of future uses of composites in doors, bonnets and other automotive structures. 11. Design Guidelines for Composites. This chapter covers designing for composites, including choice of materials.