Nanocomposites in automotive sector
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The document discusses the use of nanocomposites in the automotive sector. It begins by defining nanocomposites as solid matrices, usually polymers, containing nanoscale fillers like nanoparticles, nanotubes, or nanofibers. This allows for increased strength, barrier properties, heat resistance, and decreased flammability compared to conventional composites. The automotive industry uses nanocomposites to improve manufacturing speed, environmental stability, recycling, and reduce weight. Some early examples include Toyota using nylon-clay nanocomposites in timing belt covers in 1991. The benefits of nanocomposites for automotive applications include simpler production processes and better mechanical, thermal, and electrical properties for high-performance uses.
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Nanocomposites in automotive sector
- 1. Nanocomposites in Automotive Sector IE 450 Nanomanufacturing & Devices 22/12/2014
- 2. Table of Content Introduction Definitions Application Areas History of Nanocomposites in Automotive Sector Nanocomposites vs. Conventional Composites Benefits and Challenges Conclusion References 2
- 3. Introduction • Nanocomposites: new alternative to conventionally filled polymers -Increased modulus & strength -Outstanding barrier properties -Improved solvent and heat resistance -Decreased flammability 3
- 4. • Global expectations: fuel economy & low emission low cost high performance lightweight materials 4http://www.digitalafro.com/content/wp-content/uploads/2013/06/bmw-gina-concept-2009-03.jpg
- 5. Replace metal and glass with nano-objects for fuel-efficient, higher quality and durable vehicles 5
- 6. Nanocomposites in vehicles - To improve manufacturing speed - To enhance enviromental and thermal stability - To promote recycling - To reduce weight http://nanotechinautomotive.blogspot.com.tr/ 6
- 7. Definitions Composite : made by combining two or more materials Nanocomposite: a solid matrix (usually polymers) that contains a nanoscale filler, called a nano-object (nanoparticles, nanotubes, nanofibres, etc.). 90% of nanocomposites is made of polymer.http://www.mechanicalengineeringblog.com/wp-content/uploads/2011/03/01nanocompositenanotechnologypolymernanoparticles.jpg 7
- 9. The main characteristics of nano-objects in nanocomposites : Increased Surface Area ( Increased interaction between the particle and the matrix) Transparency (d<30nm) 9 http://www.nanowerk.com/spotlight/id6080_2.jpg
- 10. Application Areas of Nanocomposites • Automotive (gas tanks, bumpers, interior and exterior panels) • Construction (building sections and structural panels) • Aerospace (flame retardant panels and high performance components) • Electrical and electronics (electrical components and printed circuit boards) • Food packaging (containers and wrapping films) 10
- 11. Manufacturing Type of Polymer Nanocomposites: ①In Situ Polymerization ②Solution Induced Intercalation ③Melt Processing 11
- 12. Product Benefit Application Nylon Nanocomposites Improved Modulus Strength Heat Distortion Temperature Barrier Properties • Timing Belt Cover • Engine Cover • Fuel Line • Fuel Hoses • Fuel Tanks Elastomeric Nanocomposites Higher Durability Reduced Weight Reduced Rolling Resistance Easy Rubber Processing High Barrier Coating • Tires 12
- 13. Timeline for the commercialization of products by automotive players http://www.nanowerk.com/spotlight/spotid=23934.php#ixzz3M3IKx2uO History 13
- 14. History of NCs in Automotive Applications 14 Toyota Motor Company- Nylon-6-Clay NC Timing Belt Cover(1991) for Toyota Camry cars in collaboration with Ube industries. Unitika Company of Japan- Nylon-6-Clay NC for engine covers on Mitsubishi engines. GM-Polyolefin reinforced with 3% nanoclays components in collaboration with Basell for GM’s Safari and Chevrolet Astro vans(2002) GM-One piece compression molded rear floor assembly by using nano-enhanced Sheet Moulding Compounds(SMCs) developed by Molded Fiber Glass Companies.
- 15. 15 Timing Belt Cover http://home.halden.net/discovery/pics/timingbelt.jpg
- 16. Conventional Composite vs Nanocomposite Requires post- forming modification of surface Long cycle times Expensive Light-weight materials for non- cosmetic parts to reduce weight Processing of metals costly Better modulus Thermal stability Fire retardancy Dimensional stability Surface hardness Heat Distortion temperature Mar resistance Barrier properties 16
- 17. Benefits of Nanocomposites Simple and effective production process Better dispersion of the reinforcement Better interface adhesion Better mechanical, thermal and electrical properties Variety of combination Suitability for high performance applications 17
- 18. Limitations of Nanocomposite Production Cost Consistency and reliability in volume production High lead time Oxidative and Thermal Instability of Nanoclays 18
- 19. Illustration of the usage of polymer nanocomposites parts. http://www.nanowerk.com/spotlight/spotid=23934.php#ixzz3M3IKx2uO19
- 20. Conclusion 20 Today, demand for thermoplastic polyolefin/polypropylene nanocomposites has moved beyond nylon 6/clay nanocomposites, mainly because of their low cost and enhanced physico-mechanical properties.
- 21. Conclusion 21 In the past, the automotive industry was more inclined towards using nylon 6/clay nanocomposites for under-the-hood applications, where higher heat deflection temperature, enhanced stiffness, and light weight were the goals.
- 22. Conclusion 22 The performance-to-cost ratio was a main constraint which halted the rapid growth of polymer nanocomposites. However, nylon 6/clay nanocomposites (more costly) are still used for under the hood applications, fuel lines and fuel system components.
- 23. References Gacita, William et al., Polymer Nanocomposites: Syntetic and Natural Fillers A eview, 2005 Garces, Juan et al., Polymeric Nanocomposites for Automotive Applications, Lagashetty, Arunkumar and Venkaraman, a. Polymer Nanocomposites, 2005. Şeh, Faruk et al. Polimerik Nanokompozitler ve Kullanım Alanları, Makine Teknolojileri Dergisi, Vol 7, 2010. http://www.nanowerk.com/spotlight/spotid=23934.php#ixzz3M3IKx2uO http://www.jeccomposites.com/news/composites-news/nano http://www.ictp.csic.es/OfertaTecnologica/Leaflet%20PT_005_201030947_G% C3%B3mez-Rodr%C3%ADguez_2012-01-10.pdf http://www.rsc.org/Education/Teachers/Resources/Inspirational/resources/4.3. 1.pdf 23
- 24. Any Question? 24
Notes de l'éditeur
- Introduction Nanocomposites represent a new alternative to conventionally filled polymers. Because of their nanometer sizes, filler dispersion nanocomposites exhibit markedly improved proper- ties when compared to the pure polymers or their traditional composites. These include increased modulus and strength, outstanding barrier properties, improved solvent and heat resistance and decreased flammability.
- Current global expectations for fuel economy and low emissions for manufacturing and transportation are creating a demand for new low-cost, high-performance lightweight materials to replace metals. Nanocomposites are a novel class of polymeric materials exhibiting superior mechanical, thermal, and processing properties, suitable to replace metals in automotive and other applications. This new technology is attracting the attention of the automotive manufacturing industry and its suppliers.
- The use of nanocomposites in vehicle parts and systems is expected to improve manufacturing speed, enhance environmental and thermal stability, promote recycling, and reduce weight. Applying this technology only to structurally non- critical parts such as front and rear fascia, cowl vent grills, valve/timing covers, and truck beds could yield several billion kilograms of weight saved per year. Nanocomposite plastic parts offer a 25% weight savings on average over highly filled plastics and as much as 80 % over steel. Since approximately 90 %of the total energy used by an automobile during its life cycle is from fuel consumed, this reduction in weight offers the potential of significant energy savings for the auto- motive industry and vehicle users. Energy savings could be further expanded by applications into structural components, interiors, and body panels.
- Composite : A composite material is made by combining two or more materials – often ones that have very different properties. The two materials work together to give the composite unique properties. However, within the composite you can easily tell the different materials apart as they do not dissolve or blend into each other. Nanocomposite: A nanocomposite is defined as a solid matrix (usually polymers) that contains a nanoscale filler, called a nano-object (for example nanoparticles, nanotubes, nanofibres, etc.). The main characteristics of nano-objects are
- 1) increased surface area (contact between the particle and its environment): this gives increased interaction between the particle and the surrounding matrix, resulting in improved mechanical, chemical, and thermal properties and 2) transparency: when the particle diameter is lower than 30 nm, the reflection of visible light is negligible.
- Several routes are currently proposed to make polymer±clay nano- composites.[7] The clay materials can be dispersed and exfo- liated into polymers by conventional melt compounding or solution methods. Alternatively, nanocomposites can be made by the in-situ intercalation polymerization method, where the monomer is first intercalated in the clay, and subsequently polymerized in situ. This method was pioneered by Toyota Motor Company to create Nylon 6±clay hybrid (NCH), used to make a timing-belt cover, the first practical example of polymeric nanocomposites for automotive applications.[8] Nanocomposites should be net-shape moldable and may be extruded, allowing consolidation of parts and reduction in assembly steps.
- The commercialization of polymer nanocomposites started in 1991 when Toyota Motor Co. first introduced nylon-6/clay nanocomposites in the market to produce timing belt covers as a part of the engine for their Toyota Camry cars, in collaboration with Ube industries in 19912. At about the same period, Unitika Co. of Japan introduced nylon-6 nanocomposite for engine covers on Mitsubishi GDI engines3 manufactured by injection moulding, the product is said to offer a 20% weight reduction and excellent surface finish. In 2002, General Motors launched a step-assist automotive component made of polyolefin reinforced with 3% nanoclays, in collaboration with Basell (now LyondellBasell Industries) for GM's Safari and Chevrolet Astro vans, followed by the application of these nanocomposites in the doors of Chevrolet Impalas4,5. The real surge in the commercialization of nanocomposites production has occurred over the last ten years. In 2009, a one-piece compression moulded rear floor assembly was made by General Motor (GM) for their Pontiac Solace using nano-enhanced Sheet Moulding Compounds (SMCs) developed by Molded Fiber Glass Companies (MFG), Ohio. This technology is also in use on GM's Chevrolet Corvette Coupe and Corvette ZO6. The nano-filled SMCs exhibit significantly lower density than conventional SMCs resulting in improved fuel efficiency6. The automotive industry can benefit from polymer nanocomposites in several applications such as engines and powertrain, suspension and breaking systems, exhaust systems and catalytic converters, frames and body parts, paints and coatings, lubrication, tires, and electric and electronic equipment. In the latter part of the 1980s and the beginning of the 1990s, a research team from Toyota Central Research Development Laboratories (TCRDL) in Japan reported work on a Nylon-6/clay nanocomposite and disclosed improved methods for producing nylon-6/ clay nanocomposites using in situ polymerization similar to the Unichika process7-10. The largest demand for nanoclays in nanocomposites is primarily driven by the need to meet the customers' (OEMs/tier I/II/III) cost expectations and performance of end-use parts, as nanoclays are less expensive ($6 to $8/kg) than other nanomaterials and exhibit improved balance of stiffness and toughness, excellent mechanical and barrier properties, enhanced heat deflection temperature without loss in elongation, improved colorability and improved scratch and mar resistance.
- The automotive industry is a materials intensive industry. A wide variety of metals, fillers, and plastics are used today to meet the requirements of specific applications. The ultimate drivers in materials selection are, of course, cost and performance. Materials are selected by identifying the best cost/performance ratio needed to meet the requirements of the application. This reality has driven the development of numerous approaches to enhance the properties of conventional materials. Examples of these approaches include structural plastics, alternative metals and alloys, reinforcing fillers, and glass fiber composites. Each of these approaches has limitations. Structural plastics often require post-forming modifications of the surface and long cycle times and are more expensive. Light- weight metals and their alloys are seeing increased use, primarily in non-cosmetic structures, for weight reduction. These metals, however, have the same processing limitations as steel and iron, and they usually add cost. Reinforcing fillers such as talc, mica, and calcium carbon- ate, for example, introduce higher stiffness while also increasing weight and melt viscosity, and decreasing tough- ness, optical clarity, and surface quality. Glass-fiber reinforcement provides high stiffness with a corresponding increased difficulty of fabrication and cost. These traditional reinforcements and fillers must be used at high loading levels to increase modulus and improve dimensional stability, thus compromising weight, toughness, and surface quality. In contrast to traditional fillers, nanofillers such as exfoliated clays are expected to be effective at a loading under 5 % by weight, introducing only a minor increase in materials cost. They provide significant improvement in modulus, ther- mal stability, fire retardancy, dimensional stability, surface hardness, heat-distortion temperature, mar resistance, and barrier properties. Nano-scale reinforcement should enable part and system design of polymer composites that will be cost-competitive with other polymers, and eventually replace metals and glass, thus enabling the automotive industry to capture a leadership position in fuel-efficient, higher-quality, and durable vehicles.
- The production process of these nanocomposites is simple, effective and industrially scalable. Very good dispersion of the reinforcement in the polymer matrix and excellent interface adhesion between both phases. Low filler concentration is required to achieve nanocomposites with better mechanical, thermal and electrical properties than the unreinforced polymer or the polymer reinforced with similar fillers added by means of direct mixing. Different polymer matrices (PEEK or any polymer with similar structure) and also different carbon nanomaterial can be used (tubes, fibres, spirals, fullerenes or their combinations) Suitable for high-performance applications. In particular, for applications in aerospace, aeronautical or transport industries as well as for antistatic coatings and electrical shielding manufacturing.
- Processing: Compatibility, dispersion and exfoliation between nanomaterials and polymer matrices. Only a limited number of plastic matrices (mostly thermoplastics) are compatible with nanoclays/nanotubes/nanofibers as intercalation of clays with the precursor of a polymer can change the functionality of the polymer and inhibit its properties. Cost: The production of nanocomposites on a commercial scale at viable prices, as polymer matrix price depends on crude oil prices and CNTs price is also high. Consistency and reliability in volume production: It is possible to get consistency and reliability in volume production materials to a great extent. However, particle size distribution and control in volume manufacturing is not so easy. High lead time: Commercializing the end-use products would take a longer time, mainly due to stringent approval and OEMs acceptance. Oxidative and thermal instability of nanoclays: Commonly used organoclays are thermally unstable due to exchange of metal cations in clay galleries with organic ammonium salts and can degrade at temperatures as low as 170°C. It is clear that such organoclays are not suitable for most engineering plastics that are fabricated by melt processing technology.
- Today, demand for thermoplastic polyolefin/polypropylene nanocomposites has moved beyond nylon 6/clay nanocomposites, mainly because of their low cost and enhanced physico-mechanical properties. In the past, the automotive industry was more inclined towards using nylon 6/clay nanocomposites for under-the-hood applications, where higher heat deflection temperature, enhanced stiffness, and light weight were the goals. The performance-to-cost ratio was a main constraint which halted the rapid growth of polymer nanocomposites. However, nylon 6/clay nanocomposites (more costly) are still used for under the hood applications, fuel lines and fuel system components. The various stakeholders in the automotive value chain need to take note of polymer nanocomposites technology and development, which has a growing market globally, but the higher cost of the end-use components is a shortcoming which needs to be overcome.