Carbon-Fibre Composite Materials - Coursework Example

Carbon-Fibre Composite Materials Advantages of CFRP Automobiles are machines utilized for locomotion. Externally, they are seen as a single homogenous machine. Internally, they are actually complex combinations of both small and big parts. The multifarious combinations of nitty-gritty parts contribute to the total functionality of automobile. The various parts of automobile are made up various materials where their strength depends upon the raw materials used to produce them. The myriad of interconnections of the various parts, whether small or large, contributes to the overall functionality of an automobile. There are different types of automobile. A car is the most common type of automobile comprising largely in the usability in human population. Basically, the primary parts of a car includes: the exterior, lights, interior, chasis, brakes, suspension, and engine. Materials used for the various parts of a car needs to fulfill various criteria and comply with regulations and legislations that ensures the safety and environmental concerns of the machines. Traditionally, materials used for automobile parts production comprises of metallic materials, aluminum, steel, magnesium and other metallic alloys. However, with the rise of modern technology where various study discovered new researches, many of the metallic parts of car are now replaced with materials made up of composite materials (Ghassemieh, 2011). Composite materials such as carbon-fibre composites have been widely applied in automobile processing. Carbon fibres are those fiber materials derived from carbon. They are mixed and bound together with other materials such as polymer resins processed under heat, pressure and vacuum to derive the special properties for the composites (Johnson, T. n.d). They are considered as new breed for high strength materials. It contains about 90% carbon fiber which is very durable and strong. They are very suitable when used in applications requiring stiffness, strength, lesser weight and superior fatigue characteristics (Hegde, et al. 2004). Carbon Fiber composite polymers or CFRP are devised in automobile manufacturing as they are lightweight yet rigid materials. CFRP includes thermosetting of resins which includes polyester, epoxy, and vinyl ester (Johnson, T. n.d). CFRP technology is considered to be an ideal application due to the combination of strength and the weight of the material in the processed output material. In fact, many popular vehicles such McLaren and BMW are built using this technology. The use of CFRP has a high potential weight saving materials for automobile production. The potential for the carbon fiber composites are still to be discovered and explored as automobile production giants haven’t exploited the technology to its optimum use (Carney, D. 2011). There are many advantages in using CFRP in automobile production. Basically, CFRP are lightweight materials. Usually, with the same 70% fiber weight, it is much lighter than fiberglass reinforced composites. They are also rigid and strong materials. The strength of materials provided by the output composites are technically superior with that of metals and glass fiber composites. In comparison with metals, aluminum even weighs 1.5 times compared with CFRP, with lasting strength on higher strain level (Johnson, T. n.d). Carbon fiber layers have strong covalent bonds. Aggregations allow easy crack propagation and the fiber fails at low strain when bent. CFRP used in general engineering and transportation incudes in the manufacture of gears, bearings, fan blades, cams and the entire automobile structure. They provide strength; superior toughness and lightweight characteristics to the entire assemble (Hegde, et l. 2004). The Strength modulus values of CFRP can range from 85 to 90 Msi while the compression strength can range up to 1000 ksi. The tensile strength of CFRP is about three to four times higher than that of glass. Composites of carbon fiber are brittle. They might produce corrosion when used next to metals. This can be avoided by putting barriers of glass and resin in between them (ACMA, 2014). Processing of CFRP Carbon fiber processing includes combination of polymer resin, cured and infused in molds. The current practice utilizes prepegs or preimpregnated tapes and fabrics. Prepegs have higher fiber volumes of about 50 to 60%resulting to lower weight but higher stiffness. They are commonly cut into plies and laminated layer by layer. The laminates is then covered with separator film and sealed in vacuum bags over the mold. While on vacuum, an external pressure is then applied to collapse remaining air vacuoles. Curing and cooling then follows at certain temperature and time (Brosius, 2004). This is known as the Resin Transfer Molding or RTM. Generally, it produces good results as both sides of the component will result to molded surfaces. The fiber volume is intensively high with very low void contents. Also, finish products are safe, good for the health and the environment due to resins is enclosed. However, the process is slow, and is not suitable for volume applications. Match tooling is also expensive and the preparation is also costly (Norris, 2012). The process for RTM producing continuous carbon fiber composites is shown in this diagram: The curing of prepegs in autoclave is quite expensive and took long time for the process. Autoclaves are expensive and the laminating process is intensive. This is the reason why several suppliers tried to introduce products that eliminates the process of autoclave. The capital costs as well as the operating cost for the manufacture of CFRP are quite high (Brosius, 2004). The properties of CFRP are perfect for the automobile industry where they materials produced are lightweight but offer superior strength and stiffness. However, the production is still a challenge to automobile industries. CFRP are employed in small batches automotive production such as in sports car sectors (Grolms,M. 2013). Mold life range is from 500 to 5,000 parts wherein the initial mold cost is higher than traditional processes (Solid Concepts, 2014). CFRP has a lot promise in the future of the automobile industry. However, the technology requires to be explored deeper and researches are still required so as to arrive in production of the material that can topple the current trends in automobile manufacturing. The use of CFRP provides good combination of strength and weight for automobiles. But the limitations of their production are giving way for other materials to be used preferably by auto industries. Aluminum used in manufacture of automobiles are getting the chance out from CFRP as they provide low production in terms of cost, processing methods and time. There is a need for deeper and more intensive research for the production of CFRP so that they can materialize even to ordinary cars. And when that times, automobile industry would then achieve a mile leap in terms of production output as quality and cost are achieved by auto industries. The use of CFRP is still in the advent, however, the potential and promise it holds is pointing towards global competitiveness in the automobile industry. Works Cited ACMA. (2014). Automotive Composites Alliance of the American Composites Manufacturers Association. USA: Arlington, Virginia. Available from http://www.autocomposites.org/composites101/abc.cfm Borsius, Dale. (2004). Carbon Fiber: The Automotive Material of the Twenty-First Century Starts Fulfilling the Promise. Available from http://www.speautomotive.com/SPEA_CD/SPEA2003/pdf/f01.pdf Carney, Dan. (2011). Ferrari Prefers Aluminum Over Carbon Fiber. Available from http://articles.sae.org/10391/ Gasseieh, Elaheh. (2011). Materials in Automotive Application, State of the Art Prospects, New Trends and Developments in Automotive Industry. InTech. Available from http://www.intechopen.com/download /get/type/pdfs/id/13343 Grolmes,M. (2013). Cutting CFRP for Future Car Generation. Available from http://www.materialsviews.com/cutting-cfrp-for-future-car-generation/ Hegde, R., Dahiya, A., Kamath, M.G. (2004). Carbon Fibers. Available from http://www.engr.utk.edu/mse/Textiles/CARBON%20FIBERS.htm Johnson, Todd. (n.d). What is Carbon Fiber: Beginners Guide to the Lightweight Composite Material. Available from http://composite.about.com/od/aboutcarbon/a/What-Is-Carbon- Fiber.htm Johnson, Todd. (n.d). Understandin CFRP Composites: The Amazing Capabilities of Carbon Fiber Reinforced Polymers. Available from http://composite.about.com/od/aboutcarbon/a/Understanding-Cfrp-Composites.htm Norris, Bob. (2012). Manufacturing Processes for Carbon Fiber Composites – A Brief Overview. Materials of Science and Technology Division. Oak Ridge Carbon Composites Consortium Meeting. Available from http://www.cfcomposites.org/PDF/breakout_norris.pdf Solid Concept.(2014). Composites. Available from http://www.solidconcepts.com/technologies/composites/ Read More