Available online at www.sciencedirect.

com

ScienceDirect
Materials Today: Proceedings 4 (2017) 3807–3815 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

An overview of Polymeric Materials for Automotive Applications

Akshat Patila*, Arun Patela and Rajesh Purohitb
a
Mechanical Engineering Department, NRI Group of Institutions, Bhopal, India
b
Mechanical Engineering Deparmtent, M.A.N.I.T., Bhopal, India

Abstract

Mechanical components and structures are designed and developed for carrying out certain tasks and are subjected to high
stresses, high temperature and corrosive environment. This can ultimately lead to its failure. Over the past few decades, high
performance plastic materials in automobiles have experienced a real boom and their applications are increasing with a tendency
of further growth. The polymers are finding their way deep inside most of the applications primarily because of light weight and
relatively better properties. The average global plastic penetration is 120 kg/vehicle and average Indian plastic penetration is 60
kg/ vehicle. A wide variety of plastic are used in vehicles. The basic functions of such wide use of high performance plastic
materials in vehicles dictate the appearance of the automobiles, their functionality, economy and low fuel consumption. The
application of polymeric materials allows more freedom in design and approximately 82 percent of an average vehicle’s Weight
gets recycled. The focus of present study is to give comprehensive review of high performance plastic materials and their
applications in the area of automotive comfort and safety.
©2017 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials
Processing and Characterization (ICMPC 2016).

Keywords: Plastic materials, automotive applications, functionality, economy;

1. Introduction

The applications of high performance plastic are playing an important role in the automotive industry these days.
It is constantly increasing and this trend is expected to continue. The main aspect in choosing the high performance
plastic materials in relation to other materials used in automobiles are the design of automobiles, their functionality
and more economic manufacture, as well as reduced fuel consumption. It is estimated that every 10% reduction in
vehicle weight results in a 5% to 7% reduction in fuel usage.

* Corresponding author. Tel.: +09479953671.

E-mail address: rpurohit73@gmail.com

2214-7853 ©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
3808 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815

Current economic and environmental concerns make the creation of more fuel efficient Vehicle a top priority in the
automotive industry. Although the minimization of the mass of parts is the main reason of choosing high
performance plastic materials, the future rise of their usage will result in new applications in automobiles related to
comfort, safety and possibility of parts integration. The application of high performance plastic materials allows
more freedom in design, and in many cases only these materials can allow safe geometrical or economic solution for
the construction of parts. Some other advantages of increased applications of plastic materials in transport vehicles
include:

• Minimal corrosion, allowing for longer vehicle life

• Substantial design freedom, allowing advanced creativity and innovation

• Flexibility in integrating components

• Safety, comfort and economy

• Recyclability

2. Automotive Applications of High Performance Plastic Material

The average vehicle uses about 150 kg of plastics and plastic composites versus 1163 kg of iron and steel –
currently it is moving around 10-15 % of total weight of the car (Fig. 1).

Fig.1. Increasing use of plastics in automobiles

Although up to 13 different polymers may be used in a single car model (Table. 1), just three types of plastics make
up to about 66 % of the total plastics used in a car: polypropylene (32%), polyurethane (17 %) and PVC (16 %).
 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815 3809

Table.1. Plastics used in a typical car

Component Main types of plastics Average Weight in car (kg)

Bumpers PS, ABS, PC/PBT 10

Seating PUR, PP, PVC, ABS, PA 13
Dashboard PP, ABS, SMA, PPE, PC 7
Fuel systems HDPE, POM, PA, PP, PBT 6
Body (incl. panels) PP, PPE, UP 6
Under-bonnet components PA, PP, PBT 9
Interior trim PP, ABS, PET, POM, PVC 20
Electrical components PP, PE, PBT, PA, PVC 7
Exterior trim ABS, PA, PBT, POM, ASA, PP 4
Lighting PC, PBT, ABS, PMMA, UP 5
Upholstery PVC, PUR, PP, PE 8
Liquid reservoirs PP, PE, PA 1

Total 105

2.1 PC (Polycarbonate)

Polycarbonates are usually used for the application in automotive industry. They are used mainly in non-reinforced
condition. Amorphous polycarbonate polymer offers a rare combination of stiffness, hardness and toughness. It
shows excellent weathering, creep, impact, optical, electrical, thermal properties and UV resistance, with
transparency levels almost good as acrylic.
Applications: Bumpers, headlamp lenses, security screens, aircraft panels, spectacle lenses, headlamp lenses,
helmets and bullet-proof glass substitutes.

2.2 Acrylonitrile/butadiene/styrene (ABS)

Acrylonitrile Butadiene Styrene is a durable thermoplastic. It is a copolymer built by polymerizing styrene and
acrylonitrile in the presence of polybutadiene. The styrene gives the plastic a shiny, impervious surface. The
butadiene, a rubbery substance, provides resilience even at low temperatures. A variety of modifications can be
made to improve impact resistance, toughness, heat resistance, weather and some chemicals resistance.
Applications: Automotive body parts, dashboards, wheel covers manufacture of housings, Covers and linings.

2.3. Polyamide (PA, Nylon 6/6, Nylon 6)

Polyamide is known as nylon 6.6 or nylon 6. It is a general purpose nylon that can be both molded and extruded.
Nylon 6/6 has good mechanical properties and wear resistance. They are frequently used when a low cost, high
mechanical strength, rigid and stable material is required. They also absorb water easily and components in wet or
humid conditions will expand, precluding their use in applications where dimensional stability is required. The main
application of polyamide is the manufacture of parts which are under the engine hood, mainly using the types of
polyamide (PA) reinforced by fiberglass.

Applications: Gears, bushes, cams, bearings, weather proof coatings.

2.4. PVC (Polyvinyl chloride)

This is a material used in automotive industry for the manufacture of the protection for the bottom floor in the car,
for internal lining and coating of electric cables in the vehicle. Polyvinyl chloride moulding compounds can be
extruded, injection moulded, compression moulded, calendared, and blow moulded to form a huge variety of
products, either rigid or flexible depending on the amount and type of plasticizers used. It has good resistance to
chemical and solvent attack. Its vinyl content gives it good tensile strength and some grades are flexible. Coloured
3810 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815

or clear material is available.PVC has good flexibility, is flame retardant, and has good thermal stability, a high
gloss, and low (to no) lead content.
Applications: automobile instruments panels, sheathing of electrical cables, pipes, doors, waterproof clothing, and
chemical tanks.

2.5. PP (Polypropylene)

This polyolefin is readily formed by polymerizing propylene with suitable catalysts, generally aluminum alkyl and
titanium tetrachloride. Polypropylene properties vary according to molecular weight, method of production, and the
copolymers involved. Generally polypropylene has demonstrated certain advantages in improved strength, stiffness
and higher temperature capability over polyethylene. Polypropylene has been very successfully applied to the
forming of fibers due to its good specific strength which is why it is the single largest use of polypropylene [1].
Polypropylene also happens to be one of the lightest plastics available with a density of 0.905 g/cm². It is extremely
chemically resistant and almost completely impervious to water. Black has the best UV resistance and is
increasingly used in the construction industry [2].
Applications: automotive bumpers, chemical tanks, cable insulation, battery boxes, bottles, Petrol cans, indoor and
outdoor carpets, carpet fibers.

2.6. PUR (Polyurethane)

Polyurethanes are a large family of polymers with wide range of properties and uses all based on the reaction
product of an organic isocyanate with compounds containing a hydroxyl group. Polyurethanes may be thermosetting
or thermoplastic, rigid and hard or flexible and soft, solid or cellular with great property variances. Principal
applications are in coatings, elastomers and foams. Polyurethane has excellent abrasion resistance but high
hysteresis. Rigid polyurethane foams have become widely used as insulation materials because of their combination
of low heat transfer and good cost effectiveness. Use as insulation and other applications are restricted by an upper
temperature capability of about 250°F. Polyurethanes do not survive well in direct sunlight or in contact with most
organic solvents. Two types of polyurethane are common: polyester based and polyether based, with these backbone
structures actually comprising a significant part of a so-called polyurethane resin. [3]
Applications: Flexible foam seating, foam insulation panels, elastomeric wheels and tires, automotive suspension
bushings, cushions, electrical potting compounds, hard plastic parts.

2.7. PS (Polystyrene)

Polystyrene is an amorphous, glassy polymer that is generally rigid and relatively inexpensive. Unfilled polystyrene
has a sparkle appearance and is often referred to as crystal PS or general purpose polystyrene (GPPS). High impact
polystyrene grades (HIPS) are produced by adding rubber or butadiene copolymer which increases the toughness
and impact strength of the polymer. Polystyrenes possess good flow properties at temperatures safely below
degradation ranges, and can easily be extruded, injection moulded, or compression moulded. Considerable quantities
of polystyrene are produced in the form of heat-expandable beads containing a suitable blowing agent which
ultimately results in familiar foamed polystyrene articles [4]. Naturally clear, polystyrene shows excellent chemical
and electrical resistance. Special high gloss and high impact grades are widely available. This easy to manufacture
plastic has poor resistance to UV light [5].
Applications: equipment housings, buttons, car fittings, display bases.

2.8. PE (Polyethylene)

Polyethylene is a member of the important family of polyolefin resins obtained by polymerizing ethylene gas,
H2C=CH2 and it is by far the largest volume commercial polymer. It is the most widely used plastic in the world.
This thermoplastic is available in a range of flexibilities and other properties depending on the production process,
with high density materials being the most rigid. Polyethylene can be formed by a wide variety of thermoplastic
 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815 3811

processing methods and is particularly useful where moisture resistance and low cost are required. Low density
polyethylene typically has a density value ranging from 0.91 to 0.925 g/cm³, linear low density polyethylene is in
the range of 0.918 to 0.94 g/cm³, while high density polyethylene ranges from 0.935 to 0.96 g/cm³ and above [6].
Applications: car bodies (glass reinforced), electrical insulation.

2.9. POM (Polyoxymethylene)

POM (Polyoxymethylene), also known as Acetal, Polyacetal and Polyformaldehyde, is a high performance
engineering polymer. It used in precision parts which require high stiffness, low friction and excellent dimensional
stability. These properties are stable in low temperatures. POM also is highly chemical and fuel resistant.
Applications: interior and exterior trims, fuel systems, small gears, window guides, speaker grills, zips, lighters,
aerosol valves, fasteners and furniture components.

2.10. PMMA (Acrylic)

PMMA (Acrylic) is a transparent thermoplastic; it is often used as a lightweight or shatter-resistant alternative to

glass and good UV and weather resistance, high optical quality and surface finish with a huge colour range. It’s
cheaper than PC but is also more prone to scratching and shattering.
Applications: windows, displays, screens.

2.11. PBT (Polybutylene terephthalate)

Polybutylene terephthalate has good chemical resistance and electrical properties, hard and tough material with
water absorption, very good resistance to dynamic stress, thermal and Dimensional stability, They are easy to
manufacture due to fast crystallization and fast cooling.
Applications: Fog lamp housings and bezels, sun-roof front parts, locking system housings, door handles, bumpers,
carburettor components etc.

2.12. PET (Polyethylene Terephthalate)

Polyethylene terephthalate has similar conditions as PBT, good thermal stability, good electrical properties, very
low water absorption and excellent surface properties. It is mostly used to create synthetic fibres and plastic
bottles. You may recognize it on clothing labels under the name “polyester”.
Applications: Wiper arm and their gear housings, headlamp retainer, engine cover, connector housings etc.

2.13. ASA (Acrylonitrile Styrene Acrylate)

ASA (Acrylonitrile styrene acrylate) material has great toughness and rigidity, good chemical Resistance and
thermal stability, outstanding resistance to weather, aging and yellowing, and High gloss. Be careful not to burn this
material. It will cause a toxic smoke.
Applications: Housings, profiles, interior parts and outdoor applications.

In automotive design, plastics have contributed to a multitude of innovations in safety, performance and fuel
efficiency; however it requires never-ending research and improvement. Leading experts say that the easiest and
least expensive way to reduce the energy consumption and emissions of a vehicle is to reduce the weight of the
vehicle. It is estimated that every 10% reduction in vehicle weight results in 5% to 7% fuel saving. Thus for every
kilogram of vehicle weight reduction, there is the potential to reduce carbon dioxide emissions by 20 kg. The
incorporation of the lightweight materials in automobiles is a necessity and our common need [7].
3812 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815

3. Technology Activities and Properties in Four Key Areas

Plastics industry is very important in supporting the automotive industry. Automobile engineers are working
together closely to optimize other systems and to meet the important challenges associated with enhancing
automotive safety. Automotive and plastics producers, along with their suppliers, have identified a preliminary
research plan and set of priorities. The Technology Integration Workshop Report presents R&D priorities in four
automotive areas that together capture the broad range of plastics applications in vehicles (Figure 2). These four
areas are Interiors, Bodies and Exteriors, Power train and Chassis Components, and Light weighting:

• Interior – Priorities for improving safety in the passenger compartment include making safety advances
affordable through innovative design and more efficient manufacturing capabilities, designing for increased
vehicle compatibility, accommodating an aging driver population, including more safety features in
reduced package space, and enhancing safety belt designs.

• Body & Exterior – From bumpers to body panels, laminated safety glass to rear parking assists, research
activities must include energy management technologies that resist vehicle intrusion, impede roof crush,
and reduce body and exterior weight without compromising safety performance.

• Power train & Chassis – Research in this area focuses on components that generate and deliver power and
include the frame and its working parts. R&D priorities include pursuing significant advancements in
engineering and research capabilities for designing with plastics, exploring new ways to optimize safety
and fuel efficiency, expanding predictive modelling capabilities for composite materials, and developing
the new safety components that will be required for future alternative vehicles and power train options.

• Light weighting – The transition to lightweight materials from conventional ones requires research
activities that will increase the overall value of plastics in automobiles; develop new, high-performance
components that lower the centre of gravity of a vehicle; improve crash avoidance and performance
systems; and enhance pedestrian safety.

Fig.2. Summary of Highest-Priority Research and Development Needed to Enhance Future Automotive Safety with Plastics
 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815 3813

4. Manufacturing Procedures of Automotive Parts Made of Polymeric Materials

Plastics industry is very important in supporting the automotive industry. Automobile engineers are working
together closely to optimize other systems, integrating injection and blow moulded parts offering a better product
without expensive assembly work. Plastics are also finding their way into the structural design of the cars (the most
complicated design problem is the tank fuel system, has been solved by the use of plastics).

4.1. Injection moulding

Injection moulding is the most important cyclic procedure of processing polymers and it is the most widely applied
procedure in manufacturing automobile parts.
Injection moulding of polymers is a process of shaping by injecting the polymeric substance of a required shear
viscosity from the preparation units into the temperature regulated mould cavity. By polyreaction and/or cross
linking or cooling the product, the mould part becomes suitable for demoulding [8].
The injection moulding procedure can be automated and it is suitable for manufacturing moulded parts of high
dimensional stability and complexity, as well as of different sizes. Injection moulding can be applied for low-
viscous liquids (e.g. integral-polyurethane foams) or polymeric melts (e.g. thermoplastic melts).
Before, the main principle of injection was piston injection, and today it is injection moulding with screw. The
material enters a heated melting cylinder through a funnel, where it is caught by the screw. The material melts, and
gathers at the top of the screw. When enough molten material is collected, the whole screw moves forwards and
injects the melt through a nozzle into the mould feed system. At the beginning of cooling the material contracts and
the melt continues to remain under post-pressure. Later, the screw returns into the initial position and prepares for
the new quantity of material, and the mould opens and the product is demoulded .
The injection moulding machines contain only one screw, and big injection moulding machines can inject up to 175
liters of melt at a time. Successful development of injection moulding of thermosets has significantly expanded their
field of application. The injection moulding of thermosets is especially competitive in the production of thick-wall
moulding parts, due to the much shorter cycle duration. For injection moulding of thermoset melts a machine can be
used which is also used for injection moulding of thermoplastics.
Elastomers can also be injection moulded, and elasto-thermoplastics are injection moulded in compliance with the
rules of injection moulding of thermoplastics.

4.2. Blow moulding

Blow moulding is a cyclic procedure of forming a preform into a product, hollow body which strengthens its shape
by cooling. Blow moulding is a very important processing procedure, meant for production of hollow articles or
one-side open hollow bodies. In the first phase of the production of hollow bodies by blow moulding a preform is
produced by extrusion or injection moulding. In the second phase the work piece is shaped. According to the method
of producing the preform the extrusion blow moulding and injection blow moulding are distinguished [8].
Extrusion blow moulding is most often used for the production of items of many thermoplastics such as polyolefin
(PP, PE), acrylonitrile/butadiene/styrene graft copolymer (ABS), rigid and flexible polyvinyl-chloride (PVC),
polyamide (PA) etc. The products can be axis-symmetrical, but also of irregular shape (e. g. fuel tanks in
automobiles).
The semi-product of the first phase of extrusion blow moulding, preform, is obtained from the extruder in the form
of a flexible pipe (hose). A part of the pipe is then enveloped in a mould made of light metal because of efficient
heat supply. The mould is closed and in the process one end of the pipe, usually the bot- 158 tom, is squeezed by the
mould and welded. The other end of the pipe is cut off and the blow moulding machine is inserted in it. By pressing
the blow moulding machine, the neck of the future product is formed. Compressed air is then blown through the
blow moulding machine, which widens the pipe and pushes it to the mould wall [8].
Injection blow moulding also consists of two work phases. In the first, the preform is made by injection blow
moulding, after completed pressing the moulded part remains on the core and is transferred usually by turning the
core, into the mould for blow moulding. Compressed air is then blown through the blow moulding machine core and
3814 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815

the product continues to be shaped as described for extrusion blow moulding. However, unlike extrusion blow
moulding, the products of injection blow moulding feature higher quality surfaces since there are no welded edges
and consequently no flash or waste material either.

4.3. Heat forming

The films, foils or plates cut from extruded or calendared strips are used as preforms for heat forming. The preforms
are also made by direct and indirect pressing, casting and compression forming of polypropylene. Many
thermoplastics are suitable for heat forming. In order to be formed, the preform must be in rubber state. Therefore
sometimes the still non-cooled strip is conducted directly to the forming machine, but more often the preform must
be heated, usually by exposing it to infrared beams or by contact with heated part of the machine [8].
Out of the heat forming procedures stretching is most widely used, that can be caused by mechanical compression,
air pressure or sub-pressure action, and combination thereof. The most frequent are the following forming
procedures by stretching [8]:
• Free stamp forming, unheated preform is formed freely (i. e. without matrix) by pressing the heated stamp.
• Forming by compressed air, the heated preform is printed by compressed air into the matrix.
• Free forming by compressed air.
• Forming in the matrix with sub-pressure, the perform is drawn into the matrix due to the sub-pressure in it.
• Forming in the matrix with stamp and sub-pressure, the preform is stamp printed into the matrix from
which the air is drawn out, and the preform clings closely to the matrix.
• Forming on stamp with sub-pressure, the perform is stretched by stamp in which there is sub-pressure and
it clings along the stamp and acquires its shape.

4.4. Extrusion

Extrusion is the most widely used processing procedure of polymeric materials. Extrusion is used to produce the so-
called continuous products or semi- products (extrudates), i.e. such products whose dimensions are not all final nor
precisely defined (such as e.g. rigid and flexible pipes, sticks and coated cables).
Extrusion is a procedure of continuous primary shaping, by pressing the liquefied polymers through nozzles. The
extruded polymer hardens in the product, extrudate by cooling, cross- linking or polymerization. Extrudate is
stacked or winded. The cyclic piston pressing is called extrusion. The thermo-sets and thermoplastic poly
(tetraphluorethylene) are extruded.

The basic elements of extrusion line are the extruder (machine) and the mould. The extruder serves to press the
liquefied thermoplastic obtained by softening or solving. It is pressed by worm rolls, screws or plates. The most
frequent are the single-worm extruders, but the extruders with several worms are also used.
Solid polymer in the form of granules or powder enters the extruder through a funnel. The entry of polymer is often
enhanced by pre-pressure or sub- pressure. The elastomers usually enter the extruder in the form of strips. The
polymer falls into the cylinder and then it is caught by the rotating worm screw and pressed towards the extruder
head. During the process the polymer is compressed, its volume is reduced, and it is also heated. If the heating of
polymer caused by friction is not sufficient, the extruder cylinder is heated on the outside by the electro-resistant
band heaters. By passing through the cylinder the softened polymer can be very well mixed and thermally and
mechanically homogenized [8].

5. Conclusions

The plastic materials have become reliable and are in demand in the automotive industries. As in future our
necessity will be high performance cars with greater comfort, safety, fuel efficiency, style, lower prices, lower
pollution levels and increased recovery at the end of life, but it requires never-ending research and improvement.
Continuous research and development in the plastics is key feature of the increased application of plastics in cars.
Use of plastics will continue in the future to help designers and engineers to innovate and take car performance
further.
 Akshat Patil et.al./ Materials Today: Proceedings 4 (2017) 3807–3815 3815

References

[1] http:// plastics.ulprospector.com / generics /39/ polypropylene-pp.ss.

[2] G.L Wilkes, B. Orler , H. Huang, Polymer Preparation, 26 (1985) 300-301.
[3] http:// plastics.ulprospector.com/generics/45/polyurethane-pur.
[4] http :// plastics.ulprosector.com/generics/43/polystyrene.
[5] J.E. Mark, C.Y.Jiang, M.Y. Tang, Macromolecules, 17(1984) 2613-2636.
[6] H. Qin,S . Zhang, C, Zhao, G. Hu, M . Yang, Polymers, 46 (2005) 8386-8395.
[7] S . Hotta, D.R. Paul, Polymer, 44(2003) 4993-5013.
[8] J.M. Mativetsky, W.R. Datars, Physica B: Physics of condensed matter, 324 (2002) 191-204.