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 Introduction
 The automotive industry is mature for a revolution and the plastics
industry is readyto play an important role.
 The real plastics revolution in automotive industry began in 1950 when
thermoplastics made their debut, starting with ABS and going on to
polyamide, polyacetal and polycarbonate together with introduction of
alloys and blends of various polymers.
 The ongoing development of advanced, high-performance polymers has
dramatically increased their usage.
 Originally plastics were specified because they offered good mechanical
properties combined with excellent appearance, including the
possibility of self-coloring.
 The application of plastic components in the automotive industry has
been increasing over the last decades.
 Nowadays, the plastics are used mainly to make cars more energy
efficient by reducing weight, together with providing durability,
corrosion resistance, toughness, design flexibility, resiliency and high
performance at low cost.

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  Introduction
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 Increasing use of
plastics in automobiles
• The automotive industry uses
engineered polymer composites and
plastics in a wide range of
applications, as the second most
common class of automotive
materials after ferrous metals and
alloys cast iron, steel, nickel which
represent 68% by weight;
• other non-ferrous metals used
include copper, zinc, aluminum,
magnesium, titanium and their
alloys.
 The plastics contents of commercial
vehicles comprise about 50 % of all
interior components, including safety
subsystems, doorand seat assemblies.

Fig.2 Hybrid construction of a vehicle, combination of

aluminum light blue colour , magnesium red colour ,
plastics dark blue colour and steel green colour
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  Introduction
During the enormous growth of plastics components in automotive, the
advantages ofusing plastics have changed
1. Mounting costs are being met by the ability of plastics to be molded into
components of complex geometries, often replacing several parts in
other materials, and offering integral fitments that all add up to easier
assembly.

2. Many types of polymers are used in more than thousand different parts
of all shapes and sizes.

3. A quick look inside any model of the car shows that plastics are now used
in exterior and interior components such as bumpers, doors, safety and
windows, headlight and side view mirror housing, trunk lids, hoods,
grilles and wheel covers.

4. Even if up to 13 different polymers may be used in a single car model

just three types of plastics make up some 66 % of the total plastics used
in a car: polypropylene 32% , polyurethane 17 % and PVC 16 %

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  Materials
PP – polypropylene is extremely chemically resistant and almost completely
impervious to water. Black has the best UV resistance and is increasingly used
in the construction industry.
Application: automotive bumpers, chemical tanks, cable insulation, battery
boxes, bottles,petrol cans, indoor and outdoor carpets, carpet fibers,
PUR – polyurethane materials are widely used in high resiliency flexible foam
seating, rigid foam insulation panels, microcellular foam seals and gaskets,
durable elastomeric wheels and tires, automotive suspension bushings,
electrical potting compounds, hard plastic parts for electronic instruments ,
cushions.
PVC – poly-vinyl-chloride has good resistance to chemical and solvent attack.
Its vinyl content gives it good tensile strength and some grades are flexible.
Colored or clear materials available.
Application: automobile instruments panels, sheathing of electrical cables,
pipes, doors, waterproof clothing, chemical tanks

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  Materials
PET - polyethylene terephthalate has similar conditions as PBT polybutylene ,
good thermal stability, good electrical properties, very low water absorption,
excellent surface properties.
Application: wiper arm and their gear housings, headlamp retainer, engine
cover, connector rhousings
ABS – acrylonitrile-butadiene-styrene is a durable thermoplastic, resistant to
weatherand some chemicals, popular for vacuum formed components.
It is a rigid plastic with rubber like characteristics, which gives it good
impactresistance.
Application: car dashboards, covers
PA – polyamide is known as nylon 6.6 or nylon 6. Both these nylons have high
resistance to abrasion, low friction characteristics and good chemical
resistance.
They also absorb water easily and components in wet or humid conditions will
expand, precluding their use in applications where dimensional stability is
required.
Application: gears, bushes, cams, bearings, weather proof coatings,

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  Materials
PS – polystyrene is very popular, ease to manufacture, but has poor
resistance to UVlight.
Application: equipment housings, buttons, car fittings, display bases,
PE – polyethylene has good chemical resistance. Two types are used, low
density polyethylene LDPE and high density polyethylene HDPE can be
manufactured in a range of densities.
Application: glass reinforced for car bodies, electrical insulation,
packaging, where strength and aesthetics are important
POM – polyoxymethylene also know as polyacetal or polyformaldehyde has
big stiffness, rigidity and excellent yield, which are stable in low temperatures
as well. Very good chemical and fuel resistance.
Application: interior and exterior trims, fuel systems, small gears,
PC – polycarbonate has good weather and UV resistance, with
transparency levelsalmost good as acrylic.
Applications: security screens, aircraft panels, bumpers, spectacle lenses,
headlamplenses

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  Materials
PMMA – acrylic is more transparent than glass, has reasonable tensile
strength shatter proof grades are available and good UV and weather
resistance, high optical quality and surface finish with a huge colour range.
Application: windows, displays, screens,
PBT – polybutylene terephthalate has good chemical resistance and electrical
properties, hard and tough material with water absorption, very good
resistance to dynamic stress, thermal and dimension stability. Easy to
manufacture - fast crystallization, fast cooling.
Application: fog-lamp housings and bezels, sun-roof front parts, locking
system housings, door handles, bumpers, carburetor components,

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  Technology activities and priorities

 In automotive design, plastics have contributed to a multitude of

innovations in safety,
 Performance and fuel efficiency, but 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 in5% to 7% fuel saving.
 Thus for every kilogram of vehicle weight reduction, there is the
potential to reduce carbon dioxide emissions by 20kg.
 The incorporation of the lightweight materials in automotive is a
necessity and our common need.

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 Pros of Plastic Components
1. One of the biggest benefits of using plastic components is the
ability to fabricate entirely new parts that combine multiple
pieces into one molded part.
2. Most metal pieces need to be individually fabricated and welded
together, but plastic parts can be intricately designed from the start
Some other pros of plastic components are:
 Lightweight
 Easier to form and highly malleable
 Fewer parts less assembly time
 Resistant to chemical reactions such as oxidation or corrosion
 Easier to machine and very malleable
 Reduced finishing time for paint or other post-treatment
processes

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 Cons of Plastic Components
1. Despite their lightweight design and customization
opportunities, plastic components are notwithout flaws.
2. For example, polypropylene can start to degrade if it’s exposed
to extreme temperature. This would likely cause the rest of a
machine to need recalibration so as not to harm the
polypropylene part.
Some other cons of plastic components are:
 UV inhibitors needed to prevent cracking and discoloration from
prolonged UV exposure
 Limited resistance to heat and acidity
 Generally weaker in structure than metal

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 Technology activities and priorities
Plastics industry is very important in supporting the automotive
industry.
Automobile engineers are working together closely to optimize other
systems, integrating injection and blow molded 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 the tank fuel system has
been solved thanks to plastics .
There are four areas requires highest-priority research and
development with plastics. These are:
• interior,
• body and exterior,
• powertrain and chassis,
• Light-weighting.

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 Technology activities and priorities
Interior
Priorities for improving safety in the passenger compartment include:
1. making safety advances affordable through innovative design
and more efficient manufacturing capabilities,
2. designing for increased vehicle compatibility,
3. accommodating an aging driver population,
4. including more safety features in reduced package space, and
5. enhancing safety belt designs

Interior of a typical vehicle

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 Technology activities and priorities
Automotive Body Exterior
Plastics and polymer composites have revolutionized the design of body
exteriors.
From bumpers to door panels, light weight plastic provides vehicles with
better gas mileage and allows designers and engineers the freedom to create
innovative conceptsthat otherwise would be impossible.
In the past, metals were synonymous with auto body exterior design and
manufacturing.

Body and Exterior of a typical vehicle bumper, body panels and trims

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 Technology activities and priorities
Automotive Safety –
• The versatility of plastics allows design options that reduce vehicle weight
while producing safer vehicles.
• Included are plastic composite structures in the front end of a vehicle that
reduce vehicle weight without compromising safety and plastic components
in crumple zones that help absorb energy while lowering vehicle weight.
• Plastics are also used in door modules to maintain or improve side impact
safety, plastic layers in automotive safety glass prevent passenger injuries,
and plastic foams can add strength to automotive body cavities and increase
occupant safety in vehicles.
Automotive Electrical Systems –
• Over the last 20 years, the electrical systems of light vehicles have undergone
a major revolution. Automotive electrical and electronic system components
are now more numerous and important with computer chips regulating and
monitoring ABS brakes, fuel injection, and oxygen sensors, GPS navigation
equipment, obstacle sensors, state-of-the-art audio systems, and other
systems.
• Plastics make possible the inclusion, operation, interconnection and housing
of sockets, switches, connectors, circuit boards, wiring and cable, and other
electrical and electronic devices.
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 Technology activities and priorities
Automotive Chassis
• A chassis is the supporting frame of a light vehicle. It gives the vehicle
strength and rigidity, and helps increase crash-resistance through energy
absorption.
• The chassis is especially important in ensuring low levels of noise, vibration
and harshness NVH throughout the vehicle.
• Not only does a reduction in NVH allow for a more pleasant driving
experience, but by putting less stress on connecting components it can help
increase the life span of these components.
• The key determinant permitting reduced levels of NVH is energy absorption.
As a result, passenger protection can be enhanced in the event of a collision.
• Plastics are making inroads into the chassis market. Innovations in plastic
technology have brought about the development of successful chassis
applications and structure, support and suspension performance.

Powertrain and chassis of a typical vehicle

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 Technology activities and priorities
Automotive Powertrain
• The powertrain is one of a light vehicle’s most complicated parts.
• The term "powertrain" refers to the system of bearings, shafts, and gears
that transmit the engine's power to the axle. Included are composite drive
shafts that increase torque. Plastics help reduce the number of parts needed
to assemble these complex components
• Plastics also help reduce vehicle weight, which helps lower assembly costs
while increasing fuel efficiency.
• For example, the utilization of lightweight plastics in a vehicle can allow
manufacturers to utilize smaller, lighter weight engines.

Powertrain and chassis of a typical vehicle

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 Technology activities and priorities
Automotive Fuel System
• For automotive fuel system components, plastics have several advantages
that enable it to outperform metals.
• Plastic frees engineers from the design constraints that metal imposes.
• Plastic's light weight makes vehicles more fuel-efficient and from a safety
standpoint, rupture-resistant plastics with high impact strength are
helping keep automotive fuel tanks and related delivery systems leak-
proof, corrosion-resistant, and reliable.

Automotive Engine Components

• Many of today's automotive engine components are plastic.
• From air-intake manifolds and systems to cooling systems to valve covers
and other engine parts, plastic helps make engine systems easier to
design, easier to assemble, and lighter in weight.
• Plastics‘ versatility has revolutionized automotive engine component
design.

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 Technology activities and priorities
• The automotive market is an important market for plastic resins such as
nylon polyamides , other engineering polymers, and thermoplastic
polyesters.
• Light vehicle applications often account for over 30% of the demand
for each resin. Other resins include ABS and polyvinyl butyral.
• For the latter resin which is used in safety glass, the automotive market
accounts for over 85% of total demand. Engineering polymers such as
nylon, polycarbonate and polycarbonate blends and others are
supplanting metals in many applications.

• Typical plastics and composite applications include exterior panels, trim,

and bumper fascia, as well as interior trim panels, window
encapsulation, headlamp housings, manifolds and valve covers,
electronic/electric parts and components, wiring harnesses, steering
wheels, insulation, dampening and deadeners, upholstery, mechanical
parts and components, safety glass, and myriad other uses.

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 Technology activities and priorities
Light weighting
For example the marketplace offers new ultra light-weight wheel trims
successfully, which provides innovation in products with high rigidity and low
weight these components had to put through high testing due to control of
resistance to the weather conditions and long lifetime .
Continuous development of new PP types allows the replacement of steel in
automotive in the near future as well for example new type GB 266 WG is hard,
light material with perfect heat resistance and mechanical properties; suitable
for products used in high stress areas .

 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 center of gravity
of a vehicle;
 improve crash avoidance and performance systems; and enhance pedestrian
safety.

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 Technology activities: Plastic Welding

• Plastics are used in day to day life for manufacturing of toys, utensils
and complicated part such as heart valve for medical use etc.
• Plastic parts are frequently used in many industries.
• Plastics have ability to take good finish, excellent strength to weight
ratio and good corrosion resistance.
• There are two types of plastics, thermosets and thermoplastics out of
which only thermoplastic is able to be welded.
• A chemical reaction occurs during processing and curing in case of
thermosets resin, that is, as a result of irreversible cross-linking
reaction in the mold.
• Molded thermosets components cannot be reshaped by applying heat,
because of the irreversible reaction that occur. And thus in this case
joining can be obtained by mechanical fastening and adhesive bonding
only.

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 Technology activities: Plastic Welding
• But, thermoplastics are able to be softened and remolded by means
ofheating, and can fusion welded.
• Therefore thermoplastics are able to be welded by following
three methods: Thermal, Friction and Electromagnetic.
• Further the types of Thermal plastic welding are a Hot air technique
b Hot tool method c Laser beam heating d Infrared heating.

• PVC plastics are different from other geomembrane like HDPE, LLDPE,
and FPP because it is primarily amorphous while others are semi-
crystalline.
When PVC is heated it will soften, that allow a limited amount of chain
entanglements to assure a strong bond.

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 Plastic - Growing demand in the automotive sector
By volume, from bumper to bumper,
cars today contain more plastics than
traditional materials.
Yet, thanks to their light weight, they
account for on average only 9.3 per
cent or 105kg of the total weight.

Different types of polymer are used

in over 1000 parts of all shapes and
sizes, from all plastics dashboards
and fuel tanks to radiator grilles.
Each polymer in turn can be tailored
to meet exact technical, safety,
economic, environmental and
aesthetic specifications

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 Plastic Welding System: The method
• With laser beam-transmission welding, a laser transparent component and
laserabsorbing component are always merged.
• Prior to being welded, the join partners are positioned and then pressed together.
• In the actual fusion process, the laser beam gets through the transparent
component without significantly heating it up.
• But now, the absorbing component takes the laser energy so that it is
heated at the surface.
• This energy is transferred via heat
conduction onto the surface of the
transparent component at transparent
laser plastic welding.
• The absorbed energy plasticizes the
plastic which, with pressure and heat
conduction, leads to a joining of the
components.
• The existing joining pressure results in a
substance-to-substance bond for both
parts. The firmness of the resulting
welding is within the typical area of base
material strength.

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 Plastic Welding System: The method

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