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RESEARCH PAPER PROPOSAL

GERM-352
Department of Mechanical Engineering
MILITARY INSTITUTE OF SCIENCE AND TECHNOLOGY (MIST)

Group 5 Level 3 Sec B ME 20

Member Information 1

Adnan Shahriar 202218006

Name Student ID

Member Information 2

Md. Sakin Islam 202218060

Name Student ID

Member Information 3

Md. Sazzad Ahmed Sabbir 202218063

Name Student ID
Member Information 4

Mehedi Hasan Mugdho 202218072

Name Student ID

Member Information 5

Tahmid Muntasir Auhin 202218106

Name Student ID
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Title:
Mechanical Behavior of Fiberglass and Aluminum for Firewall Barriers in Automobiles.

Background Study:
SAE (Society of Automotive Engineers) conducts Formula SAE (FSAE) competition in which student build, design, and compete in small
formula styled race car which help in providing the educational theory and hands on experience (Beckel et al., 1982). The competition
promotes smarter, cheaper, and safer technologies for race cars, guided by Formula SAE Rulebooks. A firewall must separate the driver
compartment from the fuel supply system, hydraulic fluid (except brakes and dampers), flammable liquids, the low voltage battery, and any
TS components. The firewall must be a non-permeable surface made from a rigid, fire-resistant material such as Nomex, Aramid, Belcotex
and Indura which must be rigidly mounted to the vehicle’s structure (Formula SAE Rules 2024 Version 1.0, 2024). The most commonly used
material-carbon fiber often is an unrealistic option for teams to use due to its cost which leads us to find alternative materials.

Problem Statement: Rational, Justification & Significance

High cost of Carbon Fiber in Formula SAE (FSAE) Firewall Barriers Calls for Alternative Materials
Carbon fiber is the preferred material for firewall barriers in FSAE racing cars due to its exceptional strength-to-weight ratio and heat
resistance (Herbstreit, 2017.) but its high cost hinders student team budgets, forcing trade-offs between safety and optimizing other car
aspects. This ultimately creates a financial barrier towards innovation.
Finding a cost-effective, yet safe, alternative material is crucial to ensure driver safety and promote innovation in FSAE competitions.

Purpose of Study: Specific Objective & Research Hypothesis

This paper aims to identify a cost-effective alternative material to carbon fiber for firewall barriers in FSAE cars. The objective is to find a
material that has the following properties:
• To provide adequate strength and heat resistance to meet FSAE safety regulations.
• To offer a significant cost reduction.
• To maintain a lightweight design without compromising the car's overall performance.
The conclusion of the paper is expected to show Fiberglass or Aluminum as a cost-effective alternative to carbon fiber for FSAE firewall
barriers while maintaining adequate strength, heat resistance, and weight for car performance.

Literature Review:
The firewall barrier in Formula Student vehicles is a critical safety feature designed to protect the driver from fire hazards from the engine
or fuel system. This research explores various materials and design considerations for firewall barriers in Formula Student competitions.
Several materials are commonly used, each with distinct advantages and limitations. Aluminum is frequently chosen due to its lightweight
properties and ease of fabrication. Research highlights aluminum’s effectiveness in providing thermal resistance and maintaining structural
integrity under high temperatures (Shah et al., 2022). However, its low melting point poses risks during severe fire events. CFRP can
withstand higher temperatures without compromising structural integrity, making it ideal for high-performance applications (KUMAR et
al., 2018). However, the cost and complexity of manufacturing CFRP can be prohibitive for some teams.

The design of the firewall barrier must balance safety, weight, manufacturability, and cost (Peijs et al., 2022). Aerodynamic considerations
also influence firewall design. The shape and positioning of the firewall significantly impact vehicle aerodynamics (Jacuzzi, 2020).
Integrating the firewall into the vehicle’s structural framework can enhance both safety and performance, reducing drag and improving
airflow.

Recent advancements in materials science have introduced new possibilities for firewall barriers. Nanocomposite materials, incorporating
nanoparticles into traditional composites, have shown promise in laboratory settings (Shah et al., 2022). These materials exhibit superior
fire resistance and mechanical properties compared to conventional composites. Further research and development are required to evaluate
their practicality and cost-effectiveness in Formula Student applications.

In conclusion, exploring fiberglass and aluminum as alternatives to carbon fiber in firewall barriers for FSAE cars reveals significant
potential. While carbon fiber is preferred for its exceptional strength-to-weight ratio and thermal resistance, its high cost and manufacturing
complexity necessitate evaluating other materials. Fiberglass, with its cost-effectiveness, ease of manufacturing, and adequate mechanical
properties, presents a promising substitute, especially for budget-constrained teams (Hilles & Ziara, 2019). Aluminum, known for its
excellent thermal conductivity, durability, and availability, also emerges as a strong candidate where thermal management and structural
integrity are prioritized (Kadaru et al., 2020). This analysis aims to guide FSAE teams in selecting materials for firewall barriers that
balance performance, safety, and cost-efficiency.
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Material & Methodology: Subjects, Materials, Procedure, Data Management of Analysis

The study seeks to assess the viability of using fiberglass and aluminum as alternatives to
Carbon fiber in the firewall barriers of Formula SAE (FSAE) student vehicles. For aluminum,
sheets of 5052 or 6061 alloy with thicknesses ranging from 1 to 3 mm will be employed.
For fiberglass, either cloth or mat forms will be used in conjunction with compatible epoxy
or polyester resin systems. Carbon fiber composite materials will serve as the baseline for
comparison in this study. Thermal resistance of the materials will be measured using a thermal
conductivity analyzer, while them structural integrity and strength will be evaluated using a
tensile testing machine. Fabrication tools such as metal shears, jigsaws, CNC machines,
brushes, rollers, and mixing containers for fiberglass will be utilized. Multiple trials will be
conducted to ensure the consistency, reliability and validity of the results.

This study involves a comparative experimental analysis of aluminum, fiberglass, and

carbon fiber (used as the baseline). Aluminum sheets will be cut using a CNC machine,
while fiberglass panels will be prepared by layering fiberglass cloth with resin and
allowing proper curing. The thermal resistance of each material will be measured and
calculated to determine their heat resistance. Tensile tests will be performed to assess
the maximum load each material can withstand before failure. Additionally, the weight
of each firewall barrier sample will be accurately measured.

All raw data will be stored in a digital format with backups, and standardized data sheets
will be used to systematically record all measurements and observations. Fiberglass and
aluminum will be compared to carbon fiber using statistical analysis, such as ANOVA,
to identify significant differences. The study will highlight any trade-offs between weight
and performance and determine which material offers the best structural performance.
The cost of materials and fabrication will also be considered to evaluate the overall feasibility
of replacing carbon fiber with fiberglass or aluminum. By following this structured approach,
the study aims to provide a comprehensive comparative analysis of fiberglass and aluminum
as potential replacements for carbon fiber in FSAE firewall barriers, balancing factors such as
thermal resistance, weight, and structural integrity.

Gantt chart and Flowchart of Research:

Total time Academic week 6 – 13, Mid break 2 weeks
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References:
Beckel, S. A., Obregon, S., & Matthews, R. D. (1982). The 1982 National Intercollegiate Formula SAE Competition. 821093.
https://doi.org/10.4271/821093
Formula SAE Rules 2024 Version 1.0. (2024).
Herbstreit, B. (n.d.). Seat & Firewall Design for Cornell Racing FSAE.
Hilles, M. M., & Ziara, M. M. (2019). Mechanical behavior of high strength concrete reinforced with glass fiber. Engineering Science and
Technology, an International Journal, 22(3), 920–928. https://doi.org/10.1016/j.jestch.2019.01.003
Jacuzzi, E. A. (2020). Unsteady Aerodynamics and Flow Control for Race Car Applications.
https://www.lib.ncsu.edu/resolver/1840.20/37278
Kadaru, S., Manickam, M. B., Karthikeyan, R., Prashanth, S., & Reddy, B. (2020). A Review on Mechanical and Thermal Properties of
Aluminum Metal Matrix Composites. E3S Web of Conferences, 184, 01033. https://doi.org/10.1051/e3sconf/202018401033
Kumar, R., Giriraj, B., Kumar, S., & Suresh, A. R. (2018). Study of Mechanical Properties of Jute/Carbon fiber Reinforced Polymer
Hybrid Composites for Automotive Applications. Journal of the Balkan Tribological Association, 24(2), 222–237.
Peijs, T., Kirschbaum, R., & Lemstra, P. J. (2022). Chapter 5: A critical review of carbon fiber and related products from an industrial
perspective. Advanced Industrial and Engineering Polymer Research, 5(2), 90–106. https://doi.org/10.1016/j.aiepr.2022.03.008
Shah, V., Bhaliya, J., Patel, G., & Deshmukh, K. (2022). Advances in polymeric nanocomposites for automotive applications: A review. 33,
3023–3048. https://doi.org/10.1002/pat.5771

Budget: