Reinforced Plastics  Volume 00, Number 00  April 2015
Composite materials are more present
today than ever before in cars
Rosalı́a Guerra Tornero
Rosalı́a Guerra Tornero looks at the many reasons that encourage and push the composite materials
sector to be widely used in the market of cars manufacturing.
Apart from the economic reasons, the reduction of weight, the
regulations of an obligated compliance of the emissions control,
and the need of being more efficiency in the consumption of
combustible, are some reasons why parts of cars are more and more
manufactured with composite materials.
Innovator materials, like anionic polyamide composites based
on a mixture of caprolactam and additives which are processed
through typical thermoset composites techniques like Infusion or
RTM (Resin Transfer Molding), are an important innovation unlike
PA pieces obtained thought the traditional injection process, since
they need a lower temperature for its processing. In addition, this
kind of polyamides are obtained through a chemical reaction at a
temperature lower than the fusion temperature of the material, so
its demolding is possible even if the mold is warm without a
bulging of the piece. Apart from the composites with natural or
carbon fibers, the anionic polyamides have extended the range of
the use of composites, since they offer a significant improvement
in the main mechanical properties, if they are compared with the
traditional PA6-FV one or with epoxy/FV resins.
Recent studies carried out by the VW Group about the Pilar-B
show that this new generation of PA manufactured by RTM can
achieve a weight reduction up to 36% in this kind of pieces
(normally made of steel) and a better stability to heat and with
processability times which are around 3 min. All of this causes that
the production cost with this technology is more similar to the
traditional injection.
Apart from the innovative anionic polyamides, prepegs based on
thermoplastic materials like PP, PA and carbon fiber reinforcements
E-mail address: mllorens@aimplas.es.
0034-3617/ß 2015 Published by Elsevier Ltd. http://dx.doi.org/10.1016/j.repl.2015.01.004
Please cite this article in press as: R.G. Tornero, Reinf. Plast. (2015), http://dx.doi.org/10.1016/j.repl.2015.01.004
FEATURE
FEATURE
are also replacing technologies widely used like RTM, since they
offer lower processing times (60 min unlike the several minutes of
the thermoset pieces manufactured with RTM) and the possibility
of being recycled. Within the composites reinforced with carbon
fiber, there are also other studies which offer interesting compara-
tives as the saving in weight that can be achieved unlike the steal
(80%), aluminum (40%) or other composites reinforced with FV
manufactured through SMC (Sheet Moulding Compound). The big
disadvantage is the high cost of the carbon fibers unlike other
alternatives.
On the other hand, the composites incorporating natural fibers
offer, apart from respecting the environment, the big potential
that fibers like cellulose in terms of thermal, acoustic and anti-
vibrations isolation have, in addition to its famous good mechan-
ical properties which make them optimal for semi-structural
applications.
Without any doubt, one of the current goals is obtaining
composite materials from 100% renewable sources, without any
contribution to composites from petrol.
In this line, AIMPLAS, along with BOEING and other European
partners, have been recently finished the CAYLEY research project,
in which a panel which incorporates a biodegradable o recyclable
thermoplastic polymer or has been elaborated through a molding
process, using natural fibers as fabric reinforcement. Within the
CAYLEY project, the established strict requirements regarding the
resistance to fire of the panels defined according to the aeronautic
legislation. Currently, it is being working on the optimization of
their mechanical properties.
1