Lightweight and sustainable materials for automotive applications

Lightweight and

Sustainable Materials for

Automotive Applications

Edited by

Omar Faruk • Jimi Tjong • Mohini Sain

Faruk

Tjong

Sain for Automotive Applications Lightweight and Sustainable Materials

K27551

www.crcpress.com

MATERIALS SCIENCE AND ENGINEERING/AUTOMOTIVE ENGINEERING

Automotive manufacturers are required to decrease CO2

emissions

and increase fuel economy while ensuring driver comfort and safety.

In recent years, there has been rapid development in the application

of lightweight and sustainable materials in the automotive industry to

help meet these criteria. This book provides critical reviews and the

latest research results of various lightweight and sustainable materi￾als in automotive applications. It discusses current applications and

future trends of lightweight materials in the automotive area. While

there are a few books published mainly focusing on automotive appli￾cations of metallic lightweight materials, to date there is no available

book focusing on a broad spectrum of lightweight materials, includ￾ing metal, plastic, composites, bio-fiber, bio-polymer, carbon fiber,

glass fiber, nanomaterials, rubber materials, and foaming materials, as

this work does. The book also includes case studies of commercial

lightweight automotive parts from sustainable lightweight materials,

providing an invaluable resource to those involved in this in-demand

research and commercialization area.

• Covers metal, plastic, composites, bio-fiber, bio-polymer, carbon

fiber, glass fiber, nanomaterials, rubber materials, and foaming

materials

• Features case studies of commercial lightweight automotive parts

developed from sustainable lightweight materials

• Offers lifecycle analysis

• Discusses applications and future trends

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Lightweight and Sustainable Materials

for Automotive Applications

ISBN: 978-1-4987-5687-7

9 781498 756877

90000

Lightweight and Sustainable

Materials for Automotive

Applications

http://taylorandfrancis.com

Lightweight and Sustainable

Materials for Automotive

Applications

Edited by

Omar Faruk

Jimi Tjong

Mohini Sain

CRC Press

Taylor & Francis Group

6000 Broken Sound Parkway NW, Suite 300

Boca Raton, FL 33487-2742

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To My Beloved Wife

Shaila Shumi

and

My Beloved Daughter

Ornela Suhiya

Omar Faruk

To My Beloved Wife

Jasmin Reyes Tjong

and

My Beloved Daughter

Dr. Vehniah Kristin Tjong

Jimi Tjong

http://taylorandfrancis.com

vii

Contents

Preface.......................................................................................................................ix

Editors.......................................................................................................................xi

Contributors........................................................................................................... xiii

Chapter 1 Natural Fiber Reinforced Thermoplastic Composites..........................1

Omar Faruk, Birat KC, Ahmed Sobh, Jimi Tjong, and Mohini Sain

Chapter 2 Bio-Fiber Thermoset Composites ......................................................39

Ashok Rajpurohit and Frank Henning

Chapter 3 Wood Fiber Reinforced Thermoplastic and Thermosets Composites...93

Arne Schirp

Chapter 4 Bio-Based Thermoplastic and Thermosets Polymer........................ 139

Hans-Josef Endres

Chapter 5 Bio-Based EPDM Rubber and Sustainable EPDM Compounding ... 167

Martin van Duin, Philip Hough, Joyce Kersjes, Marjan van Urk,

M. Montserrat Alvarez Grima, and Niels van der Aar

Chapter 6 Carbon Fiber Composite Materials..................................................203

Abdullah Al Mamun, Moyeenuddin Ahmad Sawpan,

Mohammad Ali Nikousaleh, Maik Feldmann, and Hans-Peter Heim

Chapter 7 Glass Fiber Composite Materials..................................................... 239

T. Palanisamy Sathishkumar

Chapter 8 Lightweight Nanocomposite Materials............................................277

Wojciech (Voytek) S. Gutowski, Weidong Yang, Sheng Li,

Katherine Dean, and Xiaoqing Zhang

Chapter 9 Tribology of Aluminum and Aluminum Matrix Composite

Materials for Automotive Components............................................303

Sandeep Bhattacharya and Ahmet T. Alpas

viii Contents

Chapter 10 Magnesium and Its Alloys................................................................ 329

D. Sameer Kumar and C. Tara Sasanka

Chapter 11 Thermoplastics Foams: An Automotive Perspective .......................369

Sai Aditya Pradeep, Srishti Shukla, Nathaniel Brown,

and Srikanth Pilla

Chapter 12 Lightweight Thermoset Foams in Automotive Applications........... 401

Numaira Obaid, Mark T. Kortschot, and Mohini Sain

Chapter 13 Life Cycle Assessment of Lightweight Materials for Automotive

Applications...................................................................................... 423

Masoud Akhshik, Jimi Tjong, and Mohini Sain

Chapter 14 Case Studies—Sustainable and Lightweight Automotive Parts

via Injection Molding ....................................................................... 453

Birat KC, Omar Faruk, Mohini Sain, and Jimi Tjong

Index...................................................................................................................... 471

ix

Preface

World automotive manufacturers are required to decrease CO2 emissions and increase

fuel economy while assuring driver comfort and safety. In recent years, there has

been rapid development in lightweight and sustainable materials application in the

automotive industry to meet the above-mentioned criteria. Researchers are seeking to

develop vehicle lightweighting strategies that will allow them to cost-effectively meet

fuel economy targets, and increasingly shifting their focus to incorporating mixed￾material solutions at mass produced scales. The global automotive lightweight mate￾rials market is expected to grow at a CAGR of 8.1% during 2014–2019. The major

drivers of the global automotive lightweight materials market are government regula￾tions on fuel economy and emission controls, increasingly stringent safety regulations,

high vehicle production, increasing use of lightweight materials, higher gasoline prices

and fuel economy, and replacement of traditional materials. Aluminum, magnesium,

and carbon fiber are emerging to be the frontrunners in achieving lightweight results.

Besides these materials, composite materials, thermoplastic, thermoset polymer,

rubber material, nanocomposite materials, and foaming materials are also significantly

employed as lightweight materials in automotive applications. The appeal of bio-based

parts for use in the next generation of vehicles is increasing, and there are compel￾ling factors such as stringent fuel economy, emissions regulations, and sustainability

at work. There is rising demand for lighter-weight materials, which can translate into

huge energy and cost savings for manufacturers. Bio-fiber reinforced composite mate￾rials are not only lightweight, they also reduce dependence on nonrenewable resources

such as conventional petroleum-based polymeric plastics, which are fossil-fuel materi￾als. Biocomposite materials are made from renewable resources and the latest gen￾eration can achieve price-performance competitiveness, potentially lowering costs

for both manufacturers and consumers. These factors have prompted the Ford Motor

Company and other automakers to invest in bio-based material research. However,

there are challenges to overcome before these materials can be more widely adopted.

This book provides critical reviews and the latest research results and applications

of various lightweight and sustainable materials in automotive applications. It also pro￾vides current applications and future trends of lightweight materials in the automotive

area. In recent years, enormous research and commercialization have been performed

with lightweight and sustainable materials. There are few books published on light￾weight materials in automotive applications mainly focusing on metallic lightweight

materials. To date, no book has been published that focuses on lightweight materials

including metal, plastic, composites, bio-fiber, bio-polymer, carbon fiber, glass fiber,

nano materials, rubber materials, and foaming materials. Therefore, this book will be

a significant guide to academia, researchers, and industries that are involved in this

current in-demand research and commercialization area.

Omar Faruk

Jimi Tjong

Mohini Sain

http://taylorandfrancis.com

xi

Editors

Dr. Omar Faruk works at the Powertrain Engineering

Research & Development Centre of Ford Motor

Company, Canada. He is also an adjunct professor at the

Centre for Biocomposites and Biomaterials Processing,

University of Toronto, Canada. He earned his PhD in

mechanical engineering from the University of Kassel,

Germany, and was previously a Visiting Research

Associate at Michigan State University. He has more

than 75 publications to his credit including 12 book

chapters which have been published in different inter￾national journals and conferences. He also edited two

books, titled Biofiber Reinforcement in Composite

Materials and Lignin in Polymer Composites, published by Woodhead Publishing

Ltd and Elsevier Ltd, respectively. In addition, he is an invited reviewer for 69 inter￾national reputed journals, government research proposals, and book proposals.

Dr. Jimi Tjong is the Technical Leader and Manager of

the Powertrain Engineering, Research & Development

Centre of Ford Motor Company, Canada. He earned his

PhD in mechanical engineering from the University

of Windsor, Canada, and he has worked for more than

30 years at Ford Motor Company. His principal field

of research and development encompasses optimizing

automotive test systems for cost, performance, and full

compatibility. It includes the development of test meth￾odology and cognitive systems, calibration for internal

combustion engines, alternative fuels, bio fuels, lubri￾cants and exhaust fluids, lightweight materials with the

focus on aluminum, magnesium, bio materials, batteries,

electric motors, super capacitors, stop/start systems, HEV, PHEV, BEV systems,

nano sensors and actuators, high performance and racing engines, nondestructive

monitoring of manufacturing and assembly processes, advanced gasoline and diesel

engines focusing on fuel economy, and performance and cost opportunities. He has

published and presented numerous technical papers in the above fields internation￾ally. Dr. Tjong is also an adjunct professor at the University of Windsor, McMaster

University and the University of Toronto in Canada. He mentors graduate students in

completing course requirements as well as career development coaching.

xii Editors

Prof. Mohini Sain specializes in advanced nano￾cellulose technology, biocomposites, and bio￾nanocomposites at the University of Toronto,

Faculty of Forestry. He is cross-appointed to

the Department of Chemical Engineering and

Applied Chemistry. He is a fellow of the Royal

Society of Chemistry, UK, and a Fellow of the

Canadian Engineering Society. He is also an

adjunct professor at the University of Guelph

and the University of Lulea, Sweden; an honor￾ary professor at the Slovak Technical University

and the Institute of Environmental Science at

the University of Toronto; and collaborates with

American and European research institutes and

universities. Prof. Sain is the recipient of sev￾eral awards, most recently the Plastic Innovation Award and KALEV PUGI Award

for his innovation and contribution to the industry. He is the author of more than

400 papers and is designated as a “high-cited” researcher by Reuter Thompson.

Prof. Sain hugely contributed to the society at large by translating research to com￾mercialization. He has tens of patents, 30 technology transfers to industry, and created

new companies for making products ranging from packaging to automotive to build￾ing construction to packaging materials. He is also the co-author of the world’s first

book on cellulose nanocomposites, cellulose for electronic devices, and has co-edited

a number of books on renewable advanced materials. Prof. Sain’s role as a pioneer in

creating nonprofit organizations is highly meaningful for society at large.

xiii

Contributors

Masoud Akhshik

Centre for Biocomposites and

Biomaterials Processing

University of Toronto

Toronto, Ontario, Canada

Abdullah Al Mamun

Adler Pelzer Group

HP Pelzer Holding GmbH

Witten, Germany

Ahmet T. Alpas

Engineering Materials Program

Department of Mechanical, Automotive

and Materials Engineering

University of Windsor

Windsor, Ontario, Canada

M. Montserrat Alvarez Grima

ARLANXEO Performance Elastomers

Geleen, the Netherlands

Sandeep Bhattacharya

Engineering Materials Program

Department of Mechanical, Automotive

and Materials Engineering

University of Windsor

Windsor, Ontario, Canada

Nathaniel Brown

Department of Automotive Engineering

Clemson University

Greenville, South Carolina

Katherine Dean

Industrial Interfaces Team,

Commonwealth Scientific and

Industrial Research Organisation

(CSIRO), Manufacturing Flagship

Melbourne, Australia

Hans-Josef Endres

Institute for Bioplastics and

Biocomposites

University of Applied Sciences and Arts

Hanover, Germany

Omar Faruk

Centre for Biocomposites and

Biomaterials Processing

University of Toronto

Toronto, Ontario, Canada

Maik Feldmann

Institute for Materials Engineering,

Polymer Engineering

University of Kassel

Kassel, Germany

Wojciech (Voytek) S. Gutowski

Industrial Interfaces Team,

Commonwealth Scientific and

Industrial Research Organisation

(CSIRO), Manufacturing Flagship

Melbourne, Australia

and

Professor, Chinese Academy of

Sciences

Institute of Applied Chemistry

Changchun, China

Hans-Peter Heim

Institute for Materials Engineering,

Polymer Engineering

University of Kassel

Kassel, Germany

xiv Contributors

Frank Henning

Fraunhofer Institute for Chemical

Technology (ICT)

Pfinztal, Germany

and

Karlsruhe Institute of Technology (KIT)

Karlsruhe, Germany

Philip Hough

ARLANXEO Performance Elastomers

Geleen, the Netherlands

Birat KC

Centre for Biocomposites and

Biomaterials Processing

University of Toronto

Toronto, Ontario, Canada

Joyce Kersjes

ARLANXEO Performance Elastomers

Geleen, the Netherlands

Mark T. Kortschot

Department of Chemical Engineering

and Applied Chemistry, Advanced

Materials Group

University of Toronto

Toronto, Ontario, Canada

D. Sameer Kumar

Department of Mechanical Engineering

R.V.R. & J.C. (Rayapati Venkata

Rangarao & Jagarlamudi

Chandramouli) College of Engineering

Guntur, India

Sheng Li

Industrial Interfaces Team,

Commonwealth Scientific and

Industrial Research Organisation

(CSIRO), Manufacturing Flagship

Melbourne, Australia

Mohammad Ali Nikousaleh

Institute for Materials Engineering,

Polymer Engineering

University of Kassel

Kassel, Germany

Numaira Obaid

Department of Chemical Engineering

and Applied Chemistry, Advanced

Materials Group

University of Toronto

Toronto, Ontario, Canada

Srikanth Pilla

Department of Automotive Engineering

and Department of Materials Science

and Engineering

Clemson University

Greenville, South Carolina

Sai Aditya Pradeep

Department of Automotive Engineering

and Department of Materials Science

and Engineering

Clemson University

Greenville, South Carolina