TAGS: Automotive Metal Replacement Thermoplastic Composites New Energy Solutions
Vehicles of the future will depend on overall weight reduction, energy challenges in emerging electric cars, and autonomous auto interior redesign that can be achieved by a combination of:
- Material substitution
- Optimization of component design/system layout, and
- Innovation in manufacturing processes
Consumer preferences have limited the downsizing options available to automakers. And also, the safety and performance standards have resulted in a very limited ability to reduce weight further with conventional materials.
Every vehicle component lightweighting potential is under investigation.
Material substitution replacing heavier iron and steel with weight saving advanced composites and other plastics, aluminum, magnesium, and advanced high strength steel is essential for boosting the fuel economy.
Material substitution is dependent on:
- Mechanical properties
- Cost
- Design, and
- Manufacturing capabilities
In addition to reduced fuel consumption, weight reduction enables smaller power plant and energy storage systems, with corresponding cost and/or performance benefits as well as secondary weight reductions in load bearing structures.
The global market value for innovative lightweight materials used in the transportation industry grew to $130 billion by yearend 2017, up from an estimated $100 billion in 2012, for a five-year compound annual growth rate (CAGR) of 6%.
The pie chart below depicts the materials used in a vehicles:
We at SpecialChem, recently did a
survey to ask our community of material engineers about the specific challenges posed to materials.
Here are the results:
We identified 3 main segments of challenges –
- ENERGY
- DESIGN
- INTERIOR
Meeting New Mobility Demands: Materials of Importance
To
realize the needs of new mobility, following are some of the key materials that will play a critical role in
Lightweighting,
Batteries, and
Sensors...
Carbon Fiber & Thermoplastic Composites
Carbon fiber offers the biggest weight advantage and new design opportunities.
Key players have announced expansions of CF Business / Production in 2017:
Use of CFRP in Lightweighting
Source: Arkema
However,
high costs (precursor + energy intensive production) and
poor recyclability are some of the drawbacks.
Good news is that there are significant advances in research on
Lignin-based precursors (cheaper and greener) for carbon fibers production (EU H2020 - LIBRE, WSU…)
Solvay says future innovations will include
Thermoplastic prepregs, Rapid cure...; Full Automation & Full recycling.
Source: Solvay
And
Airbus confirms the need for newer composites and the move towards increased
recycling. In addition,
additive manufacturing will play a key role here.
And talking about new composites,
UBE Exsymo has developed an innovative thermoplastic composite that is:
- Thermoformable
- Impact resistant
- Lighter than carbon fiber
- Stronger than most plastics
It also enables short production cycle at lower temperature for cost reduction while being 100% recyclable.
Smart Sensors of Tomorrow - Piezoelectric Polymers
Among polymers,
poly vinylidene fluoride (PVDF) & its copolymers exhibit high level of piezolectricity.
PVC and nylon are other polymer examples but not in the same league as PVDF. Also ceramics are used to develop piezoelectric films for sensors.
Source: Solvay
With increased connectivity, sensors will be indispensable in future cars and other applications. This will drive the innovation for such materials.
Also Read: Recent Advances in Piezoelectric Films and Sensors
Battery Materials - Lithium, Graphite and More
 |
According to stats: by 2030
− Demand for Li Ion battery would be above 700 GWh
− Price would be ~$73/KWh
− Cumulative copper demand from electric vehicles - can grow 15x
|
Estimated Reserves for Lithium: 17 MT to 25 MT; with Bolivia + Chile + Argentina with more than 15 MT, but the good news is that energy / kg is increasing, which means
more kilometers per kilo of Lithium.
Conducting additives (
graphite, carbon black) are also needed for lifespan and fast charging of EV Li-Ion batteries. Graphite demand for these batteries is expected to grow at 21%/ year.
With the drive towards full electrification, many other minerals and materials would see growth in demand in the coming years!
Lastly, I would like to leave you with this video that showcases
new concept of Urban Mobility (combining Land & Air travel). The possibilities are truly endless!
Plastics Professionals - Meet Tomorrow’s Automotive Industry Needs
Get ready for the future by identifying innovative multi-purpose plastics & composite solutions enabling weight reduction. Join the course:
Lightweighting Vehicles of the Future: Plastics & Composites Solutions on
September 6, 2018.