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    High Performance Plastics

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    Alok Mallick
    High performance plastics are increasingly being used in the automotive industry due to their ability to reduce vehicle weight and improve fuel efficiency. The top three plastics used, which make up approximately 66% of high performance plastics in vehicles, are polypropylene at 32%, polyurethane at 17%, and PVC at 16%. These plastics provide benefits like minimal corrosion, design freedom, safety, and recyclability. The document then lists and describes 13 common high performance plastics used in automotive applications, including their properties and common uses.

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    High Performance Plastics

    Uploaded by

    Alok Mallick
    118 views6 pages
    High performance plastics are increasingly being used in the automotive industry due to their ability to reduce vehicle weight and improve fuel efficiency. The top three plastics used, which make up approximately 66% of high performance plastics in vehicles, are polypropylene at 32%, polyurethane at 17%, and PVC at 16%. These plastics provide benefits like minimal corrosion, design freedom, safety, and recyclability. The document then lists and describes 13 common high performance plastics used in automotive applications, including their properties and common uses.

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    High performance plastics are increasingly being used in the automotive industry due to their ability to reduce vehicle weight and improve fuel efficiency. The top three plastics used, which make up approximately 66% of high performance plastics in vehicles, are polypropylene at 32%, polyurethane at 17%, and PVC at 16%. These plastics provide benefits like minimal corrosion, design freedom, safety, and recyclability. The document then lists and describes 13 common high performance plastics used in automotive applications, including their properties and common uses.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    118 views6 pages

    High Performance Plastics

    Uploaded by

    Alok Mallick
    High performance plastics are increasingly being used in the automotive industry due to their ability to reduce vehicle weight and improve fuel efficiency. The top three plastics used, which make up approximately 66% of high performance plastics in vehicles, are polypropylene at 32%, polyurethane at 17%, and PVC at 16%. These plastics provide benefits like minimal corrosion, design freedom, safety, and recyclability. The document then lists and describes 13 common high performance plastics used in automotive applications, including their properties and common uses.

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    © All Rights Reserved
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    of 6

    High performance plastics are playing an important role in the 

    automotive
    industry these days.

    The light weight of plastics makes for more fuel-efficient vehicles.


    It is estimated that every 10% reduction in vehicle weight results in a 5% to 7%
    reduction in fuel usage. Current economic and environmental concerns make the
    creation of more fuel-efficient cars a top priority in the automotive industry. The use
    of modern materials like aluminum and carbon fiber are helpful, but the wise
    allocation of plastics are making an increasing difference.

    Some other advantages of high performance plastics used in transport vehicles


    include:

    1. minimal corrosion, allowing for longer vehicle life


    2. substantial design freedom, allowing advanced creativity and innovation
    3. flexibility in integrating components
    4. safety, comfort and economy
    5. recyclability.

    Here are the top 13 high performance plastics used in automotive hardware.  While
    all 13 may easily be used in a single vehicle, just three types of plastic make up
    approximately 66% of the total high-performance plastics used in a car:
    polypropylene (32%), polyurethane (17%) and PVC (16%).

    1)      Polypropylene (PP)
    Polypropylene is a thermoplastic polymer used in a wide variety of applications.  A
    saturated addition polymer made from the monomer propylene. PP does not present
    stress-cracking problems and offers excellent electrical and chemical resistance at higher
    temperatures. PP doesn't melt below 160 deg cel.
     Semi-rigid
     Translucent
     Good chemical resistance
     Tough
     Good fatigue resistance
     Integral hinge property
     Good heat resistance
    Price /
    /£ 680 620
    Tonne
    Most typically PP Products are manufactured by: Extrusion Blow Moulding, Injection Moulding,
    and General Purpose Extrusion.
    Application: automotive bumpers, chemical tanks, cable insulation, gas cans,
    carpet fibers.

    2)      Polyurethane (PUR)
    Solid Polyurethane is an elastomeric material of exceptional physical properties
    including toughness, flexibility, and resistance to abrasion and temperature. 
    Polyurethane has a broad hardness range, from eraser soft to bowling ball hard. 
    Other polyurethane characteristics include extremely high flex-life, high load-bearing
    capacity and outstanding resistance to weather, ozone, radiation, oil, gasoline and
    most solvents.

    Application: flexible foam seating, foam insulation panels, elastomeric wheels and


    tires, automotive suspension bushings, cushions, electrical potting compounds, hard
    plastic parts.

    3)      Poly-Vinyl-Chloride (PVC)
    PVC has good flexibility, is flame retardant, and has good thermal stability, a high
    gloss, and low (to no) lead content.   Polyvinyl chloride molding compounds can be
    extruded, injection molded, compression molded, calendered, and blow molded to
    form a huge variety of products, either rigid or flexible depending on the amount and
    type of plasticizers used.
     Controlled oxygen and water vapour transmission.
     Affordable.

     Soft and scratch resistant skins for dashboards.


     Cold temperature resistance.
     UV stability.
     Durability.
     Light weight.

    Application: automobile instruments panels, sheathing of electrical cables, pipes,


    doors.
     instrument panels and associated mouldings, sun visors, synthetic leather seat coverings, headlining ,
    seals, mud flaps, noise and vibration reduction components, floor coverings, exterior side moulding
    and protective strips.
    4)      ABS
    Acrylonitrile Butadiene Styrene is a copolymer made by polymerizing styrene and
    acrylonitrile in the presence of polybutadiene. The styrene gives the plastic a shiny,
    impervious surface. The butadiene, a rubbery substance, provides resilience even at
    low temperatures. A variety of modifications can be made to improve impact
    resistance, toughness, and heat resistance.
    ABS is an ideal material of choice for various structural applications
     High rigidity
     Good impact resistance, even at low temperatures
     Good insulating properties
     Good weldability
     Good abrasion and strain resistance
     High dimensional stability (Mechanically strong and stable over time)
     High surface brightness and excellent surface aspect

    Application: automotive body parts, dashboards, wheel covers.


     Instrument panels
     Pillar trim
     Dashboard components
     Door liners and handles
     Seat backs, seat belt components, etc.

    5)      Polyamide (PA, Nylon 6/6, Nylon 6)


    When reinforced with glass fibers (short or long), their stiffness can compete with metals, this is
    why Polyamides are often considered in metal replacement projects.
    Nylon 6/6 is a general-purpose nylon that can be both molded and extruded. Nylon
    6/6 has good mechanical properties and wear resistance.  It is frequently used when
    a low cost, high mechanical strength, rigid and stable material is required.  Nylon is
    highly water absorbent and will swell in watery environments.
     High strength and stiffness at high temperature
     Good impact strength, even at low temperature
     Very good flow for easy processing
     Good abrasion and wear resistance
     Excellent fuel and oil resistance
     Good fatigue resistance
     PA 6 has excellent surface appearance and better processability than PA66 (due to its
    very low viscosity)
     Good electrical insulating properties
     High water absorption and water equilibrium content limits the usage

    Polyamide 6/ PA6 is also known as Nylon 6 or polycaprolactam. It is one of the most extensively
    used polyamides globally. It is synthesized by ring-opening polymerization of caprolactam.
    Melting point of Polyamide 6 is 223°C.

    While, Polyamide 66/PA66/Nylon 66 is one of the most popular engineering thermoplastics and


    is majorly used as a replacement to metal in various applications. Nylon 66 is synthesized by
    polycondensation of hexamethylenediamine and adipic acid (two monomers each containing 6
    carbon atoms). Melting point of Polyamide 66 is 255°C.

    Application: gears, bushes, cams, bearings, weather proof coatings.

    6)      Polystyrene (PS)
    Naturally clear, polystyrene exhibits excellent chemical and electrical resistance. 
    Special high gloss and high impact grades are widely available.  This easy to
    manufacture plastic has poor resistance to UV light.

    Application: equipment housings, buttons, car fittings, display bases.

    7)      Polyethylene (PE)
    Polyethylene has high impact resistant, low density, and exhibits good toughness. It
    can be used in a wide variety of thermoplastics processing methods and is
    particularly useful where moisture resistance and low cost are required.

    Application: car bodies (glass reinforced), electrical insulation.

    8)      POM (polyoxymethylene)
    POM has excellent stiffness, rigidity, and yield strength.  These properties are stable
    in low temperatures.  POM also is highly chemical and fuel resistant.

    Application: interior and exterior trims, fuel systems, small gears.


    9)      Polycarbonate (PC)
    Amorphous polycarbonate polymer offers a unique combination of stiffness,
    hardness and toughness. It exhibits excellent weathering, creep, impact, optical,
    electrical and thermal properties.  Because of its extraordinary impact strength, it is
    the material for car bumpers, helmets of all kinds and bullet-proof glass substitutes.

    Application: bumpers, headlamp lenses.

    10)   Acrylic (PMMA)
    A transparent thermoplastic, PMMA is often used as a lightweight or shatter-resistant
    alternative to glass.  It’s cheaper than PC but is also more prone to scratching and
    shattering.

    Application: windows, displays, screens.

    11)   PBT (polybutylene terephthalate)


    The thermoplastic PBT is used as an insulator in the electrical and electronics
    industries.  It is highly chemical and heat resistant.  Flame-retardant grades are
    available.

    Application: door handles, bumpers, carburetor components.

    12)   Polyethylene Teraphthalate (PET)


    PET is mostly used to create synthetic fibers and plastic bottles.  You may recognize
    it on clothing labels under the name “polyester.”

    Application: wiper arm and gear housings, headlamp retainer, engine cover,


    connector housings.

    13)   ASA (acrylonitrile styrene acrylate)


    Similar to ABS, ASA has great toughness and rigidity, good chemical resistance and
    thermal stability, outstanding resistance to weather, aging and yellowing, and high
    gloss.  Be careful not to burn this material.  It will cause a toxic smoke.

    Application: housings, profiles, interior parts and outdoor applications.

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