1、Biocomposites in Automotive Applications Biocomposites in Automotive Applications Pilla, Lu Srikanth Pilla Y. Charles Lu PT-165 ISBN: 978-0-7680-8148-0 Biocomposites in Automotive Applications Srikanth Pilla, Y. Charles Lu The automotive sector has taken a keen interest in lightweighting as new requ
2、ired performance standards for fuel economy come into place. This strategy includes parts consolidation, design optimization, and material substitution, with sustainable polymers playing a major role in reducing a vehicles weight. Sustainable polymers are largely biodegradable, biocompatible, and so
3、urced from renewable plant and agricultural stocks. A facile way to enhance their properties, so they can indeed replace the ones made from fossil fuels, is by reinforcing them with bers to make composites. Natural bers are gaining more acceptance in the industry due to their renewable nature, low c
4、ost, low density, low energy consumption, high speci c strength and sti ness, CO2 sequestration potential, biodegradability, and less wear imposed on machinery. Biocomposites then become a very feasible way to help address the fuel consumption challenge ahead of us. Biocomposites in Automotive Appli
5、cations, edited by known experts in the eld, is segmented into three sections and includes eleven hand-picked SAE International technical papers covering: Processing and characterization of biocomposites Automotive applications of biocomposites A perspective on automotive sustainability It is a must
6、 read for those interested in the growing importance of composites used in automotive applications and their impact on sustainable mobility. Professor Srikanth Pilla Dr. Pilla is an assistant professor in the Department of Automotive Engineering at Clemson University and holds an a liated appointmen
7、t in the Department of Materials Science and Engineering. He got his PhD from the University of Wisconsin-Milwaukee, with postdoctoral training at Stanford University. Dr. Pilla currently serves as an associate editor of the SAE International Journal of Materials and Manufacturing. Dr. Pilla has edi
8、ted two books and authored 70 scienti c articles, including 40 journal papers. His research focuses on the mechanics, processing, and characterization of polymers, biopolymers, multifunctional composites, nanocomposites, and microcellular foams and LCA modeling and analysis. Professor Y. Charles Lu,
9、 PhD, PE. Dr. Y. Charles Lu is H.E. Katterjohn Professor of mechanical engineering at the University of Kentucky and an associate editor of SAE International Journal of Materials and Manufacturing. His research interests include micro and nano-mechanics, polymers, and composites, nite-element analys
10、is and computational materials science. Dr. Lu has extensive experience both in the automotive industry, including senior positions at Dana Corporation and at Akron Rubber Development Laboratory. He received his PhD in Engineering Sciences from the University of Western Ontario in 2000 and is a lice
11、nsed professional engineer in the state of Kentucky. SAE INTERNATIONAL AUTOMOTIVEBiocomposites in Automotive Applications P150877_PT-165_Insides.indb 1 8/10/15 2:22 PMOther SAE books of interest: CAE Design and Failure Analysis of Automotive Composites By Srikanth Pilla and Charles Lu (Product Code:
12、 PT-166) Design of Automotive Composites By Srikanth Pilla and Charles Lu (Product Code: PT-164) Automotive Carbon Fiber Composites: From Evolution to Implementation By Jackie D. Rehkopf (Product Code: T-124) For more information or to order a book, contact: SAE INTERNATIONAL 400 Commonwealth Drive
13、Warrendale, PA 15096 Phone: +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) Fax: +1.724.776.0790 Email: CustomerServicesae.org Website: books.sae.org P150877_PT-165_Insides.indb 2 8/10/15 2:22 PMBiocomposites in Automotive Applications By Srikanth Pilla and Y . Ch
14、arles Lu Warrendale, Pennsylvania, USA P150877_PT-165_Insides.indb 3 8/10/15 2:22 PM Copyright 2015 SAE International eISBN: 978-0-7680-8243-9Copyright 2015 SAE International. All rights reserved. Printed in the United States of America No part of this publication may be reproduced, stored in a retr
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16、 724-772-9765. Library of Congress Catalog Number 2015947540 SAE Order Number PT-165 http:/dx.doi.org/10.4271/pt-165 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accura
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18、nformation, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. ISBN-Print 978-0-7680-8148-0 ISBN-PDF 978-0-7680-8243-9 ISBN-epub 978-0-7680-8245-5 ISBN-prc 978-0-7680-8244-7 To pu
19、rchase bulk quantities, please contact SAE Customer Service e-mail: CustomerServicesae.org phone: +1.877.606.7323 (inside USA and Canada) +1.724.776.4970 (outside USA) fax: +1.724.776.0790 Visit the SAE Bookstore at books.sae.org 400 Commonwealth Drive Warrendale, PA 15096 E-mail: CustomerServicesae
20、.org Phone: +1.877.606.7323 (inside USA and Canada)+1.724.776.4970 (outside USA) Fax: +1.724.776.0790 P150877_PT-165_Insides.indb 4 8/10/15 2:22 PMv Table of Contents Introduction . 1 Processing and Characterization of Biocomposites . 5 Processing and Characterization of Solid and Microcellular PHBV
21、/Coir 2 Fiber Composites (2010-01-0422) .7 Effects of Natural Fiber Surface Treatments and Matrix Modification on Mechanical Properties of Their Composites (2010-01-0426) 27 A Study on Impact Perforation Resistance of Jute-Polyester Composite Laminates (2014-01-1055) 37 A Comparative Study on the Ax
22、ial Impact Performance of Jute and Glass Fiber-Based Composite Tubes (2013-01-1178) .45 Utilization of Agricultural By-products as Fillers and Reinforcements in ABS (2010-01-0424) 53 Analysis of the Microstructure and Mechanical Resistance of Laminated Polyester Composites Reinforced with Curau Fibe
23、rs (2013-36-0376) 63 Automotive Applications of Biocomposites . 71 Agro-Waste Based Friction Material for Automotive Application (2014-01-0945) 73 Friction Performance of Eco-Friendly Cu-Free Brake Materials with Geopolymer Matrixes (2013-01-2026) .81 Natural Oil Polyol (NOP) Based Polyurethane Slab
24、stock Foam for Automotive Interior Foam-Fabric/Vinyl Laminate Construction (2011-01-0459) .91 Development of Flax Fiber/Soy-Based Polyurethane Composites for Mass Transit Flooring Application (2010-01-0428) 99 A Perspective on Automotive Sustainability 107 SAEs Green Technology Systems Group: Focus
25、on Environmental Sustainability for the Automotive Industry (2011-01-1258) 109 About the Editors .131 P150877_PT-165_Insides.indb 5 8/10/15 2:22 PMP150877_PT-165_Insides.indb 6 8/10/15 2:22 PM1 Lightweight materials are an integral component in product design and integration across several industrie
26、s, including aviation and automotive, where driving dynamics and efficiency are key factors. The automotive sector has taken a keen interest in lightweighting, from 1941 when Henry Ford unveiled his plastic bodied car made from hemp, sisal, and cellulose-based plastics. Currently, the Boeing 787 and
27、 the BMW I series are constructed largely of carbon fiber reinforced plastic (CFRP) support structures. Additionally, the use of CFRP based bearings for an Airbus A340 horizontal tail and car fenders have led to a weight reduction of 50 and 30 percent, respectively 1. Legislation and regulations in
28、the form of Corporate Average Fuel Economy (CAFE) standards first enacted by Congress in 1975 have been a major driver in improving the fuel economy of automobiles and reduction in greenhouse gas emissions. The CAFE standard for 2025 (Figure 1) is set to have a fleet-wide average of 54.5 mpg, which
29、would translate to over $1.7 trillion in consumer savings and prevent emissions of 6 billion metric tons of CO 22. Automakers employ several approaches to meet their CAFE targets, chief among which are transmission, electrification, hybrid technologies, and lightweighting. However, as seen in Figure
30、 2, vehicle weight has been generally increasing because OEMs have been adding features 4. The CAFE standards for 2025 have propelled the automotive industry to renew their focus on lightweighting materials. While steel has traditionally played a major role in the automotive industry, it is increasi
31、ngly being replaced by alternatives in the form of aluminum, magnesium alloys, and plastics. The replacement of metals by composites in automotive core structure, body, or powertrain offers significant weight reduction, as shown in Figure 3. Greater reduction can be achieved in structural and nonstr
32、uctural components such as underbody cover, dashboards, roof, front- end, and door modules. The major pathways to automotive lightweighting include parts consolidation, design optimization, and material substitution. Material substitution, in particular the use of polymers and polymer composites, ha
33、ve led to enormous weight savings without compromising on safety while offering tailor-made solutions that can suit specific requirements. Plastics Introduction Figure 2 Increasing vehicle weight due to features added. Figure 1 CAFE standard for 2025. Figure 3 Hood weight by material. P150877_PT-165
34、_Insides.indb 1 8/10/15 2:22 PM2 are currently one of the most valuable materials due to their extraordinary adaptability and low cost 6. Most commercially available plastics are derivatives of polyolefins such as poly (propylene) (PP), polycarbonate (PC), poly (vinyl chloride) (PVC), poly (ethylene
35、) (PE), and polystyrene (PS). All synthetic polymers are derived from petroleum-based resources that take millions of years to form and are largely non-biodegradable. The advent of anthropogenic climate change and increasing environmental regulations has led to a renewed interest in the development
36、of environmentally sustainable and bio- sourced polymers. The major advantages of sustainable polymers is that they are largely biodegradable, biocompatible, and sourced from renewable bio-based plant and agricultural stocks 7, 8. Some of the most commonly used biopolymers are polylactic acid (PLA),
37、 polyhydroxybutyrate (PHB), soy-based plastics, cellulose polyesters, starch-based bioplastics, vegetable oil derived bioplastics, poly (trimethylene terephthalate), and biopolyethylene. While biopolymers are intriguing and fit well in this new paradigm shift of sustainable and environmentally compa
38、tible materials, they possess inferior properties compared to their synthetic counterparts. Their application is limited in areas that are currently dominated by petroleum-sourced plastics. A facile way to enhance the properties of biopolymers is via reinforcing them with fibers to make composites 9
39、, 10. Fibers can be classified as both organic (including natural fibers) and synthetic. Although synthetic fibers offer superior reinforcement capability compared to natural fibers, the latter are gaining renewed interest due to the following advantages: renewable nature, low cost, low density, low
40、 energy consumption, high specific strength and stiffness, CO 2sequestration, biodegradability, and less wear on machinery 11, 12. A classification of natural fibers is shown in Figure 4. Depending on the types of polymers and the reinforcing fibers, composites can be classified as: Biocomposites re
41、fer to composites made from: (a) biopolymers reinforced with synthetic fibers, and (b) synthetic polymers reinforced with natural fibers. Green composites refer to composites made from biopolymers reinforced with natural fibers. Although both biocomposites and green composites provide environmentall
42、y friendly solutions, it is the latter that advocates total sustainability. Due to competing superior performance characteristics, biocomposites are largely investigated for plausible applications in the automotive sector. However, research and development is underway for green composites to be empl
43、oyed in the next generation of vehicles. Figure 4 Classification of natural fibers. P150877_PT-165_Insides.indb 2 8/10/15 2:22 PM3 This book, entitled Biocomposites in Automotive Applications, is segmented into three sections: Processing and Characterization of Biocomposites Automotive Applications
44、of Biocomposites A Perspective on Automotive Sustainability The first section consists of six papers, focused on investigating the structure-property relationships of various bio- and green composites. The first study investigated the effect of coir fibers (with and without surface modification) on
45、the mechanical and thermophysical properties of poly (hydroxy butyrate-co-valerate) (PHBV) processed via conventional and supercritical fluid assisted technologies. They observed that the addition of coir fibers have enhanced the specific toughness and strain-at-break while decreasing the specific m
46、odulus and strength. Furthermore, the surface modification had a positive impact on the specific properties. Moreover, the degree of crystallinity of PHBV was substantially improved upon by adding the coir fibers. In the second study, vinyl ester resin was infused using three types of fiber mats, vi
47、z., European unidirectional (EU) flax, North American (NA) flax mat, and North American hemp mat, and its mechanical properties were investigated. To achieve better wettability with the vinyl ester resin and thus advocate reinforcing ability, the fibers were surface modified with NaOH and then acryl
48、ic resin. Overall, it was observed that the modified fibers enhanced the interfacial strength through improved adhesion between fibers and resin. The third study assesses the potential of jute polyester (JP) composites as a cost-effective alternative to glass polyester (GP) composites by comparing t
49、heir respective impact perforation resistance. Tensile and compressive strength were ascertained for the JP composites. A new parameterenergy absorbed per unit peak loadis identified to characterize these composite laminates. Although JP laminates do not perform as well as their GP counterparts, it is observed that increasing the thickness of the JP laminates does improve its impact resistance. The focus of the fourth study is on woven JP composite cylindrical tubes subjected to an axial impact load, in comparison
