Executive Summary Plastics have entered engineering applications within the automotive industry at a significant rate during the last 30 years. Although plastics have a poor strength-to-density ratio by themselves@ plastics with inorganic fillers and plastic composite systems have advanced as structural materials while offering many advantages over metal. This book focuses on some of the various types of plastics and plastic composites and their applications within passenger vehicles. It also discusses the future of plastics in the automotive industry. Plastics are classified as thermoplastics@ rubbers@ or thermosets. Available in a variety of forms and blends@ their advantages include durability@ strength@ lightness of weight@ and excellent thermal and electrical insulating properties. Progress made in the recycling of plastics has added to the acceptance of plastics. Interior components make up the largest use of plastics in automotive vehicles@ in applications such as instrument panels (IPs)@ body panels@ door panels@ dashmats@ seat backs@ seat bases@ steering wheels@ and airbag covers. The use of plastics in exterior horizontal and vertical body panels of vehicles has been difficult@ but some have found their way into the body panels@ hoods@ and especially fenders of vehicles. Plastics are commonly used in bumpers and are appearing as underbody shields and exterior door handles. Environmental conditions and stresses have limited the use of plastics in the exterior parts of vehicles. While once viewed as unsuitable for the extreme environment found near engines@ plastics now are being used under the hood as replacements for metal parts. These plastics meet the requirements for strength@ high temperatures@ and even flame resistance needed for powertrain applications while offering the advantages of lower weight and cost@ improved air flow@ and corrosion resistance. Plastics also are used in fuel systems@ with the largest application being fuel tanks. They are the predominant material today for headlight lenses and other automotive lighting. However@ wheel systems remain primarily metal@ except for decorative uses of plastics such as found on hubcaps. Plastics will continue to permeate automotive applications@ and hybrid polymer?Cmetal technologies are expected to be developed in the years ahead. Increased use of airbags also will translate into the need for more plastic solutions. Acceptance of plastics engineering into vehicles will be driven by the need for lightness of weight@ fuel efficiency@ freedom from petroleum dependence@ and improved methods of reuse and recycling of plastics. The future of plastics in the automotive industry depends largely on technological and manufacturing innovation@ as well as economic and environmental factors.
SAE T-122-2009 history
2009SAE T-122-2009 Engineering Plastics and Plastic Composites In Automotive Applications