The automotive industry has experienced more than 100 years of development and has evolved from an initial simple means of transport to a high-tech product that combines the best of contemporary technology. More and more new materials and new technologies have emerged, making the car lighter, lower cost and more intelligent. Therefore, the development of materials and technology has made an indelible contribution to the advancement of the automotive industry. Automotive materials are the basis of automotive quality, and the development of automotive technology is largely dependent on the development of automotive materials. In order to develop a car that is more economical and more adaptable to various environments, synthetic materials with high technology content are indispensable.
Overview of new materials for automobiles
The development of automotive materials is an important aspect of automotive technology development. Materials are the foundation of car quality assurance and are a key part of developing a more economical, safer and lighter car. With the rapid development of science and technology, the composition of modern automobile manufacturing materials has undergone great changes, the proportion of high-density materials has declined, and low-density materials have grown substantially. Since the 1990s, automotive materials have grown in weight, resources, performance and functionality. The application of aluminum alloys, magnesium alloys, plastics, nano-materials, etc. in the automotive field has had a major impact on the development of automobiles.
Steel material
Automobile steel is mainly divided into two categories, one is steel plate for body parts, and the other is special steel bar for transmission system parts. Automotive steel mainly includes high-strength steel plate materials, structural steel, stainless steel, high-strength cast iron materials, iron-based powder metallurgy materials, and powder metallurgy materials.
In the process of development of high-strength, ultra-deep-drawing and coating, the most promising development of automotive steel sheets is high-strength IF steel, dual-phase steel DP, phase-change-induced plastic TRIP steel, etc. These materials have high strength and high plasticity. The advantages of formability, solderability and impact resistance. High-strength steel is one of the main development directions of automotive steel materials in the future. At present, the high-strength steel used in automobiles is mainly sheet and pipe, which replaces ordinary steel and cast iron for body parts and other structural parts. There are also more and more high-strength steel components produced by hydroforming, such as engine brackets, radiator brackets, instrument panel beams, seat frames, and lightweight rear axles and frames. High-strength steel has become a competitive lightweight material for automobiles, and it has greater advantages in terms of impact resistance, corrosion resistance and cost than other materials.
2. Non-ferrous metal materials
The rapid growth of non-ferrous alloys in automotive applications is a major trend in the development of automotive materials.
(1) Aluminum alloy aluminum alloy is the fastest and most widely used light metal in automobiles. Aluminum alloy castings are mainly used in engine cylinder blocks, cylinder heads, pistons, intake manifolds, rocker arms, engine mount brackets, air compressor connecting rods, transmission housings, clutch housings, wheels, brake parts, handles and Cover shell parts, etc. Deformed aluminum alloy refers to aluminum alloy sheet and strip, extruded profiles and forged materials. It is mainly used in automobile bodies for body panels, body frames, engine radiators, air conditioner condensers, evaporators, wheels, decorative parts and suspension system parts. . Aluminum-based composites have demonstrated superior performance in testing or the use of components such as connecting rods, pistons, cylinder bores, brake discs, brake calipers and driveshaft tubes.
(2) Magnesium alloy magnesium is about 1/3 lighter than aluminum. The use of magnesium alloy is conducive to automobile lightweighting, energy saving and emission reduction. Magnesium alloys are mostly used in automotive applications in the form of die castings. The production efficiency of magnesium die castings is 30% to 50% higher than that of aluminum. The earliest examples of magnesium castings used in automobiles are wheel rims. At present, magnesium is mainly used for body and chassis parts, such as dashboard skeletons and beams, seat frames, steering wheels, intake manifolds, and various brackets. Cover, etc. The next target for the application of magnesium in automobiles is the powertrain components such as engines.
(3) Titanium alloy engine connecting rod made of α+β-based titanium alloy, the strength is equivalent to the level of 45 steel quenching and tempering, and the weight can be reduced by 30%; β-type titanium alloy (Ti-13V-11Cr-3Al, etc.) Strong cold working and aging treatment, strength up to 2000Mpa, can be used to manufacture suspension springs, valve springs and valves. Titanium springs can reduce weight by 20% compared to high strength steels with a tensile strength of 2100 MPa. Titanium for automotive use in Japan is mainly used for the following components: engine air valves, connecting rods and crankshafts, exhaust pipes, suspension springs, silencers, car bodies and fasteners. After using titanium, weight reduction, corrosion prevention and improvement can be achieved. Burning efficiency and other purposes. Among them, the use of titanium exhaust system (exhaust pipe and silencer) and suspension springs can provide designers with two ways to minimize weight, while titanium valves are relatively widely used, mainly because of the simple processing method and low cost.
(4) Foam metal foam is a porous lightweight material with low density, high specific modulus and high specific strength, and has the characteristics of vibration damping and energy absorption. Commonly used as structural foam substrates are polyurethane, epoxy, nylon and fiberglass composites. Structural foams are currently used as reinforcing linings in a number of key locations in car frames. Front bumper cushioning foam under low speed collision.
3. Composite materials
The composite parts used in automobiles mainly include instrument panels, door guards, inner cover panels, carpets, seats and parcel guards, which are basically composed of a skin, a sound-damping portion and a skeleton portion. In addition to satisfying certain functions, such parts can make people feel comfortable and beautiful. The composite material has simple production process, low cost, strong applicability and rapid development, and will be the main development direction of automotive interior materials. Automotive composite materials are automotive rubber products, plastics, engineering plastics, fiberglass, carbon fiber and interior materials.
(1) The rubber and rubber industry is an important supporting industry for the automobile industry, and the automobile industry is also the main market for rubber products. In addition to steel, a car uses many rubber products, which account for about 6% of the total cost of the car. More than 70% of the world's annual consumption of raw rubber is used in the automotive industry, of which 60% is used for tires and 40% is used for non-tire rubber products, ie automotive rubber products, including various hoses, transmission belts (V-belts, timing belts), Various rubber parts such as sealing products (oil seals, sealing strips, gaskets, etc.), shock absorbing rubber and safety products. There are 100-200 rubber parts required for each car, and the number is 200-500. In recent years, the promotion and application of special rubbers such as fluororubber (FKM) in automobiles has made it one of the fastest growing rubber grades for automotive special rubber. In the automotive industry, FKM is mainly used for engine stem seals, cylinder liner seals, clutch seals, fuel pump seals and fuel hose inner seals. Hydrogenated nitrile rubber (HNBR) is an alternative to nitrile rubber (NBR), which is excellent in heat resistance and oil resistance, and resistant to aging and various media. It is widely used in high-performance auto parts and is mainly used for automobile synchronization. With primer, high-performance V-bottom glue, automotive inner rubber hose, fuel-contact seals. Acrylate rubber (ACM) is relatively moderate in price, excellent in heat-resistant oil and thermal aging properties. In recent years, it has become a sealing material developed and promoted by the automotive industry. It is mainly used as a high temperature resistant oil seal, shock absorbing parts and hydraulic hose. The biggest use of TPE in automobiles is the sealing strip.
(2) Plastic plastics have always been valued by the automotive engineering community due to their light weight, corrosion resistance and easy processing. Plastics are mainly used in bushings, trims and certain parts of the body. The main types of automotive plastics include general engineering plastics, plastic alloys and reinforced plastics. Plastics are used in automobiles for interior fittings such as instrument panels, door inner panels, ceilings, sub-dashboards, glove compartment covers, seats and various types of panels, and then gradually expand outwards, structural parts and functional parts, such as bodywork. Outer plates, rear spoilers, bumpers, wheel covers, front and rear fenders, lift doors, and fuel tanks, radiator water chambers, fan blades, engine intake pipes, valve cover, etc.
(3) Engineering plastics Engineering plastics, especially high-performance engineering plastics, have good mechanical properties, comprehensive mechanical properties, heat resistance, acid resistance, long life and good reliability. They are used more and more widely in the automotive industry, and the prospects are very good.
(4) FRP fiberglass has many advantages, widely used in bumpers, roof covers, deflectors, sunshades, battery brackets, fenders, front face parts, skirt parts and body shells, etc., fiberglass The application has a tendency to expand further.
(5) Among the non-metallic materials of modified PP material, the most used ones are modified PP series materials. The use components include large interior parts such as instrument panels, door guards, decorative panels, and exterior parts such as bumpers, water tank masks, and fenders. Polyolefin materials based on modified PP have accounted for more than 50% of automotive plastics.
(6) ABS type materials ABS has many varieties, good surface treatment effect and low price. Therefore, it has been very popular in body materials.
(7) SMC and other glass fiber reinforced materials SMC comprehensive performance far exceeds other engineering plastics, and is a material that can be painted online, and has always occupied an important position in the development of commercial vehicle body.
4. New ceramic materials
Engineering ceramics currently include silicon nitride (Si3N4), silicon carbide (SiC), tungsten silicide (WSi2), zirconium dioxide (ZrO2), and tri-alumina (A12O3). Engineering ceramics are mainly used on the engine. Engineering ceramics is not a common ceramic that can't be attacked. It has good comprehensive performance. Therefore, replacing it with metal materials can greatly improve the efficiency of heat engines and reduce energy consumption, thus achieving the lightweight effect of automobiles. Currently, engineered ceramics have been used to make engine and heat exchanger parts.
Special ceramics have various excellent and unique properties. They are applied to automobiles and have positive significance for reducing the quality of the vehicle itself, improving the thermal efficiency of the engine, reducing fuel consumption, reducing exhaust pollution, improving the life of wearing parts and improving the intelligent function of the vehicle. Ceramics for vehicles have attracted the attention of materials science in the engineering field. The main applications are ceramic engines, thermal ceramic sensors, ceramic carriers for catalytic converters for vehicles, honeycomb ceramic materials for exhaust gas purification, ceramic honeycomb filters for diesel exhaust and ceramics. Automotive brake pads and automotive ceramic bearings, automotive ceramic new materials research and development and application prospects.
Smart ceramic products used in automobiles, including functional materials, smart material systems or structures that combine drive systems with feedback systems. Because of its comprehensive functions, the car products can sense and respond to changes in the external environment while driving, so that the car products have many functions such as self-test, self-test, self-diagnosis, self-repair, and self-adaptation.
5. Nanomaterials
The automotive industry uses a wide range of nanomaterials and technologies, from internal to external, from engine to tire, from structural parts to decorative parts, from lighting to protective paints, involving more than 100 nanomaterials. GM, Toyota, etc. are actively developing nanomaterials for automobile bodies and frames. These nanomaterials, because of their light weight and high strength, can not only increase the strength but also reduce the weight of the car as a body and frame material.
Smart catalyst developed using nanotechnology. Japan Daihatsu Motor Co., Ltd., while ensuring the high-efficiency purification performance of the exhaust gas catalytic converter of the vehicle engine after-treatment device, uses nanotechnology to reduce the use of precious metal catalyst by 70%. This new type of catalyst for gasoline engines for vehicles uses nano-materials as a "self-recycling" function, so it is also called smart catalyst, and is used in ultra-low emission vehicles (ULEV) and mini cars sold in the Japanese market in 2002.
6. Other new materials
(1) Eco-plastics Toyota's newly developed "ecological plastics" have been used in anti-slip boards, car roofs, seat cushions and other automotive interiors.
(2) The new fluorine material Daikin Industries Co., Ltd. opened a new type of fluorine material. The material has "softness" required for movable materials such as bending and twisting, and has "low permeability" for hydrocarbons (HC) contained in automobile fuels, and is mainly used for rubber in automobile fuel hoses. Compared with the company's fluorocarbon rubber, this product can reduce the penetration of automotive fuel by about 1/20.
Overview of new materials for automobiles
The development of automotive materials is an important aspect of automotive technology development. Materials are the foundation of car quality assurance and are a key part of developing a more economical, safer and lighter car. With the rapid development of science and technology, the composition of modern automobile manufacturing materials has undergone great changes, the proportion of high-density materials has declined, and low-density materials have grown substantially. Since the 1990s, automotive materials have grown in weight, resources, performance and functionality. The application of aluminum alloys, magnesium alloys, plastics, nano-materials, etc. in the automotive field has had a major impact on the development of automobiles.
Steel material
Automobile steel is mainly divided into two categories, one is steel plate for body parts, and the other is special steel bar for transmission system parts. Automotive steel mainly includes high-strength steel plate materials, structural steel, stainless steel, high-strength cast iron materials, iron-based powder metallurgy materials, and powder metallurgy materials.
In the process of development of high-strength, ultra-deep-drawing and coating, the most promising development of automotive steel sheets is high-strength IF steel, dual-phase steel DP, phase-change-induced plastic TRIP steel, etc. These materials have high strength and high plasticity. The advantages of formability, solderability and impact resistance. High-strength steel is one of the main development directions of automotive steel materials in the future. At present, the high-strength steel used in automobiles is mainly sheet and pipe, which replaces ordinary steel and cast iron for body parts and other structural parts. There are also more and more high-strength steel components produced by hydroforming, such as engine brackets, radiator brackets, instrument panel beams, seat frames, and lightweight rear axles and frames. High-strength steel has become a competitive lightweight material for automobiles, and it has greater advantages in terms of impact resistance, corrosion resistance and cost than other materials.
2. Non-ferrous metal materials
The rapid growth of non-ferrous alloys in automotive applications is a major trend in the development of automotive materials.
(1) Aluminum alloy aluminum alloy is the fastest and most widely used light metal in automobiles. Aluminum alloy castings are mainly used in engine cylinder blocks, cylinder heads, pistons, intake manifolds, rocker arms, engine mount brackets, air compressor connecting rods, transmission housings, clutch housings, wheels, brake parts, handles and Cover shell parts, etc. Deformed aluminum alloy refers to aluminum alloy sheet and strip, extruded profiles and forged materials. It is mainly used in automobile bodies for body panels, body frames, engine radiators, air conditioner condensers, evaporators, wheels, decorative parts and suspension system parts. . Aluminum-based composites have demonstrated superior performance in testing or the use of components such as connecting rods, pistons, cylinder bores, brake discs, brake calipers and driveshaft tubes.
(2) Magnesium alloy magnesium is about 1/3 lighter than aluminum. The use of magnesium alloy is conducive to automobile lightweighting, energy saving and emission reduction. Magnesium alloys are mostly used in automotive applications in the form of die castings. The production efficiency of magnesium die castings is 30% to 50% higher than that of aluminum. The earliest examples of magnesium castings used in automobiles are wheel rims. At present, magnesium is mainly used for body and chassis parts, such as dashboard skeletons and beams, seat frames, steering wheels, intake manifolds, and various brackets. Cover, etc. The next target for the application of magnesium in automobiles is the powertrain components such as engines.
(3) Titanium alloy engine connecting rod made of α+β-based titanium alloy, the strength is equivalent to the level of 45 steel quenching and tempering, and the weight can be reduced by 30%; β-type titanium alloy (Ti-13V-11Cr-3Al, etc.) Strong cold working and aging treatment, strength up to 2000Mpa, can be used to manufacture suspension springs, valve springs and valves. Titanium springs can reduce weight by 20% compared to high strength steels with a tensile strength of 2100 MPa. Titanium for automotive use in Japan is mainly used for the following components: engine air valves, connecting rods and crankshafts, exhaust pipes, suspension springs, silencers, car bodies and fasteners. After using titanium, weight reduction, corrosion prevention and improvement can be achieved. Burning efficiency and other purposes. Among them, the use of titanium exhaust system (exhaust pipe and silencer) and suspension springs can provide designers with two ways to minimize weight, while titanium valves are relatively widely used, mainly because of the simple processing method and low cost.
(4) Foam metal foam is a porous lightweight material with low density, high specific modulus and high specific strength, and has the characteristics of vibration damping and energy absorption. Commonly used as structural foam substrates are polyurethane, epoxy, nylon and fiberglass composites. Structural foams are currently used as reinforcing linings in a number of key locations in car frames. Front bumper cushioning foam under low speed collision.
3. Composite materials
The composite parts used in automobiles mainly include instrument panels, door guards, inner cover panels, carpets, seats and parcel guards, which are basically composed of a skin, a sound-damping portion and a skeleton portion. In addition to satisfying certain functions, such parts can make people feel comfortable and beautiful. The composite material has simple production process, low cost, strong applicability and rapid development, and will be the main development direction of automotive interior materials. Automotive composite materials are automotive rubber products, plastics, engineering plastics, fiberglass, carbon fiber and interior materials.
(1) The rubber and rubber industry is an important supporting industry for the automobile industry, and the automobile industry is also the main market for rubber products. In addition to steel, a car uses many rubber products, which account for about 6% of the total cost of the car. More than 70% of the world's annual consumption of raw rubber is used in the automotive industry, of which 60% is used for tires and 40% is used for non-tire rubber products, ie automotive rubber products, including various hoses, transmission belts (V-belts, timing belts), Various rubber parts such as sealing products (oil seals, sealing strips, gaskets, etc.), shock absorbing rubber and safety products. There are 100-200 rubber parts required for each car, and the number is 200-500. In recent years, the promotion and application of special rubbers such as fluororubber (FKM) in automobiles has made it one of the fastest growing rubber grades for automotive special rubber. In the automotive industry, FKM is mainly used for engine stem seals, cylinder liner seals, clutch seals, fuel pump seals and fuel hose inner seals. Hydrogenated nitrile rubber (HNBR) is an alternative to nitrile rubber (NBR), which is excellent in heat resistance and oil resistance, and resistant to aging and various media. It is widely used in high-performance auto parts and is mainly used for automobile synchronization. With primer, high-performance V-bottom glue, automotive inner rubber hose, fuel-contact seals. Acrylate rubber (ACM) is relatively moderate in price, excellent in heat-resistant oil and thermal aging properties. In recent years, it has become a sealing material developed and promoted by the automotive industry. It is mainly used as a high temperature resistant oil seal, shock absorbing parts and hydraulic hose. The biggest use of TPE in automobiles is the sealing strip.
(2) Plastic plastics have always been valued by the automotive engineering community due to their light weight, corrosion resistance and easy processing. Plastics are mainly used in bushings, trims and certain parts of the body. The main types of automotive plastics include general engineering plastics, plastic alloys and reinforced plastics. Plastics are used in automobiles for interior fittings such as instrument panels, door inner panels, ceilings, sub-dashboards, glove compartment covers, seats and various types of panels, and then gradually expand outwards, structural parts and functional parts, such as bodywork. Outer plates, rear spoilers, bumpers, wheel covers, front and rear fenders, lift doors, and fuel tanks, radiator water chambers, fan blades, engine intake pipes, valve cover, etc.
(3) Engineering plastics Engineering plastics, especially high-performance engineering plastics, have good mechanical properties, comprehensive mechanical properties, heat resistance, acid resistance, long life and good reliability. They are used more and more widely in the automotive industry, and the prospects are very good.
(4) FRP fiberglass has many advantages, widely used in bumpers, roof covers, deflectors, sunshades, battery brackets, fenders, front face parts, skirt parts and body shells, etc., fiberglass The application has a tendency to expand further.
(5) Among the non-metallic materials of modified PP material, the most used ones are modified PP series materials. The use components include large interior parts such as instrument panels, door guards, decorative panels, and exterior parts such as bumpers, water tank masks, and fenders. Polyolefin materials based on modified PP have accounted for more than 50% of automotive plastics.
(6) ABS type materials ABS has many varieties, good surface treatment effect and low price. Therefore, it has been very popular in body materials.
(7) SMC and other glass fiber reinforced materials SMC comprehensive performance far exceeds other engineering plastics, and is a material that can be painted online, and has always occupied an important position in the development of commercial vehicle body.
4. New ceramic materials
Engineering ceramics currently include silicon nitride (Si3N4), silicon carbide (SiC), tungsten silicide (WSi2), zirconium dioxide (ZrO2), and tri-alumina (A12O3). Engineering ceramics are mainly used on the engine. Engineering ceramics is not a common ceramic that can't be attacked. It has good comprehensive performance. Therefore, replacing it with metal materials can greatly improve the efficiency of heat engines and reduce energy consumption, thus achieving the lightweight effect of automobiles. Currently, engineered ceramics have been used to make engine and heat exchanger parts.
Special ceramics have various excellent and unique properties. They are applied to automobiles and have positive significance for reducing the quality of the vehicle itself, improving the thermal efficiency of the engine, reducing fuel consumption, reducing exhaust pollution, improving the life of wearing parts and improving the intelligent function of the vehicle. Ceramics for vehicles have attracted the attention of materials science in the engineering field. The main applications are ceramic engines, thermal ceramic sensors, ceramic carriers for catalytic converters for vehicles, honeycomb ceramic materials for exhaust gas purification, ceramic honeycomb filters for diesel exhaust and ceramics. Automotive brake pads and automotive ceramic bearings, automotive ceramic new materials research and development and application prospects.
Smart ceramic products used in automobiles, including functional materials, smart material systems or structures that combine drive systems with feedback systems. Because of its comprehensive functions, the car products can sense and respond to changes in the external environment while driving, so that the car products have many functions such as self-test, self-test, self-diagnosis, self-repair, and self-adaptation.
5. Nanomaterials
The automotive industry uses a wide range of nanomaterials and technologies, from internal to external, from engine to tire, from structural parts to decorative parts, from lighting to protective paints, involving more than 100 nanomaterials. GM, Toyota, etc. are actively developing nanomaterials for automobile bodies and frames. These nanomaterials, because of their light weight and high strength, can not only increase the strength but also reduce the weight of the car as a body and frame material.
Smart catalyst developed using nanotechnology. Japan Daihatsu Motor Co., Ltd., while ensuring the high-efficiency purification performance of the exhaust gas catalytic converter of the vehicle engine after-treatment device, uses nanotechnology to reduce the use of precious metal catalyst by 70%. This new type of catalyst for gasoline engines for vehicles uses nano-materials as a "self-recycling" function, so it is also called smart catalyst, and is used in ultra-low emission vehicles (ULEV) and mini cars sold in the Japanese market in 2002.
6. Other new materials
(1) Eco-plastics Toyota's newly developed "ecological plastics" have been used in anti-slip boards, car roofs, seat cushions and other automotive interiors.
(2) The new fluorine material Daikin Industries Co., Ltd. opened a new type of fluorine material. The material has "softness" required for movable materials such as bending and twisting, and has "low permeability" for hydrocarbons (HC) contained in automobile fuels, and is mainly used for rubber in automobile fuel hoses. Compared with the company's fluorocarbon rubber, this product can reduce the penetration of automotive fuel by about 1/20.
(3) Glass With the improvement of the safety of automobiles, in addition to the use of tempered glass and the prevention of scattered laminated glass, it also gives new features to automotive parts. For example, in rainy days, the attached water droplets are uniform in shape and have a high slippery non-stick glass; in summer, the temperature inside the car rises, and the sun directly hits the skin, which makes people feel uncomfortable, and can cut off the IR-irradiated IR glass; A UV-cut UV glass that protects against aging of interior materials. Especially in rainy days, in order to ensure a good view, the door mirrors are given hydrophobic and hydrophilic properties, and the door glass is given hydrophobic performance. Due to the recyclability of the material, a lead-free layer is used, and a new technology for recycling is used at the interlayer film of the laminated glass.
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