VEHICLE BODY MATERIALS 1

MODULE 2
VEHICLE BODY MATERIALS

Vehicle Body Materials:

An Automotive body depends on the manufacturer's considerations with the legislation and
regulation, and some on the requirements of the customers. Most of the manufacturers prefer
featured materials which are lightweight, economic, safety and recyclability.

Steel:
The main elements of selecting material especially for the body is involved in a wide variety
of characteristics such as thermal, chemical or mechanical resistance, manufacturing efficiency
and durability. Steel stands as the first choice for manufacturers with all the required
characteristics. The improvement or development in the steel industry made the steel stronger,
lightweight and stiffer than the earlier. Steel includes not only vehicle bodies, but also engine,
chassis, wheels and many other parts. Iron and steel develop the critical components of
structure for the bulk manufacturing of vehicles and are low-cost.
The best reason for using steel as a body structure is its natural capability to absorb the impact
energy produced in a crash.

Aluminium:
Aluminium is widely used in the automotive industry, in chassis and body structure. Use of
aluminium can possibly decrease the weight of the vehicle. Its low weight and high specific
energy absorption and precise strength are its most significant characteristics. Aluminium is
resistant to corrosion, but according to its low modulus of flexibility, it cannot substitute steel
parts. Hence those parts need to be re-engineered to adopt the same mechanical strength.
Aluminium usage in the automotive industry has vastly grown within less period of time. In
the automotive industry, aluminium castings have been used for pistons, cylinder heads, intake
manifolds and transmission. In chassis applications, it is used as wheels, for brackets, brake
components, suspension, steering components and instrument panels. Aluminium is used for
body structures, finishing and exterior attachments such as crossbeams, doors or bonnets.
Latest improvements showed that 50per cent of the steel is saved for the body in white by the
substitution of steel by aluminium. This can result in up to 20-30 per cent reduction in the total
weight of the vehicle.

Magnesium:
Magnesium is another light-weight metal that is growing increasingly next to aluminium in
automotive engineering. It is 33% lighter than aluminium and 75% lighter than steel elements.
Magnesium components have many mechanical disadvantages that need a unique design for
utilisation to automotive products.
Magnesium has lower tensile strength, fatigue strength, and creep strength compared to
Aluminium. The modulus and hardness of magnesium alloys are lower than aluminium, while
the thermal expansion coefficient is greater. As it has low mechanical strength, pure magnesium
cannot be used, must be alloyed with other components. The most common alloying

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 2

components for room temperature applications is Mg-Al-Zn group, which include aluminium,
manganese, and zinc.

Features:

Lightweight:
As there is a high importance on greenhouse gas reductions, decrease of emission and
improving fuel efficiency is the most important one for an automotive company. Lightweight
metals can improve fuel effectiveness more than other factors. Experiments reveal that 10 per
cent of weight reduction can lead to 6 to 8 per cent improvement in fuel usage. Weight reduction
can be obtained in three ways:
• Substituting elements of high precise weight with moderate density materials without
decreasing rigidity and durability. For example, replacement of steel with aluminum,
magnesium, composites and foams.
• Optimizing the design of load-carrying elements and exterior attachments to reduce their
weight without any loss in rigidity or functionality.
• Optimizing the production process, such as decreasing spot welding and arranging with new
joining techniques.

Economic:
Most important industry driven factor in the vehicle industry is the cost, which determines any
new element has an opportunity to be chosen for vehicle components. It includes three major
economic factors; the actual cost of raw materials, manufacturing added value, and the cost to
design.
Aluminium and magnesium alloys are more costly than the currently used steel and cast irons.
Since the cost is expensive, decisions to select light elements must be justified on the basis of
advanced functionality. Meanwhile, the high cost is one of the major barriers in the use of
composite materials.

Safety:
Safety plays a major role in the automotive industry, the manufactured Body components and
the chassis are ensured meeting the quality test. Safety plays a major role in the automotive
industry, the manufactured body components and the chassis are ensured meeting the quality
test. The two important safety measures in the automotive industry considered are
crashworthiness and penetration resistance. In more detail, crashworthiness is the potential of
absorption of the energy through controlled crash modes and mechanisms. Penetration
resistance is concerned with the total absorption without allowing fragment piercing.

Recyclability:
The most important concerns in automotive industries are ‘protection of resources’, ‘reduction
of CO2 emissions’, and ‘recycling’. Europe and Asian countries have guidelines about the
recyclability. The United States has no issues and regulations about automotive end-of-life.
Steel material can be easily recyclable while the aluminium involves in high cost.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 3

PLASTICS
Plastics are able to extend the life of vehicles by preventing corrosion and providing versatility
in deploying components. From a design perspective, they offer thrifty solutions for both
artistic and fundamental automotive applications.
Plastics are used in many exterior applications, such as side-view mirrors, roof rails, spoilers,
doors, fenders, bonnets, and bumpers. They are also used for interior finishing, carpet fibers,
and cable insulation.

Plastics are used in the automotive industry for a variety of reasons, including:
• Weight reduction
Plastics are lighter than metal, which can improve fuel efficiency and reduce greenhouse gas
emissions. For every 10% of parts that are plastic instead of metal, a vehicle can gain 8% in
fuel efficiency.
• Design
Plastics can be used to create custom parts that are difficult to achieve with other materials, and
moulded plastics can improve design features at a reduced cost.
• Durability
Plastics have better mechanical strength and durability than steel.
• Chemical resistance
Some plastics, like polypropylene and polyurethane, are resistant to solvents, radiation, and
environmental wear.

METAL MATRIX COMPOSITES (MMCs)

Metal matrix composites (MMCs) are a class of material that is increasingly being used in the
automotive industry. They offer a number of advantages over traditional metals, including:

• Lighter weight: MMCs can be significantly lighter than traditional metals, which can
help to improve fuel efficiency.
• Higher strength: MMCs can be stronger than traditional metals, which can improve
the performance and safety of vehicles.
• Improved wear resistance: MMCs can be more wear-resistant than traditional metals,
which can extend the life of components.
• Better heat dissipation: MMCs can dissipate heat more effectively than traditional
metals, which can improve the performance of engines and brakes.

These advantages make MMCs ideal for a number of automotive applications, including:
• Engine components: Pistons, cylinder liners, connecting rods, and valve train
components can all be made from MMCs to reduce weight and improve performance.
• Brake components: Brake rotors and drums can be made from MMCs to improve wear
resistance and heat dissipation.
• Drivetrain components: Driveshafts and suspension components can be made from
MMCs to reduce weight and improve strength.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 4

The most common type of MMC used in automobiles is aluminium matrix composite (AMC).
AMCs are made by reinforcing an aluminium matrix with ceramic particles, such as silicon
carbide (SiC) or aluminium oxide (Al2O3).

STRUCTURAL TIMBER
Structural timber, also known as mass timber, is gaining popularity in the automobile industry
due to its potential to replace traditional materials like concrete and steel. The use of wood in
car manufacturing is not new, as it has been used in the past, but the current focus is on
developing new technologies to utilize wood in a more significant way.

Benefits of Structural Timber in the Automobile Industry

1. Sustainability: Wood is a renewable resource, making it a more sustainable option
compared to traditional materials.
2. Lightweight: Wood is significantly lighter than steel and concrete, which can improve
fuel efficiency and reduce emissions.
3. Cost-effective: Wood can be more cost-effective than traditional materials, especially
for smaller-scale production.
4. Aesthetics: Wood can add a unique and premium look to vehicles, making them more
attractive to consumers.

Applications of Structural Timber in the Automobile Industry

1. Car bodies: Wood can be used as a structural component in car bodies, replacing
traditional steel and aluminium.
2. Interior components: Wood can be used for interior components such as dashboards,
door panels, and trim.
3. Packaging: Wood can be used as a sustainable alternative to traditional plastics for
packaging and crating.

GLASS-REINFORCED PLASTICS (GRP)

Glass-reinforced plastics (GRP), also known as fiber-reinforced plastics (FRP) when referring
to various fiber types, are composite materials that have become increasingly important in the
automotive industry.
GRP is a composite material, which means it's made by combining two or more distinct
materials to create a final product with properties superior to its individual parts. In GRP, the
two key components are:
• Glass Fibers: These fibers act as the reinforcement, providing strength and rigidity to
the material.
• Resin: A plastic resin, typically epoxy or polyester, binds the glass fibers together and
transfers stresses between them.

Advantages of GRP in Cars:

• Lightweight champion: GRP shines in weight reduction compared to traditional
materials like steel. This translates to improved fuel efficiency and performance, a
major benefit for automakers.
Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.
VEHICLE BODY MATERIALS 5

• Design flexibility: Unlike heavy metals, GRP can be molded into complex shapes,
giving designers more freedom to create stylish and aerodynamic car parts.
• Strength and Durability: Modern GRP composites, when properly engineered, can
offer impressive strength-to-weight ratios and good durability, making them suitable
for various car parts.
• Corrosion resistance: Unlike metals, GRP is not susceptible to rust or corrosion,
eliminating a major concern for car longevity.
• Part consolidation: GRP parts can sometimes integrate multiple functionalities,
reducing the number of parts needed and simplifying manufacturing.

Common GRP Applications in Cars:

• Body panels: GRP is widely used for non-critical body parts like fenders, hoods, trunk
lids, and door components due to its lightweight and design advantages.
• Interior components: Car dashboards, door panels, and even some structural supports
for seats can be made from GRP, offering design flexibility and weight savings.
• Under-the-hood parts: Applications include air intake manifolds, valve covers, and
even some engine components due to GRP's ability to handle moderate heat.

Types of GRP used in Cars:

• Short Glass Fiber Reinforced Plastic (S-GFRP): Offers a good balance of strength,
weight, and affordability. Commonly used for interior parts and some exterior panels.
• Long Glass Fiber Reinforced Plastic (L-GFRP): Provides superior strength and
stiffness due to longer fibers. Used for structural components requiring more rigidity.

Challenges of GRP in Cars:

• Strength variability: GRP strength can vary depending on fiber orientation and resin
type. Careful engineering is needed to ensure consistent performance.
• Recyclability: Recycling GRP can be more complex than traditional materials like
steel. New technologies are being developed to improve recyclability.
• Repair complexity: While repairable, GRP repairs can be more involved than those
for metal parts.

HIGH STRENGTH COMPOSITES

High-strength composites are essentially materials made by combining two or more distinct
components to create a final product with properties superior to its individual parts.

In the context of the automotive industry, they are composite materials where:
• Reinforcement: High-strength fibers like carbon fiber or aramid fibers are used for
reinforcement. These fibers provide incredible strength and stiffness.
• Matrix: A resin, typically a polymer, acts as a matrix to bind the fibers together and
transfer stresses between them.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 6

Here's what makes them special:

• Unbeatable Strength-to-Weight Ratio: The magic lies in the combination. High-
strength fibers are incredibly strong for their weight, and the resin matrix holds them
together efficiently. This translates to a material that's much lighter than traditional
metals like steel but can be even stronger.
• Tailored Properties: By varying the type and orientation of the fibers, and the
properties of the resin, engineers can design composites with specific properties for
different applications.

Types of High-Strength Composites for Cars:

• Carbon Fiber Reinforced Plastic (CFRP): The king of the hill, CFRP boasts an
incredible strength-to-weight ratio. It's the go-to material for high-performance cars and
parts needing exceptional strength without weight penalty.
• Aramid Fiber Reinforced Plastic (AFRP): Also known as Kevlar-reinforced plastic,
AFRP offers outstanding impact resistance and energy absorption. This makes it
valuable for car parts that need to be resilient in crashes, like bumpers and underbody
components.

Impact on Automotive Industry:

High-strength composites are revolutionizing car design and manufacturing by enabling:
• Lighter, More Efficient Cars: Significant weight reduction translates to dramatic
improvements in fuel efficiency and performance, especially for electric vehicles.
• Enhanced Safety: CFRP's high strength allows for lighter yet stronger car structures,
improving passenger protection. AFRP's impact resistance further bolsters safety in
specific areas.
• Aerodynamic Designs & Performance: The ability to be moulded into complex
shapes facilitates aerodynamic designs and lighter weight, leading to better handling
and a more engaging driving experience.

THERMOPLASTICS
Thermoplastics are a type of plastic that can be melted and reshaped multiple times without
undergoing any significant chemical change. They have an open-chain molecular structure,
which allows them to be reheated, reshaped, and frozen repeatedly. Most thermoplastics have
a high molecular weight.

Thermoplastics have become increasingly popular in the automotive industry due to their
unique properties, such as high strength, stiffness, and durability.

Here are some examples of thermoplastics used in automotive applications:

1. Mixed Material Solutions
Thermoplastics are often combined with other materials, such as metals or fibers, to create
hybrid components. For instance, the Honda Clarity rear bumper and door-module carriers are
made from a combination of continuous fibers and thermoplastics.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 7

2. Thermoplastic Composites
Thermoplastic composites are used in various automotive applications, including body panels,
bumpers, and interior components. They offer high strength, stiffness, and durability,
making them an attractive alternative to traditional materials.

3. Lightweighting
Thermoplastics are used to reduce the weight of vehicles, which improves fuel efficiency and
reduces emissions. For example, thermoplastic materials are used in the production of car mats,
which are designed to be lightweight and durable.

4. Insulation and Acoustic Properties

Thermoplastics are used to improve the thermal and acoustic insulation of vehicles. They
can be used in applications such as door seals, trunk seals, and engine mounts.

5. Electrical and Electronic Components

Thermoplastics are used in the production of electrical and electronic components, such as
connectors, switches, and sensors. They offer high insulation properties, making them ideal for
these applications.

Examples of Thermoplastics Used in Automotive Applications:

• Polyethylene terephthalate (PET)
• Polyamides (PA)
• Polypropylene (PP)
• Carbon fiber reinforced plastic (CFRP)
• Glass fiber reinforced plastic (GFRP)
• Thermoplastic elastomers (TPE)

Benefits of Thermoplastics in Automotive Applications:

• High strength and stiffness
• Low weight
• Good thermal insulation properties
• High chemical resistance
• Recyclable
• Sustainable

ABS & STYRENE’s

ABS (Acrylonitrile Butadiene Styrene) is a type of thermoplastic that incorporates the
properties of three different monomers: acrylonitrile, butadiene, and styrene. Here's a
breakdown of ABS and its relation to styrene:

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 8

ABS:
• Composition: A terpolymer, meaning it's formed by combining three monomers.
o Acrylonitrile (AN) contributes strength, chemical resistance, and heat
deflection.
o Butadiene (BD) provides toughness and impact resistance.
o Styrene (S) offers rigidity, processability, and a glossy finish. The ratio of these
monomers can be adjusted to achieve specific properties for different
applications.
Styrene:
• Individual Properties: Styrene itself is a monomer, a single building block used to
create polymers. It's a colourless liquid that's a major component in the production of
many plastics, including polystyrene (PS).
o Styrene contributes rigidity and ease of processing to ABS, making it mouldable
and workable during manufacturing.
o It also helps with the final surface finish, allowing ABS to have a smooth and
potentially glossy appearance.

Some properties of ABS:

• ABS provides favourable mechanical properties such as impact resistance, toughness,
and rigidity when compared with other common polymers.
• A variety of modifications can be made to improve impact resistance, toughness, and
heat resistance.
• The impact resistance can be amplified by increasing the proportions of polybutadiene
in relation to styrene and also acrylonitrile, although this causes changes in other
properties.
• Impact resistance does not fall off rapidly at lower temperatures.
• Stability under load is excellent with limited loads.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 9

LOAD BEARING PLASTICS

The term "load-bearing plastics" isn't quite a standardized category, but it refers to plastics that
can withstand significant forces and be used in situations where they need to support weight or
pressure.

Types of Load-Bearing Plastics:

1. High-Strength Composites: These are the champions when it comes to strength-to-
weight ratio. Examples include:
o Carbon Fiber Reinforced Plastic (CFRP): The king of the hill, CFRP offers
incredible strength without much weight. It's ideal for high-performance
applications like car parts needing exceptional strength or components requiring
high structural integrity.
o Aramid Fiber Reinforced Plastic (AFRP): Also known as Kevlar-reinforced
plastic, AFRP excels in impact resistance and energy absorption. This makes it
valuable for car parts that need to be resilient in crashes, like bumpers and
underbody components.

2. Engineering Plastics: These are specifically formulated thermoplastics designed for

demanding applications. They often have fillers, reinforcements, or special additives to
enhance their ability to bear loads. Some examples include:
o Nylon: Known for its strength, stiffness, and wear resistance. It's used for gears,
load-bearing components in machines, and even some structural automotive
parts.
o Polycarbonate (PC): Offers a good balance of strength, impact resistance, and
dimensional stability. It can be used for load-bearing applications in electronics,
appliances, and even some transparent structural parts.
o Polyacetal (POM): Provides high stiffness, good wear resistance, and
dimensional stability. It finds uses in gears, bearings, and other parts requiring
low friction and high load-bearing capacity.

3. Glass Reinforced Plastic (GRP): While not the strongest option, GRP offers a good
balance of affordability, strength, and design flexibility. It's used in various load-bearing
applications where extreme strength isn't the sole focus. Examples include:
o Boat hulls: GRP is a popular choice for boat hulls due to its lightweight strength
and good resistance to moisture.
o Storage tanks: Chemical storage tanks and water tanks can be made from GRP,
depending on the specific application and required load-bearing capacity.
o Certain automotive parts: Non-critical car body panels and some structural
components can benefit from GRP's lightweight strength.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 10

Choosing the Right Load-Bearing Plastic:

The selection depends on various factors like:
• Required strength and stiffness: The level of load the plastic needs to handle is
crucial.
• Weight considerations: If lightweighting is a priority, high-strength composites or
some engineering plastics like nylon might be preferable.
• Environmental factors: Exposure to heat, chemicals, or moisture needs to be
considered.
• Cost and recyclability: Certain high-performance options can be expensive, and
recyclability is a growing concern.

SEMI RIGID PUR FOAMS AND SANDWICH PANEL CONSTRUCTION

Semi-rigid PUR (polyurethane) foams are a type of foam material that offers a balance between
the rigidity of traditional foams and the flexibility of softer materials. This makes them a
valuable option for use in sandwich panel construction, which combines a lightweight core
material sandwiched between two stronger surface layers.

Properties of Semi-rigid PUR Foam:

• Balance of Strength and Flexibility: Compared to rigid PUR foams used in some
panels, semi-rigid foams offer slightly less rigidity but with some degree of flexibility.
This can be beneficial in certain applications where some give is desirable.
• Thermal Insulation: Similar to their rigid counterparts, semi-rigid PUR foams provide
good thermal insulation properties, helping to maintain desired temperatures within a
structure.
• Lightweight: They are significantly lighter than traditional materials like wood or
metal, contributing to the overall lightweight advantage of sandwich panels.
• Good Adhesion: Semi-rigid PUR foams can bond well with the facings (surface layers)
of the sandwich panel, creating a strong and cohesive structure.

Benefits of Using Semi-rigid PUR Foam in Sandwich Panels:

• Improved Impact Resistance: The slight flexibility of the foam core can help absorb
impact to some extent, compared to very rigid cores that might be more prone to
cracking.
• Design Flexibility: The ability to deform slightly can be advantageous in applications
where some minor shaping of the panel might be required during construction.
• Reduced Weight: Compared to rigid foams, they can offer a slight weight reduction
while still maintaining good structural integrity.

Applications of Sandwich Panels with Semi-rigid PUR Foam:

• Building Construction: Wall and roof panels in prefabricated buildings, warehouses,
and even some residential applications can benefit from semi-rigid PUR foam cores.
• Transportation: Cladding for trucks, trailers, and even some recreational vehicles can
utilize these panels due to their lightweight and insulating properties.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 11

• Cold Chain Applications: Refrigerated containers and storage units can benefit from
the good thermal insulation properties of semi-rigid PUR foam cores.

Benefits of Semi-Rigid PUR Foams in Sandwich Panel Construction

The use of semi-rigid PUR foams in sandwich panel construction offers several benefits,
including:
• Improved thermal insulation: Semi-rigid PUR foams provide high thermal insulation,
reducing energy loss and improving building energy efficiency.
• Increased durability: Semi-rigid PUR foams are resistant to degradation and can
withstand harsh environmental conditions.
• Fire resistance: Semi-rigid PUR foams have a high fire resistance, making them
suitable for use in applications where fire safety is a concern.
• Reduced weight: Semi-rigid PUR foams are lightweight, reducing the overall weight
of the sandwich panel and making it easier to handle and install.

PAINTS & ADHASIVES

In the automotive industry, paints and adhesives play crucial roles, but they serve distinct
purposes:

Paints:
• Function: Car paint provides a protective and aesthetic finish for the vehicle's exterior.
It offers several benefits:
o Protection: High-quality paint shields the car's bodywork from weather
elements like sun, rain, and road debris. It also helps prevent corrosion.
o Aesthetics: Automotive paint provides a glossy, finished look and comes in a
wide variety of colours, allowing for personalization and visual appeal.
o Visibility and Safety: Reflective paints enhance nighttime visibility, while
clear coat protects reflective elements on headlights and taillights.

• Types of Paints used in Cars:

o Primer: Provides a base coat for better adhesion of the main paint layers.
o Basecoat: This coloured layer determines the car's overall colour.
o Clearcoat: The final layer provides a glossy finish, protects the underlying paint
from UV rays and scratches, and offers additional durability.

Adhesives:
• Function: Automotive adhesives are used for various purposes, including:
o Bonding body panels: Certain adhesives are used alongside welds or rivets to
create strong and seamless joints between car body panels.
o Attaching interior components: Adhesives help secure dashboards, door
trims, headliners, and other interior parts.
o Windshield installation: Modern windshields are often bonded to the car frame
using special adhesives for improved structural integrity and safety in rollovers.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.

VEHICLE BODY MATERIALS 12

o Sealing applications: Adhesives are used as sealants around lights, windows,

and other gaps to prevent leaks and improve noise reduction.

• Types of Adhesives used in Cars:

o Structural adhesives: High-strength adhesives used for bonding body panels,
often alongside welding for added security.
o Polyurethane adhesives: Offer good flexibility and adhesion to various
materials, commonly used for interior components.
o Acrylic adhesives: Fast-drying and versatile, used for trim pieces, emblems,
and some non-structural applications.
o Anaerobic adhesives: Cure in the absence of air, ideal for sealing threaded
connections or gaps where oxygen might be limited.
There isn't a specific category called "paint adhesives" in the automotive industry. While
paints and adhesives are both essential, they are distinct materials.

Pavan T S, Asst. Professor, 6th Sem Automobile Engineering, GEC Challakere.