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Abstract
For cars, weight and fuel efficiency are two important issues. Research has shown that the best way
to improve fuel efficiency is to reduce the overall weight of the car, without sacrificing the safety of
the passengers. The use of composites in the production of car parts has proven to be able to
balance the reducing the weight and preserving passenger safety. The car bumper is one of unique
area that has benefited from the use of composite material. In this review, two bumpers made from
nylon-6 nanocomposite and polyethylene/palm kernel shell-iron filings composite are analysed. The
mechanical properties of these composite materials are then compared to conventional car bumper
material such as aluminium and steel, this comparison showed a reduction in weight, cost and
environmental impact, disadvantages such as difficulty in mass production and sophistication of the
production process were also noted.
Contents
Abstract ................................................................................................................................................... 1
Introduction ............................................................................................................................................ 2
Bumpers .................................................................................................................................................. 2
Bumper material requirements .......................................................................................................... 2
Aluminium bumpers ........................................................................................................................... 2
Steel bumpers ..................................................................................................................................... 3
Dimensions and Properties of existing steel Bumpers ................................................................... 3
The production of steel bumpers ................................................................................................... 3
Composite Bumper ................................................................................................................................. 3
Composite materials used .................................................................................................................. 4
Glass fibres ...................................................................................................................................... 4
Epoxy resin ...................................................................................................................................... 4
Design of a composite bumper ............................................................................................................... 4
Recycled Polyethylene/palm kernel shell-iron filings composite ................................................... 5
Nylon-6 ............................................................................................................................................ 6
Summary ......................................................................................................................................... 7
Appendix ................................................................................................................................................. 8
Bibliography ......................................................................................................................................... .10
Introduction As stated earlier, the National highway traffic safety
administration produced a set of standards which
This literature review will focus on car bumpers, the
govern the base requirements of bumpers for
National Highway Traffic Safety Administration
passenger automobiles. The bumper standards
(NHTSA) defines a bumper as a shield made of
imposed are [3] [4]:
aluminium, plastic, rubber or steel that is mounted on
the front and rear of a passenger car. It is expected Front and rear bumpers on passenger cars
that in low speed collision the bumper system is to be should prevent damage to car body,
able to absorb the shock to reduce or prevent damage Bumper should be capable of withstanding
to the car; some make use of energy absorbers or impacts at 2 mph across full width and 1mph
brackets and other foam cushioning materials [1]. on corners,
Following current trends, weight reduction has Bumper should be able to withstand 5 mph
become a key focus of automobile manufacturers. crashes with parked cars,
Bumpers are to be placed between 16 to 20
Sustainable use and development of natural resources
inches above road surfaces.
is the main focus of automobile manufacturers in the
present market [2]. Achieving the above calls for a Satisfying these conditions during low speed impact
more innovative approach to better materials, more collisions is paramount.
effective manufacturing processes and an
introduction of superior design concepts. Bumper material requirements
Able to absorb more energy while in collision
Bumpers Easy for large scale manufacturing,
Car bumper is a safety system used to counteract low High resistance to rust,
speed collisions, it is placed in the car body and Light in weight,
designed to prevent or reduce physical damage to the Low cost.
front and rear ends of the car during low impact
collisions [1].
Hardness properties
The hardness properties were measured at room
temperature and recorded. The data shows an Figure 4: Schematic illustration for synthesis of Nylon-6/clay [20]
increase in hardness number in relation with the
increase in percentage composition of reinforcement
(see appendix figure 12); this can be attributed to the
percentage of hard and brittle phases of the ceramic
body in the polymer matrix. The large variation of
hardness number of the composite materials is as a
result of the distribution of the reinforcements in the
matrix and can be solved by ensuring a more uniform
distribution of reinforcements in the matrix.
Impact Properties
A reduction in the composites’ impact energy was
noted as the concentration of CPKS increased. This is
largely due to the reduction in elasticity of the
material due to the addition of particles which reduce
the deformability of the matrix, thereby reducing the
matrix ability to absorb impact energy. Figure 5: Formation of Nylon-6 Nanocomposite by situ
polymerisation [21]
Nylon-6
Toyota Central Research Laboratory first reported
their work on Nylon-6 in the early 1990’s [16] [17]. It As shown in the figure above, sodium montmorillonite
was reported that small amounts of Nano-filler is mixed with an aminolauric acid in an aqueous
loading, results in a pronounced improvement in hydrochloric acid to protonate the aminolauric acid
thermal and mechanical properties. which then exchanges with the sodium counter ions.
Alkyl units of the resulting organ clay have terminal
The properties of Nylon-6 is not only a factor of its
carboxyl groups. Under certain conditions, these
individual parent components i.e. Nano-filler and
carboxyl groups initiate ring-opening polymerization
nylon, but also its morphology and characteristics
of caprolactam forming nylon-6 chains which are
[18].
ionically bonded to the alum inosilicate platelets.
Materials and Method Driven by the free energy from the polymerization,
Under appropriate thermodynamic interactions, the chains grow forcing the platelets apart until
polymers can spontaneously intercalate the galleries exfoliation is accomplished. According to a report
of organ clays. However the static diffusion cannot written by a team from the chemical engineering
lead to full exfoliation [19]. Toyota disclosed an department of Texas Materials institute,
improved method for producing nylon-6/Clay nanocomposites would have been more widely used if
nanocomposites using an in situ polymerization that they could be formed from existing polymers using
exfoliates the alum inosilicate layers through a conventional melt processing techniques such as
chemical mechanism. The Toyota process can be seen injection moulding and extrusion [21].
in figure 5 below. Also shown below in figure 4 is the
Schematic illustration for synthesis of Nylon-6/C lay.
Stress-strain properties Effect of clay on nylon-6 crystallization
One notable benefit of adding high aspect ratio, Nano Isothermal crystallization studies at 197°C shows that
scale platelets to the polymer is the increase in small crystal platelets act as nucleating agents for
modulus per unit mass of reinforcement. This results crystallization for the nylon-6 matrix. At this
in the material demonstrating higher strength, temperature, the crystallization half-life, 𝑡1⁄ is
2
hardness and scratch resistance [21], as well as a normalized by that of the extruded matrix polymer
sizably increased stress at break. This is explained without any clay. This property is of particular
using the presence of polar and ionic interactions commercial interest. While clay increases the number
between the polymers and its layers. Figure 13 show nuclei, high clay loading retards polymer crystal
the relationship between modulus and molecular growth.
weight of the nylon 6 matrix. The graph shows the
higher level of modulus at given MMT loading. The Summary
stress at break was found to be sizably strong. A car This research work has reviewed two key composite
bumpers ability to function at relatively high stress materials along with their various production routes,
and strain conditions is essential; and the stress-strain advantages and disadvantages. In the case of the Palm
properties of nylon-6 make it a good choice. kernel Shell-Iron filing composite, it was noted that
most of the composite materials’ mechanical
Thermal expansion Behaviour properties were lower than that of their conventional
Polymer nanocomposites are expected to have counterparts. In addition, the composite material with
improved thermal expansion properties, while 5wt% of and 10 wt% CPKS were recommended for use
retaining the processing and surface characteristic of in the production of car bumpers due to their high
its matrix owing to the small size and low content of impact energy to density ratios of 0.2 and 0.19
the Nano-filler [21]. Through the use of a high respectively, which puts them close to that of the
resolution transmission electron microscopy (TEM), standard failure mode exhibited during their testing.
the orientation of the clay platelets in the nylon 6 In addition, the materials used are
nanocomposite was viewed. As seen in figure 14, the
platelets are better aligned in the FD axis than their Environmental impact,
TD counterparts with there being little alignment in Low costs (roughly a 77.2% reduction); steel
the ND axis. The thermal expansion of the high bumper cost $3600 whilst its CPKS
molecular weight nylon-6 nanocomposites possesses counterpart was valued at $820.
thermal expansion coefficient in the rubbery state on
Nylon-6 nanocomposites present a many possibilities:
par with that of those below the glass state, this
these nanocomposites not only exhibit excellent
improved thermal expansion means deformation in mechanical properties, but also display outstanding
the car bumper due to temperature conditions is kept combination of optical, electrical, thermal, magnetic
as a minimum.
and other physico-chemical properties.
Impact properties One advantage of nanocomposites is that the
The formation of Nylon-6 nanocomposites does not strength, shrinkage, warpage, viscosity and optical
result in significant reduction in the impact properties properties of the polymer matrix are not significantly
of the material, the stiffness and strength of the affected; another advantage is their mechanical,
nanocomposite are greatly improved as the amount electrical, thermal, barrier and mechanical properties
of organo-clay is increased. However, the IZOD2 such as increased tensile strength, improved heat
impact strength is reduced from 20.6 to 18.1 J/m deflection temperature, flame retardant, etc., which.
when 4.7 wt. % of organo-clay is incorporated. This is can be achieved with typically 3-5 wt.% loading.
still a relatively good impact resistance value for low
speed impacts. The impact density ratio values for the However, there are huge limitations in producing
nanocomposite further supports the use of Nylon-6 them, such as costs, processing constraints, oxidative
for the production of car bumpers. More mainstream and thermal instability and unstable market share
bumper materials offer better impact resistance [22].
properties at low and high speed impact conditions.
2
ASTM standard method of determining the impact
resistance of materials.
Appendix