The automotive industry is undergoing one of the most defining moments in its history. At the heart of this unprecedented transformation are developments in automotive materials.
We’re long past the era when almost every other car was made from steel or plastic. The past decade has magnified the need to focus more on sustainability and safety and less on vehicle performance alone.
This article explores the latest trends in automotive materials, providing insights into their impact on manufacturing and the future of the materials & applied science industry.
Impact of Lightweight Materials on Fuel Economy
One of the most important advancements in the automotive industry– in recent years – other than new emerging roles, of course – has been the widespread adoption of lightweight materials. The catalyst for this? A realization amongst manufacturers that it’s possible to bump up fuel economy without ever sacrificing vehicle performance.
High-strength Steel
This material is arguably the most versatile lightweight material out there, seamlessly combining lightness with exceptional ductility. The impact on vehicle construction is notable: structurally sound units that weigh half their usual weight or less. This considerable weight reduction is crucial for increasing fuel economy, and the science behind it is quite simple.
The heavier the vehicle body, the more energy (fuel) it’ll take to move and accelerate it. High-strength steel is among the most lightweight materials out there, capable of reducing body weight by up to 25%, according to the Department of Energy. As such, it’s a solid option for keeping vehicle efficiency issues at bay.
Aluminum
It’s hard not to throw aluminum into the mix when having a weight-savings conversation. A huge number of the hoods, doors, and body panels you see on cars today are aluminum-based. And the impact on fuel efficiency is nothing short of incredible. For manufacturers racing to meet the skyrocketing demand for greener vehicles, aluminum isn’t just an option – it’s a mainstay.
Carbon Fiber Composites
If high-end steel and aluminum had a more expensive cousin, then it would undoubtedly be carbon fiber composites. This material makes up for its lofty costs with unrivaled lightness and durability. As such, it’s a go-to for luxury vehicles, performance cars, and electric vehicles (EVs) where weight plays a pivotal role in efficiency and battery performance.
Challenges in Recycling Composite Materials
For all their fuel economy benefits, lightweight materials like carbon fiber composites do present a few challenges. One of them is recycling. Unlike metals, which are pretty easy to melt down and reuse, composite materials’ inherent nature makes the whole recycling proposition hard to execute. Here’s why:
- Durability: For instance, the resins and fibers in carbon fiber composites can take hundreds of years to break down.
- Complexity: It can be a tall order to separate mixed plastics or alleviate residues from automotive parts.
- Heterogeneous materials: Automotive composites are made from some of the most chemically compatible materials and resins out there. They’re simply too strongly connected to break down easily.
Role of Materials Engineering in Crashworthiness
A vehicle, no matter how fancy or high-performance, is only as good as its safety capabilities. No wonder crashworthiness is still the single most important priority in the vehicle manufacturing space.
As manufacturers continually seek to cut down vehicle weight, they must also ensure that the vehicles meet safety standards and adequately protect occupants in the event of a crash. Fortunately, the concept of materials engineering has revolutionized how manufacturers approach crashworthiness.
After assessing the behavior of aluminum and high-strength steel over time, scientists came to an unequivocal conclusion: they are perfect for designing crumple zones. These are areas of a vehicle designed to absorb and dissipate the energy from an impact. These materials take in enough energy to ensure that even if the passenger cabin takes a hit, it’ll deform in a controlled, low-risk manner. This greatly reduces the possibility of incurring injury.
Integration of Sensors in Smart Materials for Vehicles
Smart materials that can respond to external stimuli are already causing waves in the automotive materials & applied science industry. The integration of sensors and intelligent systems into these materials opens up new, endless possibilities for adaptive, self-adjusting vehicles. In the not-so-distant future, the vehicle you’ll drive will likely feature materials capable of responding, in real-time, to the slightest environmental triggers and changes. From a driver safety and vehicle functionality perspective, that’ll be a useful perk.
Picture, for instance, materials that quickly change rigidity in response to an impact so the driver can have extra protection in a crash. Or materials that instantly alter their properties to optimize fuel efficiency and aerodynamics based on driving conditions. Pretty futuristic, right?
Read more: The Evolution of Smart Manufacturing
Future of Electric Vehicle Batteries
Electric Vehicles (EVs) are gaining traction in the automotive market at a pace never seen before. Even so, users are constantly scrutinizing the performance, cost, and environmental impact of the batteries used to power these vehicles.
As we speak, lithium-ion batteries are the presiding technology. However, manufacturers are tirelessly looking into new battery materials to tackle issues such as charging times and sustainability.
While still in the initial investment phase, solid-state batteries are one of the most promising innovations. These batteries utilize a solid electrolyte rather than the liquid one found in typical lithium batteries. The result? Greater energy density, heightened safety, and quicker charging times.
That’s not all. Researchers are also exploring alternative candidates to lithium, such as magnesium, sodium, and even organic compounds – all low-cost, environmentally friendly, and abundant.
Key Takeaway: Innovative Materials Are the Future of Auto
The future of the automotive materials & applied science industry has never been brighter, and it lies in the ability to harness the potential of innovative materials. Those who lead the charge will set the stage for a safer, more sustainable, and more efficient automotive world. Recruiting is also a great part of the automotive manufacturing future you’re ardently working towards. Let us connect you with an experienced recruiter so the next workforce you build will capably deliver on your innovation goals — one material at a time. Contact MRINetwork today.