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Transportation Industry Marine Composites A study completed by Ford in 1988 confirms the feasibility of extensive plastics use as a means of reducing production costs for low volume automobiles, such as electric powered cars. According to the study, plastics yield a parts reduction ratio of 5:1, tooling costs are 60% lower than for steel stamping dies, adhesive bonding costs are 25-40% lower than welding, and structural composites demonstrate outstanding durability and crashworthiness. Composite front axle crossmember parts have undergone extensive testing in Detroit and await a rationale for production. [1-47] The Ford Taurus and Mercury Sable cars utilize plastics extensively. Applications include exterior, interior and under the hood components, including grills, instrument panels and outside door handles, to roof trim panels and insulations, load floors, cooling fans and battery trays. The polycarbonate/PBT wraparound front and rear bumpers are injection molded of fi General Electric’s Xenoymaterial. [1-48] Other significant new plastic applications in Ford vehicles include the introduction of the high density polyethylene fuel tank in the 1986 Aerostar van. [1-48] A prototype graphite reinforced plastic vehicle was built in 1979 by Ford Motor Company. The project’s objective was to demonstrate concept feasibility and identify items critical to production. The prototype car weighed 2,504 pounds, which was 1,246 pounds lighter than the same car manufactured of steel. Automotive engineers are beginning to realize the advantages of part integration, simplified production and reduced investment cost, in addition to weight savings and better durability. [1-40] The Ford Motor Company in Redford, MI established engineering feasibility for the structural application of an HSMC Radiator Support, the primary concern being weight savings. [1-49] The Ford Motor Company and Dow Chemical Company combined efforts to design, build and test a structural composite crossmember/transverse leaf spring suspension module for a small van. Prototype parts were fabricated and evaluated in vehicle and laboratory tests, and results were encouraging. [1-50] General Motors Buick uses Hoechst Celanese’s RitefleBxP 9086 polyester elastomer alloy for the bumper fascia on its 1989 LeSabre for its paintability, performance and processability. [1-46] The Pontiac Fiero has an all-plastic skin mounted on an all steel space frame. The space frame provides all the functional strengthening and stiffening and consists of a five-piece modular design, and the plastic body panels are for cosmetic appearance. The shifter trim plate for the Pontiac Fiero is made of molded styrene maleic anhydride (SMA) and resists warping and scratching, readily accepts paints and exceeds impact targets. Drive axle seals on the 1985 GM front wheel drive cars and trucks are made of Hytrel polyester elastomer for improved maintenance, performance and life. Wheel covers for the Pontiac Grand AM are molded of Vydyne mineral reinforced nylon for high temperature and impact resistance. [1-48] GenCorp Automotive developed a low density sheet molding compound (SMC) that is claimed to be 30% lighter than standard SMC. The material has been introduced on the all-plastic bodied GM 200 minivan and the 1989 Corvette. [1-46] The automotive exterior panels on the fi 43PDF Image | Marine Componsites
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