Automotive plastics offer numerous advantages that traditional materials cannot match. They are characterized by lightweight design, excellent aesthetic appeal, a wide range of functional applications, superior physical and chemical properties, ease of processing and molding, energy efficiency, and sustainable use. These features make them highly suitable for modern vehicle manufacturing.
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**Engineering Plastics**
Engineering plastics are widely used in the automotive industry due to their outstanding mechanical properties. This paper mainly discusses polyamide (PA), polymethyl methacrylate (PMMA), polyoxymethylene (POM), polycarbonate (PC), and polyurethane (PU).
**PA (Polyamide)**
Polyamide, commonly known as nylon, is widely used in industrial applications. Common types include PA6, PA66, and PA610. It is easy to print and dye, has excellent electrical properties, and is resistant to chemicals and oils. PA exhibits high surface hardness, good tensile strength, impact resistance, fatigue resistance, and stress crack resistance. However, its tensile strength can be affected by temperature and moisture, making water a plasticizer for PA. Adding glass fiber can double its tensile and compressive strength and improve heat resistance.
Despite its strengths, PA has some disadvantages, such as poor acid resistance, light sensitivity, and stain resistance. Its dimensional stability is affected by thermal expansion and moisture absorption, with a shrinkage rate of 1–2%. The water absorption rate is up to 100%, and it can absorb 8% when fully saturated. The ideal wall thickness is between 2 and 3.5 mm.
In injection molding, PA has strong hygroscopicity due to the presence of amide groups, so it must be thoroughly dried at 120°C for 3–4 hours. Its low viscosity leads to fast flow, so a self-locking or nylon-specific nozzle is recommended. Mold accuracy is also important during the process.
PA is primarily used in automotive components such as brake hoses, fuel lines, filters, water pump housings, impellers, fans, brake fluid tanks, power steering reservoirs, sun visors, headlight casings, and seat belts.
**PMMA (Polymethyl Methacrylate)**
Polymethyl methacrylate, commonly known as acrylic or plexiglass, is highly resistant to outdoor aging and offers excellent light transmission. After 240 hours of accelerated UV exposure, it still transmits 92% of sunlight, and after a decade outdoors, it retains 89% of its transparency. It has high mechanical strength, cold resistance, corrosion resistance, good insulation, and stable dimensions. However, it is brittle, easily melted by organic solvents, and prone to scratching.
The moisture absorption rate is only 0.3%, so drying is required before injection molding at 80°C for 2–4 hours. The melt temperature should be between 240–270°C, and the mold temperature should be controlled at 35–70°C.
PMMA is widely used in automotive lighting, including signs, door glass, and lamp covers, thanks to its optical clarity.
**POM (Polyoxymethylene)**
POM, often called “plastic steel,†has high tensile strength, impact resistance, rigidity, fatigue resistance, and creep resistance. It has low water absorption, excellent wear resistance, and maintains rigidity even at high temperatures. Compared to PA, it is more cost-effective and has better resilience. It can operate effectively between -40°C and 100°C.
However, POM is vulnerable to strong acids and has limited heat resistance. Its shrinkage rate is 2–3.5%, and the ideal wall thickness is 1.5–2.5 mm.
During injection molding, POM has a distinct melting point at 175°C and decomposes at 240°C. Processing temperature usually ranges from 190–220°C. Since it does not absorb water, drying is generally unnecessary unless high-quality standards are required. It should not be processed at too high a temperature to avoid discoloration.
POM is used in instrument panel components, valves, impellers, switches, gears, handles, and door latches.
**PC (Polycarbonate)**
Polycarbonate has excellent impact resistance, creep resistance, and thermal stability. It has a low embrittlement temperature (-100°C) and high elongation and modulus. It is also relatively lightweight, with a shrinkage rate of 0.5–0.7% and good dimensional stability. It is slightly less durable than nylon 66 in terms of fatigue resistance but offers good corrosion resistance and weather resistance.
PC is sensitive to moisture and requires drying at 120°C for 4–5 hours before injection molding. The processing temperature is typically between 250–320°C. PC has high melt viscosity and requires high injection pressure. Mold temperature control helps reduce residual stress.
PC-ABS is a blend of PC and ABS, combining the best properties of both materials. It offers high surface hardness, rigidity, toughness, and resistance to stress cracking.
PC is used in automotive parts such as lampshades, wheel covers, instrument panels, wind frame covers, and bumpers.
**PU (Polyurethane)**
Polyurethane is divided into rigid and flexible types. Rigid PU has high strength, good toughness, insulation, and waterproofing properties, while flexible PU offers excellent elasticity, sound absorption, and chemical resistance. It is easy to polymerize and can be foamed, sprayed, or repaired on-site.
PU foam is widely used in automotive interiors and vibration-damping parts, such as seat cushions, dashboards, door panels, and ceiling linings. PU is also used in coatings, adhesives, and sealants.
Overall, automotive plastics continue to play a vital role in the development of modern vehicles, offering a combination of performance, cost-effectiveness, and environmental benefits.
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