1st Edition

The Role of the Chemist in Automotive Design

By H. K. Phlegm Copyright 2009
    212 Pages 109 B/W Illustrations
    by CRC Press

    212 Pages 109 B/W Illustrations
    by CRC Press

    From the development of polymers that make cars lighter to fuels that make them run cleaner, the chemist’s role in the automotive industry has evolved to be one that is more outside the laboratory than in it. Drawing on the author’s 20 years of experience in vehicle design and laboratory experience, The Role of the Chemist in Automotive Design elucidates how the skills of chemists are put to use in the automotive industry and their effect on all phases of design.

    A glance through the table of contents provides an overview of the issues commonly encountered by chemists in the automotive industry. The author discusses fuels cells, lithium ion batteries, carbon nanotubes, and nickel metal hydride technology, all of which require the technical knowledge of a chemist but cross the lines of various disciplines. He also covers future technology including items such as battery technology, fuel cell membranes, and environmentally friendly plastics such as nylons that use castor oil as a primary component. The book examines environmental concerns such as CARB legislation and how the industry plans to deal with the new legislation with strategies such as Ozone Reduction Catalyst.

    The increasing technological, environmental, and economic issues facing the auto industry underscores the need for a basic reference that covers technologies that can be used to make vehicle more fuel efficient, environmentally friendly, and cost efficient. Exploring the expanding role chemists will play in future automotive design and technology, this book delineates the areas and technologies that require the technical knowledge of a chemist but that cross the lines of many disciplines.

    Introduction to the Automobile Industry

    Introduction

    Historical Factors Affecting Today’s Industry

    Competitive Imperatives

    Indifference Maps and Curves

    Market Demand

    Vehicle Mass Targets

    Power Train Cooling Requirements

    HVAC

    Emissions

    Green Alternatives

    References

    Traditional Role of the Chemist in the Automobile Plant Environment

    Introduction

    Incoming Inspection

    Methods around Metals

    Atomic Absorption for Metal Analysis

    Separation and Chromatography of Organics

    Liquid–Solid Adsorption in HPLC

    Soluble Oils

    Lubricity Additives

    Some Problems with HPLC as a Lab Tool

    Plate Theory and Rate Theory

    Elastomer Characterization

    Plastic and Elastomer Analysis

    DSC Graphs

    Stress–Strain Relationships

    Bond Stiffness versus Modulus

    References

    Component Materials in Automobiles

    Introduction

    Polymer Market Penetration

    Methods of Production and Production Demand

    Ziegler–Natta

    Metal Oxide Initiation

    Other Methods of Production

    Chain Growth Polymerization

    Step Growth Polymerization

    Ionic Polymerization

    References

    Design Concerns and Imperatives

    Introduction

    History of Automotive Design

    Automotive Design Development

    Predictive Design Tools for the Performance Imperative

    Some History of Finite Element Analysis

    FEA Performance Predictions and Some Key Definitions

    Predictive Design for the Cost Imperative

    Structural Design Concerns

    Strength and Impact Concerns for Performance

    References

    Manufacturing and Process Technology

    Introduction

    Rubber Processing

    Plastic Processing

    Aluminum Processing

    PEM Manufacturing

    Nanotube Manufacturing

    References

    Engineering Polymers, High-Temperature and –Pressure Applications, and Structural Polymers

    Introduction

    Dynamic Sealing

    Needed Properties

    Automotive Requirements

    Materials and Processing

    Thermal Properties

    Fillers

    Polyetheretherketones

    Polyimides

    Poly(tetrafluoroethylene

    PPS

    References

    Power Train Applications

    Introduction

    Fuel Combustion

    Diesel Injection (Urea Injection)

    Engine Oil

    Engine Oil Function

    Engine Oil Groups

    Engine Oil Grades

    Some Important Additives

    Synthetic Lubricants

    Synthetic Esters

    Polyolefins

    Automatic Transmission Fluid (ATF)

    Some Testing Methods

    Transmission Fluid Types

    Engine Coolant

    Methanol

    Ethylene Glycol

    Propylene Glycol

    New Developments

    References

    Seal and Gasket Design

    Introduction

    Tear Strength

    Thermal Serviceability Range

    Compression Set

    Silicone Rubbers

    EPDM

    Natural Rubbers

    Nitrile Rubbers

    Fluoropolymer Elastomers

    Ethylene Acrylic Seals

    Polyetherketone (PEEK), Polyetherimide (PEI), and Teflon (PTFE)

    Seal Types

    Failure and Degradation in Seal Design

    Thermal Degradation

    Thermal Oxidation

    References

    HVAC System Overview and Refrigerant Design

    Introduction

    Ozone Depletion

    Montreal Protocol Treaty

    Refrigerant Design

    Global Warming Potential

    Total Equivalent Warming Impact

    Ozone Depletion Potential

    Refrigerant Performance and Some Key Definitions

    9.9 Need for Alternate Refrigerant Systems

    Refrigerant Oil Mixtures

    152a and Hydrocarbons as Alternatives

    CO2 as an Alternative to 134a

    Traditional and CO2 Refrigerant System Design

    New Developments in Refrigerant Design (1234yf)

    Material Considerations in HVAC Design

    Aluminum Heat Exchanger Material

    References

    Fuel-Cell Chemistry Overview

    Introduction

    Future Market and Usage

    Fuel Cells as Automotive Propulsion

    Hydrogen Sources

    Problems with Fuel Cells

    References

    Membranes and Hydrogen Storage Devices

    Introduction

    Hydrogen Storage Tank Size

    New Developments

    Glass Microspheres

    Carbon Nanotubes and Graphite Nanofibers

    Membrane Electrode Assembly

    Cell Stack Assembly

    References

    Developing Technology

    Introduction

    Hybrid Technologies

    Biodiesel

    Battery Technologies

    Lithium Ion Battery

    Nickel–Metal Hydride Cells

    Battery Developments

    Direct Ozone Reduction Systems

    Biomaterials

    References

    Index

    Biography

    H. K. Phlegm