Be it the evolution of design, technology or safety features, the automotive industry has come a long way in a myriad of aspects. Given all these factors, the way automobiles are manufactured has also evolved with time.
The materials chosen to build vehicles have a significant impact on their performance and reliability. In the wake of the sustainable mobility shift, lightweight automotive materials that can withstand durability tests are now widely preferred. This has resulted in faster, more fuel-efficient and safer rides.
To understand more about the evolution of auto manufacturing, let’s delve into the history of automotive raw materials and how they branched out into different types.
Automotive Raw Materials History and Types
The historical background of the automobile industry shows how auto manufacturing has progressed over the years with the help of different materials.
The Dominance of Steel
Steel has been a dominant and preferred material in the automotive industry for decades. Its strength, versatility and cost-effectiveness have made it an ideal choice for various components in vehicle manufacturing. The very first automobile, which was a tricycle, had a steel-made body frame.
As automotive manufacturing evolved over the years, different materials were tried and tested. For instance, aluminium car body panels were introduced in Ford’s T Touring line-up. However, due to high manufacturing costs, aluminium was again replaced by steel. Steel remained the only automotive manufacturing material until the 1970s.
FRP Body Panels
According to the Chevrolet Corvette’s history, the vehicle line-up came out with fibre-reinforced plastic (FRP) body panels. These panels were made with a mixture of polyester resin and glass-fibre mats. These body panels were nonconductive and corrosion-resistant, making car bodies lighter, safer and more durable.
It was the first instance of widespread adoption of FRP body panels. Among these basic body frames and panelling, there were also fabrications. For instance, the installation of wood panels to contrast with basic body panels was among the noteworthy classic car features we miss today.
The Evolution of Aluminium Car Body Panels
From car pillars to key structural features of the chassis, aluminium vacuum die casting was a game-changer in the 1970s. Key advancements in welding and joining technologies enhanced the feasibility of the production of aluminium-intensive vehicles. Together, in the automotive sector, the utilisation of advanced high-strength materials became prevalent. Such developments helped achieve lightweight structures.
Shift to All-Aluminium Car Body
One of the little-known facts about Acura is that it was among the first automakers to introduce an all-aluminium body. This marked a significant leap in the history of automobile materials. The first production-run model with an all-aluminium body was the Acura NSX. The car came out with other innovations as well, such as titanium connecting rods and other forged engine parts.
Another noteworthy car with an aluminium vehicle chassis that hit the mass market was Audi A8. According to the Audi A8 history, its 1990 model was equipped with an aluminium space frame aligned with the bodywork and car rocker panels. This noteworthy structural integration later became a flagship feature of the car brand known as the Audi Space Frame.
Carbon Fibre Application in the Auto Industry
Lightweight yet durable – carbon fibre also made an ideal contender to be used as an automotive material. It wasn’t until the 1970s that different automakers started offering optional carbon fibre parts with different car models.
One of the highly acclaimed automakers, McLaren, introduced the carbon fibre-reinforced plastic (CFRP) monocoques. These fibre-based monocoques were installed in the brand’s Formula 1 car line-ups in the 1980s. According to a recent development, the Lamborghini’s carbon fibre monocoque concept is also in the works.
The Rise of Magnesium Casting
The continuation of the evolution paved the way for new materials in the automotive industry. Due to its unique chemical and structural properties, magnesium also started gaining traction. It was one of the lightweight automotive materials, which greatly added to its industrial feasibility.
Magnesium is noticeably lighter than aluminium, iron and steel, which naturally gives it an edge. Moreover, in its alloyed form, magnesium is sturdier too. It possesses a high strength-to-weight ratio when compared to other structural metals.
The Concept of Multi-Material Vehicle Body
Combining the lightness and strength of different types of automotive materials, the multi-material vehicle body concept was introduced. The auto prototypes with these unique types of body frames started gaining attention in the 2010s.
According to the history of the Ford Motor Company, it introduced this multi-material concept in its Ford Focus line-up. The concept vehicle successfully passed different types of driving and car crash tests. After all the experimentation and testing, it was realised that a Multi-Material Lightweight Vehicle (MLV) results in significant weight reduction.
Evolution of Automotive Materials Towards Sustainability
Much like other fields, the scope of automotive manufacturing is analysed by its carbon footprint. To ensure the sustenance of operations in an eco-friendly way, automakers are keen to incorporate sustainable automotive materials. Some commonly considered alternatives in this regard include plant-based and recycled materials, sustainable alloys and bio-based plastic.
3D Printing Materials in the Auto Industry
Given the rapid advancement of technology, 3D printing in the auto industry has been a game changer. The industry application of 3D printing has made processes easier and less time-consuming.
Auto manufacturing materials used in 3D printing are thermoplastic, nylon, metal alloys, carbon fibre polymers and elastomers, among other automotive composite materials. For a real-life example of a 3D-printed automobile, take a look at Strati. The electric vehicle is the world’s first 3D-printed car.
Automotive Interior Materials
A car’s overall experience greatly depends on its interior and cushioning. From upholstery to other interior parts, cars are designed considering all these important functional and decorative components.
When it comes to cushioning, the usage of reclaimed fibre as upholstery filling material can be traced back to the advent of automobiles. Car upholstery filling has not been changed since then, but it has significantly improved. Reclaimed cotton fibres are combined with bonding agents to create self-supporting mouldings.
Polyester for Seat Covering
Seat covers used as car upholstery are made of polyester. Besides high performance and cost efficiency, polyester can withstand even intense wavelengths of UV rays. This results in better protection against sunlight and increases the life of the surface material. Other popular materials used as the surface materials of car seats include wool, original leather and synthetic leather.
ABS Plastic for Car Dashboards
The look and feel of the steering wheel and dashboard in a car also add to its in-cabin experience. For a long time now, plastic has been used for these interior components. However, it is no ordinary plastic, but PVC that is combined with Acrylonitrile Butadiene Styrene (ABS).
Moreover, the ABS plastic used in cars has unique chemical properties. It has turned out to be good at energy absorption and redistribution. As a result, ABS plastic is also used to make automotive body parts.
Automotive NVH Materials
The car interior is also equipped with NVH technology, which adds to the driver’s comfort and experience. NVH stands for Noise and Vibration Harshness. Similarly, the process of NVH fabrication refers to noise-reducing component manufacturing. Rubber and foam are the two most commonly used materials for frictional or mechanical noise reduction in vehicles. Similarly, here are some car sounds you should never ignore.
FAQs
What is automotive materials testing?
Automotive materials testing involves evaluating the physical and chemical properties of automotive materials. The incorporation of new materials in the automotive industry is to ensure they meet safety, durability and performance standards.
What are some sustainable materials for automotive applications?
Sustainable materials for automotive applications include plant-based and recycled materials as well as sustainable alloys and bio-based plastics. All these eco-friendly alternatives are aimed at reducing the industry’s carbon footprint.
What are some lightweight materials for automotive applications?
Lightweight automotive materials include aluminium, carbon fibre-reinforced plastic (CFRP) and magnesium. Moreover, the concept of multi-material vehicle bodies is another key development in this regard. This auto-manufacturing technique combines different materials for a balance of strength and weight reduction.
What are the automotive NVH materials?
Automotive NVH (Noise, Vibration, Harshness) materials for interior fabrication include rubber and foam. This fabrication layer is intended to reduce frictional or mechanical noise in vehicles, enhancing the driver’s comfort and overall in-cabin experience.
This was everything to know about the different types of automotive raw materials and their history. Be it the design or technology, the automotive industry never ceases to amaze us. For more interesting facts about cars, read here.
The efficient design, built quality and performance of modern cars are a testament to the continued automotive progress. By browsing these used cars for sale in the UAE one realises how far the automotive industry has come.
For more information on the different types of automotive plastic materials, keep reading dubizzle’s auto blog.
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