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Composites technology for the automotive market continues to advance rapidly. Increasing knowledge of composite design, simulation tools, new materials and process equipment are all contributing to make composites better performing and more affordable for mass-produced vehicles. In particular, the high pressure resin transfer molding (HP-RTM) and related liquid compression molding (LCM) processes are enabling manufacturers to produce complex composite parts at shorter and shorter cycle times. This paper describes the development of an epoxy carbon fiber roof frame targeted for future vehicle production. Several composite processes were considered for the roof frame. The case illustrates that when the (product) design, material and process are considered together, a high-performing, cost-efficient part can be produced.

Composite materials have gained the attention of the automotive industry to substantially reduce vehicle weight, reduce CO₂ emissions and improve the fuel economy of next generation vehicles. Thermosetting matrix technology combined with glass or carbon fiber reinforcements are well suited for structural applications where mostly steel and aluminum are used today. However, the lack of fast production techniques and fast reacting matrix technologies have limited composites use to low volume production models. A new generation of epoxy resin systems has been developed that allows the rapid processing of structural composites for medium to high volume models. These advanced formulations maintain the excellent properties of traditional epoxy-based composites, yet the tested systems can process in a matter of minutes using modern manufacturing technologies such as the high pressure resin transfer molding (HP-RTM) process.

The automotive industry is looking for options to reduce weight and increase engine efficiency to comply with new CO₂ emission and fuel economy regulations. Increasingly, automakers are examining their use of materials for even the smallest components. Engineering thermosets are an effective lightweighting alternative to heavier conventional steel and aluminum die cast products. They combine outstanding temperature stability, long-term mechanical strength, dimensional stability and high chemical resistance. This paper focuses on two recent projects where (BAKELITE™) phenolic-based engineering thermosets have successfully replaced traditional metals in automotive under-the-hood applications and outperformed engineering thermoplastics also considered for the applications. First, a water pump housing made with engineering thermoset material is shown to have good chemical resistance to coolants without additional corrosion protection and to maintain its mechanical properties.