Automotive commercialization

Major applications include industrial (plumbing, automotive), commercial (appliance, tools, electrical and electronic), and consumer (disposable pens, combs, zippers) products. Acetal resins are also often used in medical products because of their unique properties and resistance to sterilization conditions. 

Section VII on Testing in Industries (S. Dean, Section Editor) provides an overview of corrosion testing unique to each industry and how these tests are used to address corrosion problems. Included are descriptions of environments encountered and materials used in specific industries. Test methods for corrosion control and evaluation are described along with appropriate stand2irds. Chapters in this section include automotive, commercial aircraft, military aircraft... 

Discontinuous Glass Preforms P-4 process Automotive, commercial... 

The aerosol container has enjoyed commercial success ia a wide variety of product categories. Insecticide aerosols were iatroduced ia the late 1940s. Additional commodities, including shave foams, hair sprays, antiperspirants, deodorants, paints, spray starch, colognes, perfumes, whipped cream, and automotive products, followed ia the 1950s. Mediciaal metered-dose aerosol products have also been developed for use ia the treatment of asthma, migraine headaches, and angiaa. 

Aryl Phosphates. Aryl phosphates were introduced into commercial use early in the twentieth century for flammable plastics such as cellulose nitrate and later for cellulose acetate. CeUulosics are a significant area of use but are exceeded now by plastici2ed vinyls (93—95). Principal appHcations are in wire and cable insulation, coimectors, automotive interiors, vinyl moisture barriers, plastic greenhouses (Japan), furniture upholstery, conveyer belts (especially in mining), and vinyl foams. 

Low Expansion Alloys. Binary Fe—Ni alloys as well as several alloys of the type Fe—Ni—X, where X = Cr or Co, are utilized for their low thermal expansion coefficients over a limited temperature range. Other elements also may be added to provide altered mechanical or physical properties. Common trade names include Invar (64%Fe—36%Ni), F.linvar (52%Fe—36%Ni—12%Cr) and super Invar (63%Fe—32%Ni—5%Co). These alloys, which have many commercial appHcations, are typically used at low (25—500°C) temperatures. Exceptions are automotive pistons and components of gas turbines. These alloys are useful to about 650°C while retaining low coefficients of thermal expansion. Alloys 903, 907, and 909, based on 42%Fe—38%Ni—13%Co and having varying amounts of niobium, titanium, and aluminum, are examples of such alloys (2). 

Properties provided by the branched hydrocarbon chain stmcture of these PAO fluids include high viscosity index in the 130—150 range, pour points of —50 to —60° C for ISO 32 to 68 viscosity range (SAE lOW and SAE 20W, respectively), and high temperature stabifity superior to commercial petroleum products. In their use in automotive oils such as Mobil 1, some ester synthetic fluid is normally included in the formulation to provide sufficient solubihty for the approximately 20% additives now employed in many automotive oils. 

Polyol ester turbine oils currendy achieve greater than 10,000 hours of no-drain service in commercial jet aircraft with sump temperatures ranging to over 185°C. Polyol esters are made by reacting a polyhydric alcohol such as neopentyl glycol, trimethylol propane, or pentaerythritol with a monobasic acid. The prominent esters for automotive appfications are diesters of adipic and a2elaic acids, and polyol esters of trimethylolpropane and pentaerythritol (34). 

Phenohc resins are produced by the condensation of phenol or a substituted phenol, such as cresol, with formaldehyde. These low cost resins have been produced commercially for more than 100 years and in the 1990s are produced by more than 40 companies in the United States. They are employed as adhesives in the plywood industry and in numerous under-the-hood appHcations in the automotive industry. Because of the cycHc nature of the automotive and home building industry, the consumption of phenol for the production of phenohc resins is subject to cycHc swings greater than that of the economy as a whole. 

The main areas of commercial apphcation are automotive emission control catalysts (autocatalysts), oil refining, ammonia oxidation, hquid-phase ... 

The pelargonic acid by-product is already a useful item of commerce, making the overall process a commercial possibiUty. The 13-carbon polyamides appear to have many of the properties of nylon-11, nylon-12, or nylon-12,12 toughness, moisture resistance, dimensional stabiUty, increased resistance to hydrolysis, moderate melt point, and melt processibiUty. Thus, these nylons could be useful in similar markets, eg, automotive parts, coatings, fibers, or films. Properties for nylon-13,13 are = 56 (7 and = 183 (7 (179). 

Economic Aspects. PBT is one of the fastest growing commercial thermoplastics. In 1993 the North American market alone exceeded 90,000 t, a 15% increase over 1992 (174). This rapid growth was accounted for mainly by the electrical and electronic and automotive markets, which together accounted for over half the PBT used. The principal manufacturers of PBT in North America, Europe, and Japan are shown in Table 9. 

RCF is sold in a variety of forms, such as loose fiber, blanket, boards, modules, cloth, cements, putties, paper, coatings, felt, vacuum-formed shapes, rope, braid, tape, and textiles. The products are principally used for industrial appHcations as insulation in furnaces, heaters, kiln linings, furnace doors, metal launders, tank car insulation, and other uses up to 1400°C. RCF-consuming industries include ferrous and nonferrous metals, petrochemical, ceramic, glass, chemical, fertiH2er, transportation, constmction, and power generation/incineration. Some newer uses include commercial fire protection and appHcations in aerospace, eg, heat shields and automotive, eg, catalytic converters, metal reinforcement, heat shields, brake pads, and airbags. 

A variety of thermosetting resins are used in SMC. Polyesters represent the most volume and are available in systems that provide low shrinkage and low surface profile by means of special additives. Class A automotive surface requirements have resulted in the development of sophisticated systems that commercially produce auto body panels that can be taken direcdy from the mold and processed through standard automotive painting systems, without additional surface finishing. Vinyl ester and epoxy resins (qv) are also used in SMC for more stmcturaHy demanding appHcations. 

Sophisticated stmctural analysis techniques make it possible to determine both the amount and exact orientation of reinforcement that the product wQl need to meet the critical stresses in actual service. Hybrid reinforcement systems containing different fiber compositions with different properties are being increasingly used. For example, hybrid carbon and glass fiber automotive drive shafts are in commercial use. 

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