Automotive layer

Table 7-2 shows the emulsion polymers most often used in the various automotive layers. 

The test methods for automotive layers are designed to stimulate conditions likely to occur in the field and are of two types - appearance and performance. Appearance includes gloss, distinctness of image, mottle, orange peel. Performance properties include physical properties of hardness, flexibility, impact resistance, adhesion, stone-chip resistance, cold crack resistance i.e. stabihty to extremes of temperature and humidity, curing efficiency. 

Aliphatic isocyanates have a small but growing market application in thermoplastic polyurethanes (TPU). Medical appflcafions include wound dressings, catheters, implant devices, and blood bags. A security glass system using light-stable TPU as an inner layer is under evaluation for shatterproof automotive windshield appflcafions. 

For high, fatigue strength in automotive bearings, a very thin layer of babbitt is desirable so that much of the load is taken on a stronger backing material. Relative improvement in fatigue resistance was found to be as follows with tin babbitt (14) ... 

Cermet or carbon friction matenals operate at substantially higher temperatures than the normal automotive or tmck materials. Still the wear rates of these materials increase with the brake temperature. One unique feature of these materials is the formation of a glazed friction film at high temperatures that reduces the wear rate and stabilizes the friction level. Without this glazed layer the wear rate is usually very high. 

Some catalyst supports rely on a relatively low surface area stmctural member coated with a layer of a higher surface area support material. The automotive catalytic converter monolith support is an example of this technology. In this appHcation, a central core of multichanneled, low surface area, extmded ceramic about 10 cm in diameter is coated with high surface area partially hydrated alumina onto which are deposited small amounts of precious metals as the active catalytic species. 

If the rf source is applied to the analysis of conducting bulk samples its figures of merit are very similar to those of the dc source [4.208]. This is also shown by comparative depth-profile analyses of commercial coatings an steel [4.209, 4.210]. The capability of the rf source is, however, unsurpassed in the analysis of poorly or nonconducting materials, e.g. anodic alumina films [4.211], chemical vapor deposition (CVD)-coated tool steels [4.212], composite materials such as ceramic coated steel [4.213], coated glass surfaces [4.214], and polymer coatings [4.209, 4.215, 4.216]. These coatings are used for automotive body parts and consist of a number of distinct polymer layers on a metallic substrate. The total thickness of the paint layers is typically more than 100 pm. An example of a quantitative depth profile on prepainted metal-coated steel is shown as in Fig. 4.39. 

Fig. 4.51. SIMS (a) and IBSCA (b) depth profiles of an interference layer system used for automotive application...

The concept of protection of one layer of material by another as described in the previous category. Clad Metals, has been extended in a rather unique way to automotive safety glass. Ordinary window glass... 

The desire to replace cadmium is generally attributed to its toxicity, both in terms of process pollution and product corrosion, and several alternatives are feasible thicker zinc, tin-zinc alloy or tin-nickel alloy depending upon the precise application " . The demise of decorative nickel-chrome systems in the automotive industries of the world is partly due to cost and partly to market image, and not to technical performance where major improvements took place in the period 1960-1975 through the establishment of duplex nickel under-layers and micro discontinuous chromium top-layers. In the 1980s the trend has been towards black finishes produced generally by powder-applied epoxy polymers. 

Thermoformed chassis and body panels are featured on the car. The products were made initially in the USA for assembly in China. The car will weigh less than 2000 lb (900 kg). Automotive Design Composites, Inc of San Antonio, TX, designed the vehicle to have body panels and trunk formed from coextruded sheet of ABS with an ASA cap layer that will hang on a pultruded composite frame. Ceramic tooling is used to thermoform plastic products. 

The basic steps of the IM process produce unique structures in all molded products, whether they are miniature (micro) electronic components, compact discs, or large automotive bumpers. These structures have frequently been compared to plywood with several distinct layers, each with a different set of properties. In all IM products, a macroscopic skin-core structure results from the flow of melt into an empty cavity. Identifiable zones or regions within the skin are directly... 

Carbon black is reinforced in polymer and mbber engineering as filler since many decades. Automotive and tmck tires are the best examples of exploitation of carbon black in mbber components. Wu and Wang [28] studied that the interaction between carbon black and mbber macromolecules is better than that of nanoclay and mbber macromolecules, the bound mbber content of SBR-clay nanocompound with 30 phr is still of high interest. This could be ascribed to the huge surface area of clay dispersed at nanometer level and the largest aspect ratio of silicate layers, which result in the increased silicate layer networking [29-32]. 

At the heart of an automotive catalytic converter is a catalyzed monolith which consists of a large number of parallel channels in the flow direction whose walls are coated with a thin layer of catalyzed washcoat. The monolith catalyst brick is wrapped with mat, steel shell and insulation to minimize exhaust gas bypassing and heat loss to the surroundings. 

Pearlescent pigments give rise to a white pearl effect often accompanied by a coloured iridescence. The most important pearlescent pigments consist of thin platelets of mica coated with titanium dioxide which partly reflect and partly transmit incident light. Simultaneous reflection from many layers of oriented platelets creates the sense of depth which is characteristic of pearlescent lustre and, where the particles are of an appropriate thickness, colours are produced by interference phenomena. Pearlescent pigments are used in automotive finishes, plastics and cosmetics. 

Sometimes, part design requires multiple polymer layers. For example, an automotive gasoline tank can consist of both nylon and crosslinked polyethylene to provide combined chemical [-, resistance and strength, To produce multilayered parts, the first polymer, which will form... 

The concept of two or even three extruders in tandem, or piggy back , feeding to a common die to produce such items as tyre camelback are available from a number of producers. The machines are used to produce components having either different layers or sections consisting of a number of different compounds. Applications using this type of system are tyre components and automotive sealing profiles. 

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