Metal-matrix composites in the automotive industry: Opportunities and challenges

Metal-matrix composites offer considerable promise to help automotive engineers meet the challenges of current and future demands for recyclable, fuel-efficient, safe, and low-emission vehicles. These materials can be engineered to match the design requirements of automotive power-train or chassis components. Technological and infrastructural barriers tend to limit the implementation of these materials, but it is believed these barriers can be overcome and that metal-matrix composites can be applied in high-volume vehicle production. Reducing these barriers will require much effort by engineers and scientists, managers and planners at automotive manufacturers, and their suppliers. The result will be the gradual introduction of metal-matrix composites in high-volume vehicle production to satisfy customer desires while meeting regulatory requirements and competitive pressures.     

Characterization of molecular orientation in injection–stretch–blow‐molded poly(ethylene terephthalate) bottles by means of external reflection infrared spectroscopy

The molecular orientation at the outer surface of injection–stretch–blow‐molded bottles made from poly(ethylene terephthalate) was characterized and quantified by means of front‐surface reflection infrared spectroscopy based on a method developed previously. Results were obtained for two different bottle shapes (cylindrical and rectangular) molded at different injection mold temperatures (16, 38, and 60°C). For the cylindrical bottles, the preferred molecular chain orientation was found to be in the axial direction, with the Hermans orientation function near 0.3 for all three mold temperatures. For the less symmetrical rectangular bottles, a significant difference was observed between the large and small faces. For the large face, the orientation was mainly in the hoop direction; the Hermans orientation function was in the range of 0.3–0.5 and was essentially the same at all mold temperatures and positions along the bottle height. For the small face, on the other hand, the preferred orientation changed from the hoop direction near the bottom to the axial direction near the top, and the variation was more pronounced at lower mold temperatures. The utility of the front‐surface reflection technique was clearly demonstrated. It was also applied, with the use of an infrared microscope, to examine the orientation gradient across the wall thickness. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 1319–1327, 2007     

Biaxial deformation of polyamide‐6: Assessment of orientation by means of infrared trichroism

Infrared spectroscopy was used to study the evolution of structure in films of polyamide‐6 drawn on a Cellier tenter frame laboratory tester under conditions of simultaneous equibiaxial stretching and planar uniaxial stretching. The “tilted film” method was used to obtain trichroic spectra corresponding to the machine, transverse, and normal directions, as well the “structural factor” spectrum. From these it was possible to obtain information on the molecular orientation and the evolution of the crystalline structure. The starting films, prepared by melt casting from an extruder on a chilled roll, contained predominantly the mesomorphic β form. The structural factor spectra confirmed that strain‐induced transformation into the α form occurred upon drawing, and that the amount of α form increased with the extent of drawing. The trichroic spectra showed that the molecular orientation was localized mainly, but not exclusively, in the α form. Orientation functions could be determined for both the molecular chain axis and the normal to the hydrogen‐bonded sheets. For both the equibiaxial and planar uniaxial films, these sheets were found to be strongly oriented parallel to the plane of the film, with the degree of orientation increasing with overall draw ratio. For the biaxial samples, the molecular chain orientation was found to be equibiaxial, as expected. Mechanical test results indicated that the chains are evenly distributed in the film plane rather than showing a preference for the two orthogonal draw directions. For the planar uniaxial samples, the chain orientation was predominantly in the draw direction, but some degree of orientation in the transverse direction was also observed. The variation of orientation functions with draw ratio suggested that the α structure evolves in two stages, the first involving chain orientation in the draw direction and the second involving rotation of the sheets into the plane of the film.     

Crystallinity in PPS–carbon composites: A study using diffuse reflection FT-IR spectroscopy and differential scanning calorimetry

A method based on diffuse reflection Fourier transform infrared (FT-IR) spectroscopy has been developed for determining the state of crystallinity in composite materials made from poly(phenylene sulfide) (PPS) reinforced with carbon fibers. Using this technique, good-quality spectra can be obtained directly from the surface of prepreg or molded composite; thus the method is rapid and nondestructive. Several peaks in the spectrum are sensitive to the crystallinity and can be used for quantitative characterization purposes. The recommended indicator is the ratio of the heights of the peaks at 1075 and 1093 cm^?1. Using a range of samples of varying crystallinity prepared by annealing amorphous prepreg, it has been shown that there is a very good correlation between this ratio and the enthalpy of crystallization as determined by differential scanning calorimetry. The effects of such annealing, as well as heating in air at high temperatures, have been investigated.     

Products formed in an aged concrete

At a dam in Australia the concrete shows a widespread reaction that has caused surface cracking, and possibly a tightening up of gates that control the flow of water through diversion tunnels. The reaction has produced reaction rims to the aggregate, a crystallization of zeolite A-like material within the aggregate and in pores in the concrete, in addition to the precipitation of amorphous alkali-silicate hardened gel in other concrete pores. The hardened gel is sometimes associated with trona and is metastable. It tends to transform into zeolite A-like material or analcite. The reaction products are low in alumina and high in silica. Possible reaction mechanisms are discussed.     

Curing kinetics and mechanical properties of epoxy nanocomposites based on different organoclays

The effect of different organoclays and mixing methods on the cure kinetics and properties of epoxy nanocomposites based on Epon828 and Epicure3046 was studied. The two kinds of organoclay used in this study, both based on natural montmorillonite but differing in intercalant chemistry, were I.30E (Nanomer I.30E—treated with a long‐chain primary amine intercalant) and C.30B (Cloisite 30B—treated with a quaternary ammonium intercalant, less reactive with epoxy than the primary amine). The two mixing processes used to prepare the nanocomposites were (i) a room‐temperature process, in which the clay and epoxy are mixed at room temperature, and (ii) a high‐temperature process, in which the clay and epoxy are mixed at 120°C for 1 h by means of mechanical mixing. The nanocomposites were cured at room temperature and at high temperature. The quality of dispersion and intercalation/exfoliation were analyzed by scanning electron microscopy, transmission electron microscopy, and X‐ray diffraction. The heat evolution of the epoxy resin formulation and its nanocomposite systems was measured using differential scanning calorimetry at different heating rates of 2.5, 5, 10, 15, and 20°C min^?1. The cure kinetics of these systems was modeled by means of different approaches. Kissinger and isoconversional models were used to calculate the kinetics parameters while the Avrami model was utilized to compare the cure behavior of the epoxy systems. The cure kinetics and mechanical properties were found to be influenced by the presence of nanoclay, by the type of intercalant, and by the mixing method. POLYM. ENG. SCI., 47:649–661, 2007. © 2007 Society of Plastics Engineers.     

Effects of dietary oils and methyl ethyl ketone peroxide onin vivo lipid peroxidation and antioxidants in rat heart and liver

Weanling male Sprague-Dawley rats were fed diets for four weeks which differed in their content of n−6 (corn oil; CO) and n−3 fatty acids (fish oil; FO), but were similar in their content of saturated and monounsaturated fatty acids and vitamin E. At the end of the four-week feeding period, each dietary group was subdivided into two groups. One group received a single placebo injection of α-tocopherol-stripped corn oil (TSCO); the other group received a single injection of the free radical generator, methyl ethyl ketone peroxide (MEKP), in TSCO. Twenty-four hours after injection, the effect of dietary oil and MEKP treatment on endogenous lipid peroxide (LPO) production (measured as methylene blue formed by the “Determiner LPO” assay), glutathione (GSH) and vitamin E content, and fatty acid composition of phosphatidylcholine and phosphatidylethanolamine in heart and liver from unfasted animals were measured. FO-fed rats had significantly heavier hearts and livers, increased levels of n−3 fatty acids in membrane phospholipids, and higher liver LPO levels than CO-fed rats. MEKP treatment resulted in significantly lower body weights and liver GSH levels. The data indicate that dietary n−3 fatty acids increase lipid peroxidation in liver somewhat more than in heart. The study also demonstrates that the effect of induced oxidative stress due to a single dose of MEKP on lipid peroxide formation and antioxidant status in tissues from unfasted animals was independent of the dietary oils.     

Studies of post drawing relaxation phenomena in poly(ethylene terephthalate) by infrared spectroscopy

In this paper, we study the relaxation behavior of initially amorphous poly(ethylene terephthalate) (PET) films drawn, at 80°C using a draw rate of 2 cm/min, to a draw ratio (λ) from 1 to 5 and then quenched to room temperature. These films were then heated at different temperatures from 68 to 80°C for different times and their orientation determined. The orientation measurements were performed by transmission infrared spectroscopy and the bands used for the determination of orientation were those at 1340 and 970 cm^?1 for the trans conformers, normalized using the 1410 cm^?1 benzene ring vibration. The crystallinity was determined by thermal analysis. It is shown that when PET is drawn to λ values up to 2–2.5 (before stress-induced crystallization), the orientation relaxes rapidly at temperatures close to the glass transition temperature of PET. For λ values of 3 or higher, the orientational relaxation of the amorphous regions is hindered. This effect is ascribed to the development of strain-induced crystallites, which are believed to act as pseudo-crosslinks.