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From the development of polymers that make cars lighter to fuels that make them run cleaner, the chemist’s role in the automotive industry has evolved to be one that is more outside the laboratory than in it. Drawing on the author’s 20 years of experience in vehicle design and laboratory experience, The Role of the Chemist in Automotive Design elucidates how the skills of chemists are put to use in the automotive industry and their effect on all phases of design.
A glance through the table of contents provides an overview of the issues commonly encountered by chemists in the automotive industry. The author discusses fuels cells, lithium ion batteries, carbon nanotubes, and nickel metal hydride technology, all of which require the technical knowledge of a chemist but cross the lines of various disciplines. He also covers future technology including items such as battery technology, fuel cell membranes, and environmentally friendly plastics such as nylons that use castor oil as a primary component. The book examines environmental concerns such as CARB legislation and how the industry plans to deal with the new legislation with strategies such as Ozone Reduction Catalyst.
The increasing technological, environmental, and economic issues facing the auto industry underscores the need for a basic reference that covers technologies that can be used to make vehicle more fuel efficient, environmentally friendly, and cost efficient. Exploring the expanding role chemists will play in future automotive design and technology, this book delineates the areas and technologies that require the technical knowledge of a chemist but that cross the lines of many disciplines.
Introduction to the Automobile Industry
Introduction
Historical Factors Affecting Today’s Industry
Competitive Imperatives
Indifference Maps and Curves
Market Demand
Vehicle Mass Targets
Power Train Cooling Requirements
HVAC
Emissions
Green Alternatives
References
Traditional Role of the Chemist in the Automobile Plant Environment
Introduction
Incoming Inspection
Methods around Metals
Atomic Absorption for Metal Analysis
Separation and Chromatography of Organics
Liquid–Solid Adsorption in HPLC
Soluble Oils
Lubricity Additives
Some Problems with HPLC as a Lab Tool
Plate Theory and Rate Theory
Elastomer Characterization
Plastic and Elastomer Analysis
DSC Graphs
Stress–Strain Relationships
Bond Stiffness versus Modulus
References
Component Materials in Automobiles
Introduction
Polymer Market Penetration
Methods of Production and Production Demand
Ziegler–Natta
Metal Oxide Initiation
Other Methods of Production
Chain Growth Polymerization
Step Growth Polymerization
Ionic Polymerization
References
Design Concerns and Imperatives
Introduction
History of Automotive Design
Automotive Design Development
Predictive Design Tools for the Performance Imperative
Some History of Finite Element Analysis
FEA Performance Predictions and Some Key Definitions
Predictive Design for the Cost Imperative
Structural Design Concerns
Strength and Impact Concerns for Performance
References
Manufacturing and Process Technology
Introduction
Rubber Processing
Plastic Processing
Aluminum Processing
PEM Manufacturing
Nanotube Manufacturing
References
Engineering Polymers, High-Temperature and –Pressure Applications, and Structural Polymers
Introduction
Dynamic Sealing
Needed Properties
Automotive Requirements
Materials and Processing
Thermal Properties
Fillers
Polyetheretherketones
Polyimides
Poly(tetrafluoroethylene
PPS
References
Power Train Applications
Introduction
Fuel Combustion
Diesel Injection (Urea Injection)
Engine Oil
Engine Oil Function
Engine Oil Groups
Engine Oil Grades
Some Important Additives
Synthetic Lubricants
Synthetic Esters
Polyolefins
Automatic Transmission Fluid (ATF)
Some Testing Methods
Transmission Fluid Types
Engine Coolant
Methanol
Ethylene Glycol
Propylene Glycol
New Developments
References
Seal and Gasket Design
Introduction
Tear Strength
Thermal Serviceability Range
Compression Set
Silicone Rubbers
EPDM
Natural Rubbers
Nitrile Rubbers
Fluoropolymer Elastomers
Ethylene Acrylic Seals
Polyetherketone (PEEK), Polyetherimide (PEI), and Teflon (PTFE)
Seal Types
Failure and Degradation in Seal Design
Thermal Degradation
Thermal Oxidation
References
HVAC System Overview and Refrigerant Design
Introduction
Ozone Depletion
Montreal Protocol Treaty
Refrigerant Design
Global Warming Potential
Total Equivalent Warming Impact
Ozone Depletion Potential
Refrigerant Performance and Some Key Definitions
9.9 Need for Alternate Refrigerant Systems
Refrigerant Oil Mixtures
152a and Hydrocarbons as Alternatives
CO2 as an Alternative to 134a
Traditional and CO2 Refrigerant System Design
New Developments in Refrigerant Design (1234yf)
Material Considerations in HVAC Design
Aluminum Heat Exchanger Material
References
Fuel-Cell Chemistry Overview
Introduction
Future Market and Usage
Fuel Cells as Automotive Propulsion
Hydrogen Sources
Problems with Fuel Cells
References
Membranes and Hydrogen Storage Devices
Introduction
Hydrogen Storage Tank Size
New Developments
Glass Microspheres
Carbon Nanotubes and Graphite Nanofibers
Membrane Electrode Assembly
Cell Stack Assembly
References
Developing Technology
Introduction
Hybrid Technologies
Biodiesel
Battery Technologies
Lithium Ion Battery
Nickel–Metal Hydride Cells
Battery Developments
Direct Ozone Reduction Systems
Biomaterials
References
Index