The role of the chemist in automotive design

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.

Preface	p. xiii
The Author	p. xv
Chapter 1 Introduction to the Automobile Industry	p. 1
1.1 Introduction	p. 1
1.2 Historical Factors Affecting Today's Industry	p. 1
1.3 Competitive Imperatives	p. 2
1.4 Indifference Maps and Curves	p. 2
1.5 Market Demand	p. 4
1.6 Vehicle Mass Targets	p. 6
1.7 Power Train Cooling Requirements	p. 7
1.8 HVAC	p. 8
1.9 Emissions	p. 9
1.10 Green Alternatives	p. 9
References	p. 10
Chapter 2 Traditional Role of the Chemist in the Automobile Plant Environment	p. 11
2.1 Introduction	p. 11
2.2 Incoming Inspection	p. 11
2.3 Methods around Metals	p. 13
2.3.1 Emission Spectrophotometers	p. 13
2.3.1.1 Detection Limits	p. 15
2.4 Atomic Absorption for Metal Analysis	p. 15
2.5 Separation and Chromatography of Organics	p. 17
2.6 Liquid-Solid Adsorption in HPLC	p. 17
2.7 Soluble Oils	p. 17
2.8 Lubricity Additives	p. 18
2.9 Some Problems with HPLC as a Lab Tool	p. 21
2.10 Plate Theory and Rate Theory	p. 21
2.11 Elastomer Characterization	p. 24
2.12 Plastic and Elastomer Analysis	p. 26
2.13 DSC Graphs	p. 26
2.14 Stress-Strain Relationships	p. 27
2.15 Bond Stiffness versus Modulus	p. 28
References	p. 29
Chapter 3 Component Materials in Automobiles	p. 31
3.1 Introduction	p. 31
3.2 Polymer Market Penetration	p. 31
3.3 Methods of Production and Production Demand	p. 33
3.4 Ziegler-Natta	p. 37
3.5 Metal Oxide Initiation	p. 39
3.6 Other Methods of Production	p. 39
3.7 Chain Growth Polymerization	p. 39
3.8 Step Growth Polymerization	p. 42
3.9 Ionic Polymerization	p. 42
References	p. 43
Chapter 4 Design Concerns and Imperatives	p. 45
4.1 Introduction	p. 45
4.2 History of Automotive Design	p. 45
4.3 Automotive Design Development	p. 46
4.3.1 Exterior Design (Styling)	p. 46
4.3.2 Interior Design	p. 47
4.3.2.1 Interior Design and Performance	p. 47
4.4 Predictive Design Tools for the Performance Imperative	p. 51
4.5 Some History of Finite Element Analysis	p. 52
4.6 FEA Performance Predictions and Some Key Definitions	p. 53
4.7 Predictive Design for the Cost Imperative	p. 60
4.8 Structural Design Concerns	p. 62
4.9 Strength and Impact Concerns for Performance	p. 64
References	p. 66
Chapter 5 Manufacturing and Process Technology	p. 67
5.1 Introduction	p. 67
5.2 Rubber Processing	p. 67
5.3 Plastic Processing	p. 70
5.4 Aluminum Processing	p. 74
5.5 PEM Manufacturing	p. 76
5.6 Nanotube Manufacturing	p. 77
References	p. 79
Chapter 6 Engineering Polymers, High-Temperature and -Pressure Applications, and Structural Polymers	p. 81
6.1 Introduction	p. 81
6.2 Dynamic Sealing	p. 81
6.3 Needed Properties	p. 81
6.4 Automotive Requirements	p. 82
6.5 Materials and Processing	p. 87
6.6 Thermal Properties	p. 87
6.7 Fillers	p. 87
6.8 Polyetheretherketones	p. 89
6.9 Polyimides	p. 90
6.10 Poly(tetrafluoroethylene)	p. 90
6.11 PPS	p. 92
References	p. 92
Chapter 7 Power Train Applications	p. 95
7.1 Introduction	p. 95
7.2 Fuel Combustion	p. 95
7.3 Diesel Injection (Urea Injection)	p. 98
7.4 Engine Oil	p. 98
7.5 Engine Oil Function	p. 100
7.6 Engine Oil Groups	p. 101
7.7 Engine Oil Grades	p. 101
7.8 Some Important Additives	p. 102
7.9 Synthetic Lubricants	p. 103
7.10 Synthetic Esters	p. 104
7.11 Polyolefins	p. 104
7.12 Automatic Transmission Fluid (ATF)	p. 104
7.13 Some Testing Methods	p. 105
7.14 Transmission Fluid Types	p. 106
7.15 Engine Coolant	p. 107
7.16 Methanol	p. 107
7.17 Ethylene Glycol	p. 107
7.18 Propylene Glycol	p. 108
7.19 New Developments	p. 108
References	p. 109
Chapter 8 Seal and Gasket Design	p. 111
8.1 Introduction	p. 111
8.2 Tear Strength	p. 111
8.3 Thermal Serviceability Range	p. 112
8.4 Compression Set	p. 113
8.5 Silicone Rubbers	p. 114
8.6 EPDM	p. 117
8.7 Natural Rubbers	p. 119
8.8 Nitrile Rubbers	p. 122
8.9 Fluoropolymer Elastomers	p. 122
8.10 Ethylene Acrylic Seals	p. 124
8.11 Polyetherketone (PEEK), Polyetherimide (PEI), and Teflon (PTFE)	p. 125
8.12 Seal Types	p. 125
8.13 Failure and Degradation in Seal Design	p. 126
8.14 Thermal Degradation	p. 127
8.15 Thermal Oxidation	p. 127
References	p. 127
Chapter 9 HVAC System Overview and Refrigerant Design	p. 129
9.1 Introduction	p. 129
9.2 Ozone Depletion	p. 129
9.3 Montreal Protocol Treaty	p. 130
9.4 Refrigerant Design	p. 131
9.5 Global Warming Potential	p. 131
9.6 Total Equivalent Warming Impact	p. 133
9.7 Ozone Depletion Potential	p. 133
9.8 Refrigerant Performance and Some Key Definitions	p. 135
9.9 Need for Alternate Refrigerant Systems	p. 137
9.10 Refrigerant Oil Mixtures	p. 137
9.11 152a and Hydrocarbons as Alternatives	p. 139
9.12 CO2 as an Alternative to 134a	p. 140
9.13 Traditional and CO2 Refrigerant System Design	p. 142
9.14 New Development in Refrigerant Design (1234yf)	p. 145
9.15 Material Considerations in HVAC design	p. 147
9.16 Aluminum Heat Exchanger Material	p. 148
References	p. 148
Chapter 10 Fuel-Cell Chemistry Overview	p. 151
10.1 Introduction	p. 151
10.2 Future Market and Usage	p. 151
10.3 Fuel Cells as Automotive Propulsion	p. 152
10.4 Hydrogen Sources	p. 154
10.5 Problems with Fuel Cells	p. 154
10.5.1 Overpotential	p. 155
10.5.2 Temperature Considerations	p. 155
10.5.3 Sulfur Compounds	p. 155
10.5.4 Carbon Monoxide	p. 155
10.5.5 Catalyst Cost	p. 155
10.5.6 Hydrogen Storage	p. 157
10.5.7 Vehicle Design	p. 157
References	p. 158
Chapter 11 Membranes and Hydrogen Storage Devices	p. 159
11.1 Introduction	p. 159
11.2 Hydrogen Storage Tank Size	p. 159
11.3 New Developments	p. 160
11.4 Glass Microspheres	p. 160
11.5 Carbon Nanotubes and Graphite Nanofibers	p. 160
11.6 Membrane Electrode Assembly	p. 170
11.7 Cell Stack Assembly	p. 172
References	p. 172
Chapter 12 Developing Technology	p. 173
12.1 Introduction	p. 173
12.2 Hybrid Technologies	p. 173
12.3 Biodiesel	p. 176
12.4 Battery Technologies	p. 178
12.5 Lithium Ion Battery	p. 178
12.6 Nickel-Metal Hydride Cells	p. 180
12.7 Battery Developments	p. 181
12.8 Direct Ozone Reduction Systems	p. 182
12.9 Biomaterials	p. 187
References	p. 187
Index	p. 189

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