Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Carbon fiber cars could put U.S. on highway to efficiency

08.03.2006
Highways of tomorrow might be filled with lighter, cleaner and more fuel-efficient automobiles made in part from recycled plastics, lignin from wood pulp and cellulose.

First, however, researchers at the Department of Energy’s Oak Ridge National Laboratory, working as part of a consortium with Ford, General Motors and DaimlerChrysler, must figure out how to lower the cost of carbon fiber composites. If they are successful in developing high-volume renewable sources of carbon fiber feedstocks, ORNL’s Bob Norris believes they will be on the road to success.

"Whereas today the cost to purchase commercial-grade carbon fiber is between $8 and $10 per pound, the goal is to reduce that figure to between $3 and $5 per pound," said Norris, leader of ORNL’s Polymer Matrix Composites Group. At that price, it would become feasible for automakers to use more than a million tons of composites - approximately 300 pounds of composites per vehicle - annually in the manufacturing of cars.

The big advantage of carbon fiber is that it is one-fifth the weight of steel yet just as strong and stiff, which makes it ideal for structural or semi-structural components in automobiles. Replacing half the ferrous metals in current automobiles could reduce a vehicle’s weight by 60 percent and fuel consumption by 30 percent, according to some studies. The resulting gains in fuel efficiency, made in part because smaller engines could be used with lighter vehicles, would also reduce greenhouse gas and other emissions by 10 percent to 20 percent.

All of this would come with no sacrifice in safety, as preliminary results of computer crash simulations show that cars made from carbon fiber would be just as safe - perhaps even safer - than today’s automobiles. Today’s Formula 1 racers are required by mandate to be made from carbon fiber to meet safety requirements.

Progress in developing affordable carbon fiber composites has been steady as ORNL researchers with the support of the University of Tennessee work to optimize raw materials and spinning processes for alternative forms of carbon fiber precursors from renewable sources.

Another focus is on developing an efficient carbon fiber oxidation process, which would significantly increase production and lower cost of this raw material. One promising possibility is plasma processing technology to rapidly oxidize precursor fibers. In this area, ORNL is working with Atmospheric Glow Technologies, a high-tech company spun off from UT that has expertise in atmospheric pressure plasma processing. This is a technique to generate and use plasmas in a non-traditional way - in the open atmosphere instead of in a carefully controlled environment such as in inert gases and at very low pressures.

ORNL is also establishing a modular carbon fiber research pilot line to evaluate these revolutionary new processes on a comparable basis against conventional industrial processes.

"The goal is to demonstrate and transfer the technology to producers of carbon fiber, which could be existing carbon fiber producers or perhaps companies in the forest product industries," Norris said.

Researchers also are working to develop techniques to allow high-volume cost-effective processing of carbon fiber, hybrid glass-carbon fiber and reinforced thermoplastic material forms. In addition, ORNL recently installed an advanced preforming machine that features a robotically actuated arm that chops and sprays fiber and a binder in powder form to create fiber preforms. After being set at elevated temperature, the preforms are injected with resin in a mold and consolidated under pressure to create the final part.

"The preforming process is the first step in creating polymer composite structural and semi-structural auto parts that are lightweight and cost-competitive with metal parts they would replace," Norris said.

UT-Battelle manages Oak Ridge National Laboratory for the Department of Energy. This research is funded by DOE’s Office of Energy Efficiency and Renewable Energy.

Ron Walli | EurekAlert!
Further information:
http://www.ornl.gov

More articles from Automotive Engineering:

nachricht 3D scans for the automotive industry
16.01.2017 | Julius-Maximilians-Universität Würzburg

nachricht Improvement of the operating range and increasing of the reliability of integrated circuits
09.11.2016 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Giant Magnetic Fields in the Universe

Astronomers from Bonn and Tautenburg in Thuringia (Germany) used the 100-m radio telescope at Effelsberg to observe several galaxy clusters. At the edges of these large accumulations of dark matter, stellar systems (galaxies), hot gas, and charged particles, they found magnetic fields that are exceptionally ordered over distances of many million light years. This makes them the most extended magnetic fields in the universe known so far.

The results will be published on March 22 in the journal „Astronomy & Astrophysics“.

Galaxy clusters are the largest gravitationally bound structures in the universe. With a typical extent of about 10 million light years, i.e. 100 times the...

Im Focus: Tracing down linear ubiquitination

Researchers at the Goethe University Frankfurt, together with partners from the University of Tübingen in Germany and Queen Mary University as well as Francis Crick Institute from London (UK) have developed a novel technology to decipher the secret ubiquitin code.

Ubiquitin is a small protein that can be linked to other cellular proteins, thereby controlling and modulating their functions. The attachment occurs in many...

Im Focus: Perovskite edges can be tuned for optoelectronic performance

Layered 2D material improves efficiency for solar cells and LEDs

In the eternal search for next generation high-efficiency solar cells and LEDs, scientists at Los Alamos National Laboratory and their partners are creating...

Im Focus: Polymer-coated silicon nanosheets as alternative to graphene: A perfect team for nanoelectronics

Silicon nanosheets are thin, two-dimensional layers with exceptional optoelectronic properties very similar to those of graphene. Albeit, the nanosheets are less stable. Now researchers at the Technical University of Munich (TUM) have, for the first time ever, produced a composite material combining silicon nanosheets and a polymer that is both UV-resistant and easy to process. This brings the scientists a significant step closer to industrial applications like flexible displays and photosensors.

Silicon nanosheets are thin, two-dimensional layers with exceptional optoelectronic properties very similar to those of graphene. Albeit, the nanosheets are...

Im Focus: Researchers Imitate Molecular Crowding in Cells

Enzymes behave differently in a test tube compared with the molecular scrum of a living cell. Chemists from the University of Basel have now been able to simulate these confined natural conditions in artificial vesicles for the first time. As reported in the academic journal Small, the results are offering better insight into the development of nanoreactors and artificial organelles.

Enzymes behave differently in a test tube compared with the molecular scrum of a living cell. Chemists from the University of Basel have now been able to...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

International Land Use Symposium ILUS 2017: Call for Abstracts and Registration open

20.03.2017 | Event News

CONNECT 2017: International congress on connective tissue

14.03.2017 | Event News

ICTM Conference: Turbine Construction between Big Data and Additive Manufacturing

07.03.2017 | Event News

 
Latest News

When Air is in Short Supply - Shedding light on plant stress reactions when oxygen runs short

23.03.2017 | Life Sciences

Researchers use light to remotely control curvature of plastics

23.03.2017 | Power and Electrical Engineering

Sea ice extent sinks to record lows at both poles

23.03.2017 | Earth Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>