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Module Code: PM 505
Class/Group: Group A
Module Title: Science & Engineering Double Project
Assessment Title: Secondary Research Project
Assignment Title: Feasibility of Carbon Fibers to Replace Steel in Manufacturing Civilian vehicles
Tutor Name: Bob Wallace, Ben Brown
Student ID Number: 2014268
Date of Submission: Thursday 26th June 2012
Word count:7350
Abstract
Carbon fiber composites have recently attracted much attention as lightweight materials in the automotive industry, particularly in civilian vehicles. An increasing number of engineers have concerned about the feasibility of carbon fibers to replace conventional steel which still dominate the material market of manufacturing vehicles. In order to find out the feasibility of replacing steel, a number of literatures and data had been read which has helped to give a comprehensive overview of basic concepts of this topic. During this secondary research project, a comparative analysis had been conducted between these two materials using several criteria to obtain the results. Implications for further research have been pointed out, which are, developing the technology in the process of fabricating carbon fibers in order to reduce the cost during the fabricating steps, on the other hand, improving the public cognition of the new material in order to receive the acception from public and to minimise controversy.

Key words: Carbon fiber, replacing, feasibility, cost.

Contents
Abstract……………………………………………………………2
1. Introduction………………………………………………………4 2. Literature review…………………………………………………7 1. Introduction……………………………………………………….7 2. Definition of composites………………………………………….7 3. Two dominant classes of commercial carbon fibers……………...8 4. Structure of carbon fibers………………………………………..10 5. Properties of carbon fibers………………………………………11 6. Study of building a conventional steel vehicle………………….12 7. Application for Carbon fiber composites………………………..13 3.



References: Andrew, R. and Grulke, E. (2000). Mechanical properties of carbon fiber composites for environmental application. USA: University of Kentucky. Cantwell, W. J. and Morton. J. (1991). The Impact Resistance of Composite Materials - a review". Composites 22 (5): 347–362. Chung, D. D. L. (1989). Electronic Properties of Carbon Fiber Reinforced Gypsum Plaster. Composites Science and Technology, 36, 1-6. Chung, D. D. L. (1994). Carbon Fiber Composites. USA: Butterworth-Heinemann. Costin, M. and Phipps, D. (1966). Racing and Sports Car Chassis Design. London, UK: B. T. Batsford Ltd. Cantwell, W. J. and Morton. J. (1991). The Impact Resistance of Composite Materials - a review". Composites 22 (5): 347–362. Davis, D Deakin, A., Crolla, D., Ramirez, J. P. and Hanley, R. (2000). The Effect of Chassis Stiffness on Race Car Handling and Balance, SAE Technical Paper, 00MSV-5 Dhakate, S Dhami, T. L., Bahl, O. P. and Jain, P. K. (1995). Carbon–carbon composites made with oxidised PAN (PANEX) fibers. Carbon, 33, 1517–1524. Edie, D. D. (1998). The Effect of Processing on the structure and properties of carbon fibers. Great Britain: Elsevier Science Ltd. Edie, D.D. and McHugh, J. J. (1996). High Performance Carbon Fibers. USA: Clemson University. Elson, G. L. (2003). Vehicle Production Issues in America. Business Briefing: Global Automotive Manufacturing & Technology, p16‐19. Gill, R. M., Ceram, F. I. and Inst, A. M. (1972). Carbon Fiber in Composite Materials. London: The Plastics Institute. Heisler, H. (2002). Advanced Vehicle Technology. London, UK: Butterworth Heinemann Ibrahim, O Japan Iron and Steel Federation. (2005). Contribution of Steel Products to Energy Savings in Society. Retrieved July12th, 2012, from: http://www.jisf.or.jp/en/activity/warm/commit/society.html James, M Maurice, P. (1960). The Structure of the Automobile. London, UK: The Institute of Mechanical Engineers, Automobile Division. Montes-Moran, M Oak Ridge National Laboratory. (2000). Carbon‐Fiber Composites for Cars. Oak Ridge National Laboratory Review, 33 (3). Oak Ridge National Laboratory. (2006, March 6). Carbon fiber cars could put U.S. on highway to efficiency. Retrieved July 14th, 2012, from: http://www.ornl.gov/info/press_releases/get_press_release.cfm?ReleaseNumber=mr20060306‐00 Paiva, M. C., Bernardo, C. A. and Edie. D. D.(2001). A comparative analysis of alternative models to predict the tensile strength of untreated and surface oxidised carbon fibers. Carbon,39, 1091–101. Rocky Mountain Institute (RMI). (2011). Comparison of carbon fiber vs steel manufacturing costs. Retrieved June 29th, 2012 from: http://www.rmi.org/RFGraph-carbonfiber_vs_steel_manufacturing Safarova, V Sato, T and Kurumada, A. (1989). Tensile Properties and Fracture Toughness of Carbon-Fiber Felt Reinforced Carbon Composites at High Temperature. Carbon, 27(6), 791-801. Starek, J., Zukal, A. and Rathousky, J. (1994). Comparison of the adsorption of humic acids from aqueous solutions on active carbon and activated charcoal cloths, Carbon, 32(2), 207- 21 1. Suzuki, T. and Takahashi, J. (2005). Prediction of energy intensity of carbon fiber reinforced plastics for mass-production passenger cars. The ninth Japan Interational SAMPE symposium. Nov. 29- Dec. 2, The university of Tokyo, 113-8656. World Steel Association (WSA). (2012). Automotive: Introduction. Retrieved June 26th, 2012 from: http://www.steeluniversity.org/content/html/eng/default.asp?catid=22&pageid=2081272206

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