Chloe Zhang
Cars have come a long way since the first automobile was invented in the 19th century. While metal, especially steel, is still the most common raw material in cars, advances in technology have led to an increase in the use of plastic in automotive design and manufacturing. This shift towards plastic car parts is driven by economic and safety considerations, as well as a desire to reduce the environmental impact of the automotive industry.
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What You'll Learn
- Plastic is cheaper, rust-proof, and easier to mould than metal
- Metal is seen as a raw material for engines and transmissions
- Steel is the most common metal in cars, but aluminium is catching up
- Plastic is now associated with technology and sustainability
- Car makers combine materials to balance cost, weight, and safety
Plastic is cheaper, rust-proof, and easier to mould than metal
Plastic is a more economical choice than metal. It is cheaper to produce, as it requires less energy and resources to manufacture. Bioplastic production, for example, uses 68% fewer fossil fuels and resources, which drives down costs for consumers. Plastic is also lighter than metal, which helps reduce the cost of building cars and increases fuel efficiency.
Plastic is also rust-proof, unlike metal, which can be damaged by rust and oxidation. This is especially important for cars, as rust can cause significant damage to metal parts over time. Plastic's chemical resistance means it is less likely to be damaged by chemicals or chemical reactions.
The flexibility of plastic is another advantage over metal. It can be moulded into complex shapes and features much more easily, keeping manufacturing times and costs down. Plastic parts can often be manufactured as a single piece, whereas metal parts often require welding or assembly. This also makes plastic parts easier to repair or replace, as they suffer less wear and tear.
Plastic's durability is also notable, as it generally provides a longer service life than metal. This is especially true for polypropylene, which has a longer lifespan than metals in most applications. However, it is important to note that plastic can degrade when exposed to extreme temperatures and is not suitable for prolonged outdoor use without a UV inhibitor to prevent discolouration and cracking.
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Metal is seen as a raw material for engines and transmissions
While the automotive industry has seen a shift towards the use of plastics and other materials, metal remains a vital raw material for engines and transmissions. Aluminium castings, in particular, have been used in automobile engines and transmissions for a long time.
Aluminium is now the dominant metal in cars, replacing steel and iron in many critical auto parts, including engine blocks. Aluminium is favoured for its lightweight nature, which increases fuel efficiency and extends the range of electric vehicle batteries. The use of aluminium in engines and transmissions also results in significant weight reduction. In 1975, only 84 pounds of aluminium was used in a typical car, but by 2020, this figure had increased to about 466 pounds. The industry expects this number to reach 565 pounds by 2030.
Other metals used in engines and transmissions include cast iron, steel, and magnesium. Cast iron is still used in engine parts, gearboxes, and axles, although its use is decreasing in favour of aluminium. Steel is also used in engines, as well as in vehicle bodies, chassis, and wheels. Magnesium is the lightest of all engineering metals, but its use is limited by its price and stability.
In summary, while plastics and other materials have replaced metal in some car parts, metal remains essential in engines and transmissions. Aluminium is the most common metal used in these parts due to its lightweight and durable nature, although other metals like steel, cast iron, and magnesium also play a role. As the automotive industry continues to evolve, the use of metal in engines and transmissions may change, but for now, it remains a key raw material.
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Steel is the most common metal in cars, but aluminium is catching up
Cars are made from a variety of materials, including metals, plastics, glass, and other compounds. Metals are used in cars due to their strength, durability, and low cost. Metal parts are also generally easier to manufacture than other materials, making them ideal for mass production. Metals are excellent conductors of heat and electricity, which helps keep sensitive electronics in the engine bay cool and prevents them from overheating.
Steel is the most common metal in cars and has been for almost 100 years. It is used in everything from buildings to home appliances to ships to surgical tools. Steel is an alloy of iron and carbon containing less than 2% carbon and 1% manganese, as well as small amounts of silicon, phosphorus, sulfur, and oxygen. It is strong, durable, and easily formed into desired shapes and sizes. Engineers can select the type of steel and its grade to create a part with the exact properties needed. For example, high-strength low-alloy steels, advanced high-strength steels, and ultrahigh-strength steels are used in automobile parts. It takes around 900 kilograms of steel to build a car, and it is used in everything from the body shape to mufflers, exhaust pipes, and engine blocks.
However, aluminium is a fast-growing rival to steel in vehicle manufacturing. Aluminium is lighter and stronger than steel and is used in engine blocks, wheels, transmission housings, suspension systems, body panels, and interior trim. It is also often used as a reflector or heat shield in headlights and taillights. Aluminium is gaining popularity among auto engineers as it helps remove mass from cars, improving fuel economy and reducing emissions. While aluminium was once only used in exotic and luxury cars, it is now common in mainstream cars for hoods, doors, and trunk lids.
Other metals used in cars include copper, which is primarily used in electrical wiring and electric motors due to its excellent ability to conduct electricity; lead, which is used in lead-acid batteries; and platinum, palladium, and rhodium, which are rare and expensive metals used in catalytic converters. Additionally, magnesium and titanium, which are strong for their weight, are used in some expensive high-performance vehicles.
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Plastic is now associated with technology and sustainability
Plastic is now synonymous with technology and sustainability. The automotive industry is increasingly turning to plastic as a more sustainable alternative to metal. Plastic parts are essential building blocks for the design and function of vehicles, and their use has expanded since the 1960s. They are cheaper, lighter, and easier to manufacture, and with advances in technology, they now offer equal strength and performance to metal parts. This shift is driven by the need to reduce the auto industry's significant contribution to greenhouse emissions, which stands at almost 17%.
Ford, Audi, and Volvo are among the car brands adopting recyclable plastic parts. The use of plastic in car manufacturing helps to lower costs for consumers, with biodegradable polymers requiring 68% fewer fossil fuels and resources to produce than their metal counterparts. This reduction in fossil fuels also helps car manufacturers adhere to government regulations.
The plastic production industry as a whole is also evolving to meet sustainability goals. China's decision to halt plastic waste imports from the West in 2018 was a significant catalyst for change, prompting investment in research and development, with a focus on creating a more sustainable, circular lifecycle for plastics. Manufacturers are now adopting machinery that minimises waste, and bioplastics sourced from renewable materials, such as vegetables, are becoming more popular.
Technological innovations are also contributing to sustainability in plastic manufacturing. For example, the extrusion process, which is essential for creating recycled plastics, demands precise control of the extruder's speed and torque. Variable Speed Drives (VSDs) and Programmable Logic Controllers (PLCs) enable this precision control, allowing for significant cuts in energy usage and associated carbon emissions, as well as reduced costs. These technologies support the industry's shift towards a circular economy and help to enhance the quality of recycled materials.
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Car makers combine materials to balance cost, weight, and safety
Car makers use a variety of materials, including metals and plastics, to construct vehicles, with each material chosen for its specific properties and contribution to the overall balance of cost, weight, and safety.
While steel is the most common raw metal material used in car manufacturing, it is heavy, and its use can be reduced by replacing it with lightweight materials such as high-strength steel, aluminium alloys, magnesium alloys, carbon fibre, and polymer composites. These lightweight materials can reduce the weight of a vehicle's body and chassis by up to 50%, leading to improved fuel efficiency and reduced fuel consumption. This is particularly important for electric vehicles, where lightweight materials can offset the weight of heavy power systems like batteries and electric motors.
Plastics and polymer composites are also increasingly used in car manufacturing due to their ability to reduce vehicle weight while maintaining or improving safety and performance. They are also more environmentally friendly, with biodegradable options reducing the use of fossil fuels and adhering to government regulations. The use of plastics can also help reduce manufacturing costs, making vehicles more affordable for consumers.
However, metal parts are still crucial for engines and transmissions, and steel remains important for its ability to absorb impact energy in crashes. Car makers must carefully select materials that balance weight, cost, safety, and performance, ensuring that each component works together to create a functional and efficient vehicle.
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Frequently asked questions
Both. Metal still composes the majority of a car's weight, but plastic parts are essential building blocks for the design and function of a vehicle.
Metal is used in cars because it is a good electricity conductor, malleable, ductile, and lustrous. Steel, an alloy of iron and carbon, is the most common metal used in cars.
Plastic is used in cars because it is cheaper, lighter, and safer than metal. Plastic breaks more easily than metal, which is important for the safety of pedestrians. Plastic is also more environmentally friendly, as it uses fewer fossil fuels and resources to produce.
