Work with your partner. Choose one of the smart materials in the text. Think of five interesting ways it could be used. Compare your ideas with other students.

AUTOMOTIVE MATERIALS

Materials are a fast-changing aspect for automotive engineers. Concept vehicles displayed demonstrate that new uses of plastics, composites, aluminum and other non-conventional materials are to be a part of future automobiles and light trucks. The engineer of the next generation must know the capability of a wide range of materials and the latest production processes for these materials.

By most accounts, aluminum is the most recently discovered commonly used metal that exists only in combination with other materials such as silicates and oxides. It has been produced commercially only since 1854. By contrast, the Iron Age, characterized by smelting of iron and its use in industry, began before 1000 B.C.

Considering its relatively recent entrance into not only the automotive industry but the metal industry as well; aluminum has made great strides in grabbing a respectable amount of the automotive spotlight from steel. Between 1991 and 1999 the use of automotive aluminum doubled and is expected to double again in the nearest future.

Audi 2 is claimed to be the world’s first aluminum car to be signed off for volume production. Its space frame is composed of 60% panels, 22% cast elements and 18% profiles. Audi’s A2 is aerodynamically efficient for a small car and uses the company’s aluminum space frame technology.

Among engineering alloys, titanium possesses the strength, density and modulus to use it in automotive applications. Various titanium alloys are suitable for making springs and exhaust system components. The cold spring winding and cold setting (blocking) are basically the same for titanium springs as for steel. But there are not as many turns required for titanium springs as steel springs. Since the density of titanium is about half that of steel, it can perform the same task as steel springs on most applications while weighing 60 – 70% less.

Unlike steel springs, titanium springs do not require protective coatings. A primary mechanical engineering property considered in the design of steel suspension springs is corrosion fatigue strength.

 

5. Complete the sentences with the information from the text:

a) Concept vehicles displayed demonstrate that ………

b) The engineer of the next generation must know ………

c) Aluminum is the most recently discovered commonly used metal ………

d) ……… aluminum has made great strides in ………

e) Audi 2 is claimed to be ………

f) Among engineering alloys ………

g) Since the density of titanium is about half that of steel, ………

h) A primary mechanical engineering property considered in ………

6. Find a better and cheaper way to produce parts and the auto industry takes notice! For example, hydroformed parts offer weight, design and cost advantages over stampings.

Tube hydroforming is a pressurized hydraulic forming process that produces complex shapes. Prime candidates include frame rails, engine cradles, radiator and instrument panel supports, roof headers and seat frames. Hydroformed blanks can be manufactured from a variety of less-expensive materials, including low carbon hot rolled steel, cold rolled steel, high strength low alloy steels and even aluminum.

Prepare a short report or presentation to tell your group mates about different materials and their usage in automobile industry. Try to find as original information as possible.

 

 

LESSON 34

HOW IT WORKS: THE MOTOR CAR

The motor car is a form of mechanical transport and it is composed of many different working units and parts. To provide the energy to make it go, it has an engine which in turn needs electric current, petrol and air. The engine needs cooling so that it does not become too hot and oil to lubricate the bearing surface. Also, there is the transmission system of clutch, gearbox, propeller shaft and axle, which transmits the power from the engine to the wheels to move the car. Steering mechanism is needed to guide the car in the right direction, brakes to slow it down and stop it and suspension to smooth out most of the bumps and jolts.

CAR MAINTENANCE

Car maintenance means to inspect or test the condition of car subsystems (engine, for example) and service or replace parts and fluids. Regular maintenance is critical to ensure the safety, reliability, drivability, comfort and longevity of a car. A number of parts are replaced preventively to avoid major damage or even safety issues, e.g. timing belt replacement.

Many automobile service technicians feel that the most exciting part of their work is troubleshooting – locating the source of a problem and successfully fixing it. To solve these problems, there are two types of automobile service technicians: generalists and specialists. Generalists work under a broad umbrella of repair and service duties. Their work is routine and basic. Specialists concentrate in one or two areas. As more automobiles rely on a variety of electronic components, technicians have become more proficient in the basics of electronics. Many previously mechanical functions in automobiles are being replaced by electronics. So technicians use an array of tools in their everyday work.

The actual schedule of car maintenance varies depending on the Year/Make/Model of a car and its driving conditions and driver behaviour. Car makers recommend the so-called extreme or the ideal service schedule based on impact parameters such as:

· number of trips and distance travelled per trip per day

· extreme hot or cold climate conditions

· mountainous, dusty or de-iced roads

· heavy stop and go vs. long distance cruising

· towing a trailer and other heavy load

Experienced service advisors in dealerships and independent shops recommend schedule intervals, which are often in-between, the ideal or extreme service schedule. They base it on the driving conditions and behaviour of the car owner/driver.

Common car maintenance tasks include:

· car wash

· check or flush the engine oil and replace fuel filters

· inspect or replace windshield wipers

· check or refill windshield washer fluid

· inspect tires for pressure and wear

· tire balancing

· tire rotation

· wheel alignment

· check, clean or replace battery terminals and top up battery fluid

· inspect or replace brake pads

· check or flush brake fluid

· check or flush transmission fluid

· check or flush power steering fluid

· check and flush engine coolant

· inspect or replace spark plugs

· inspect or replace air filter

· inspect or replace timing belt and other belts

· lubricate locks, latches, hinges

· check all lights

· check if rubber boots are cracked and need replacement