Nanotechnology and automotive manufacturing

Nanotechnology is the engineering of functional systems at a molecular scale. This technology is indispensable because many common substances have different and useful properties when reduced in size. It promises to improve the performance of existing technologies significantly.

“Nanotechnology is expected to be a key driver for innovation in the automotive industry,” says Wijia Xie, an industry analyst from research and consulting firm Frost & Sullivan.

“The technology has a wide variety of applications in many vehicle components, including the car body, windows, tires, control system, catalytic converter, and engine systems,” Xie adds.

“The application of nanotechnology is usually done so as to significantly improve the safety, comfort, efficiency and eco-friendliness of future generation cars.”

Indeed, there are a number of processes and products enhanced by nanomaterials that are making an impact in the automotive industry.

These include nanocomposites incorporating a variety of materials for structural reinforcement and safety; nanoparticle catalysts for fuel economy; nanoadditives for lubricants; and easy-clean, anti-fogging, anti-abrasion, anti-corrosion and self-repairing coatings. Companies like Toyota, General Motors, Ford and Rolls-Royce are all taking a lead in developing technologies in these areas.

Over the past decade, one of the most significant technological developments in the plastics industry has been in the use of nanocomposite materials.

Nanocomposites are stiffer, lighter and less brittle in cold temperatures than conventional plastics. They exhibit properties that are greatly different from macroscopic composites and have been shown to yield multiple benefits at relatively low cost compared to traditional methods of plastic enhancement, such as polymerisation.

“Exatec and DuPont developed scratch-resistant coatings for cars with polymer nanocomposite or metal oxide nanoparticles that provide excellent anti-scratch properties against hard-object impacts,” says Xie.

In 2002, General Motors used nanocomposite technology with thermoplastic olefins, thus opening up a whole new area of commercialisation.

The advanced thermoplastic nanocomposite part was used on the maker’s GMC Safari and Chevrolet Astro mid-size vans. It was the first automotive exterior application of this lightweight, high-performance and affordable material. Other automotive parts that have been developed from the material include exterior door and rear quarter panels. The plastic enables these items to spring back into shape following low-speed impacts.

Usage
Nanoparticle technology is being used in the automotive industry to protect engines and enable them to perform better.

Ford, for example, is using a device called the Local Electrode Atom Probe to conduct research into making metals and plastics lighter and stronger. The device works at the atomic scale and is useful for removing atoms from metallic surfaces and locating the atom position on those surfaces.

Nanoparticles are also being used as ‘fillers’ for metals and plastics to increase the strength of produced materials and reduce their weight in the process. Ford’s ‘Atoms to Engines’ team looked at the structure of cast aluminium alloys at near atomic levels. A detailed analysis of the structure, property and process relationship of the aluminium alloy engine blocks led to reduced engine weight, which in turn resulted in increased fuel efficiency.

Researchers are looking into ways in which Nanoparticles can be added to glass and paints to enable them to better withstand radiation and provide self-cleaning mechanisms.

Nanostructured surfaces result in improved paint adhesion and colour durability. It is no surprise then the Ford Motor Company has predicted that by 2015, nanomaterials will be used in 70 percent of its production materials. The move could likely position the company as a leader of the automotive industry once again. This is how big it is.

Clean technology
Nanotechnology’s many applications in clean technology range from solar panels to EV batteries. A report from Lux Research sees a $29 billion clean tech nanotechnology market in 2015.

Considering its features and what it has to offer, there seems no doubt that potential for nanotechnology in the manufacturing processes of electric cars is immense.
To exemplify, Lithium ion batteries are currently being intensively developed across the world for use in electric vehicles. Nanotechnology promises to improve the performance and the life-times of these batteries.

Additionally, it also has the potential to enhance the energy and power density, shorten the recharge time, as well as decrease the size and weight while improving safety and stability of the batteries.

“Nanotechnologies can further enable some sci-fi concepts for future vehicles, such as collisionless auto-driving cars, shape-shifting cars, and solar power cars. Its potential truly is astounding,” points out Xie.