This document provides an overview of materials used in automotive industries. It discusses the chassis and frame, which is made of galvanized steel, aluminum, and other alloys. It also discusses the different types of frames like ladder, backbone, and monocoque frames. Other automotive components discussed include the engine, which uses materials like iron, steel, aluminum, and composites. Additional components and their materials mentioned include tires made of rubber, lights made of plastics, and an electrical system containing copper. The document concludes by acknowledging those who provided guidance for the project.

1. A presentation on Materials used in Automotive Industries
By-
Vidyasagar Ghantoji Aditya. Guded
Prithvi Patil Sharankumar G.S
Vinay Kalmoodkar Varun Kumar
Vikas Mathapathi Mahesh Avantagi

2. Chassis & Frame:
Automotive Chassis is a skeletal frame on which various
mechanical parts like engine, tyres, axle, assemblies, breaks &
steering etc. are bolted. The chassis is considered to be the
most significant component of an automobile.
Main components of Chassis are as follows:
Frame
Engine or Power plant
 Clutch
 Gear Box
U Joint
 Propeller Shaft
 Differential

3. Types of Chassis are:
 Ladder Chassis :
Main material used in this type is Galvanized steel, Galvanized Iron,
High grade Aluminum.
 Backbone Chassis :
Glass fibre is used in preparing the Backbone chassis
Since Glass fibre is high in its tensile strength.
 Monocoque Chassis :
This is manufactured by welding floor pan and other pieces together.
In some chassis like race cars Two of the layers are made using a
plastic resin reinforced with carbon fiber with the interior layer of
aluminium honeycomb sandwiched between the inner and outer
layer.

4. CHASSIS FRAME:
The frame is the main part of the chassis on which remaining parts of chassis
are mounted. The frame should be extremely rigid and strong so that it can
withstand shocks, twists, stresses and vibrations to which it is subjected
while vehicle is moving on road. It is also called under body. The following are
the types of Frames.
 Conventional Frame:
The body is made of flexible material like wood and isolated frame by
inserting rubber mountings in between. The frame is made of channel
section or tubular section of box section.
 Semi-integral Frame:
In this case the rubber mountings used in conventional frame between frame
and suspension are replaced by more stiff mountings.
Integral Frame or Frame-less Construction:
In this type of construction, there is no frame. It is also called unitized
frame-body construction. The under body is made of floor plates and channel
and box sections welded into single unit.

5. Based on the design , the chassis frames are classified as follows:
 Ladder Frame
 Backbone Frame
 X- Frame
 Perimeter Frame
 Platform Frame
 Superleggera

6. Ladder Frame:
Galvanized steel and High grade Aluminum are used to manufacture these frames.
Backbone Frame :
High grade Iron strong and tubular in structure is used to manufacture these
frames.

7. X-Frame :
This frame is usually made up of Iron
Perimeter-Frame:
This frame is usually made up of Iron and Aluminum

8. Platform Frame :
This frame is usually made up of Aluminum
Superleggera :
This frame is usually made up of Aluminum

9. Unibody :
This frame is usually made up of Copper and Aluminum
Sub Frame :
This frame is usually made up of Copper

10. Automotive fasteners are a
collection of products that are used
in automotive and vehicle assembly.
They are usually designed for
specific makes/models of vehicles.
Copper, Iron, Nickel and stainless
Steels are used.
Automobile Gaskets and Seals:
Automotive gaskets refers to a
mechanical seal which is used for
filling the gap between the two
components in order to ensure that
there is no leakage between them
during compression stage. These are
manufactured using variety of
materials like gasket paper, plastic
polymer, rubber, fiberglass, silicone,
metal, cork, and felt

11. AUTOMOBILE ENGINES
Automobile engine refers to a fuel-consuming machine or device that is used for
propelling automobiles, airplanes, tractors, buses, two wheelers, cars etc. Engine
forms an integral component of a vehicle that transforms chemical energy in fuel into
mechanical energy for power. Usually, automobile engines make use of four strokes to
turn chemical energy into mechanical energy with the help of combustion of gases or
hydrocarbon fuel.

12. Components of Automobile Engine:
The following are main components of an Engine:
CAMSHAFT:
Materials used here are:
Chilled iron castings
Billet Steel
CRANKSHAFT:
Carbon Steel, Nickel
Chrome or other Alloy
Steel.

13. Connecting Rods :
These rods are actually
made with plain carbon
steel ,aluminum alloys,
Which is characterized by
low weight . Nickel alloy
steel is also used for
heavy duty engines.
Steel, aluminum,
titanium, iron and other
types of metals.
Crank case:
Magnesium, Cast Iron,
Aluminum and alloys. Are
the main metals used in
the manufacture of Crank
case .

14. CYLINDER HEADS:
Cylinder head is made up of
aluminum or cast iron and are
respectively called as aluminum
cylinder head and cast iron
cylinder head.
ENGINE BELTS:
These belts are made of a
flexible polymer over fabric
reinforcement
Synthetic rubber and
polyurethane
nylon, Kevlar or other aramid
fibers and carbon fibers .

15. ENGINE VALVE:
Materials used here are
given below Structural
Ceramics, Steels, Super
alloys and Titanium alloys.
Engine Blocks:
Engine blocks are made from
different materials including
Aluminium alloys, gray cast
iron, ferrous alloys, white
iron, gray iron, ductile
iron, malleable iron, etc.

16. ENGINE PULLEY:
Molded plastics, iron and
steel are commonly used
metals in this pulley.
Engine Brackets:
Ductile Iron Cast,
Aluminium, Polypropylene,
Fiberglass and alloys. Are the
common metals used here in
Engine Brackets.

17. ENGINE MOULTING
BOLTS:
Alloys, silicon bronze, bronze,
ceramic, carbon, aluminum,
nylon, phosphor bronze, nickel
silver, plastic, titanium,
zirconium and stainless steel are
utilized to produce these bolts.
PISTON:
Materials for the piston are cast
aluminium, forged aluminium
and forged steel etc. Aluminium
alloys are the ideal materials due
to their very high thermal
conductivity.

18. PISTON RINGS:
It is generally made up of cast iron and
chrome steel.
PUSH RODS:
Titanium, Aluminum, Chrome Moly and
Tempered Chrome Moly.

19. VALVE TRAIN:
Materials used in Valve Train are cast iron and galvanized steel.
The primary components of valve train are:
a) Tappet
b) Rocker Arms
c) Valve Timing System

20. Car Body Panels
Metals such as steel, aluminium and magnesium are mainly used for elements of the
body structure and panels. Plastics are applied for exterior attachments to the body.
Cars consist mainly of steel and iron.
Steel:
Most commonly used materials for vehicles are still different types of steel. They offer
a wide variety of material characteristics such as thermal, chemical or mechanical
resistance, ease of manufacture and durability.
Aluminium:
Aluminium has already established itself in the car industry for many years. Its low
density and high specific energy absorption performance and good specific strength
are its most important properties.
Plastic:
Plastics are important material for the automotive industry. It has a low density, are
mostly economic to produce and their characteristics can be fitted to specific
demands. Unreinforced plastics can be used to make bumper coverings or exterior
attachments to the body structures.

21. Magnesium:
Magnesium is another light metal that is becoming increasingly common in automotive
engineering. It is even lighter than aluminium and is used in the manufacture of
transmission housings or parts of doors and bonnets for lightweight constructed cars.
Carbon-Fibre Epoxy Composites:
The most of the racing car companies much more rely on composites form whether it
would be plastic composites, Kevlar and most importantly carbon-fibre epoxy
composition. Mainly; carbon (graphite), Kevlar and glass fibres, pre-impregnated
with high temperature epoxy resins are used.
Plastic & Plastic Composites:
Autos are fully loaded with plastic car seats, dashboards, side paneling and/or
bumpers. Representing more than 7.6% of an auto’s prime bulk material used, the
typical automobile today contains about 260 pounds of plastic and this also helps in
reducing the weight and increasing the fuel efficiency.
Plastic composites are also one of the popular materials among composite family in
car chassis. Plastics composites are so light that the average car is lighter than the
minimum weight permitted.

22. Glass-Fibre Composites:
Glass fibre is being used mostly for the sports car which includes Formula 1 cars. It is
lighter than steel and aluminium, easy to be shaped and rust-proof.
Cooling system
Cooling System Fluids are the liquids or gases which are passed through an internal
combustion engine with the key function of regulating temperature, stopping
overheating and maintaining the temperature of the automobile.

23. Water Cooling Systems:
An automobile engine cooling
system basically need water and
other anti-freeze mixtures to
lower down the shooting
temperature of the engine. The
material used here is plastics,
iron, steel.
A/C Parts:
The air conditioning system of a
vehicle makes use of refrigerant
for cooling the air and taking
away the heat from the
passenger compartment.

24. Aluminium Housing:
Aluminium Housing as its name
suggest, aluminium housing are
the protective coverings or fully
enclosed cases made of
aluminium metal for containing or
supporting mechanical
components of a vehicle.
Cooling System Gaskets:
Cooling System Gaskets are seals
or packing especially designed for
joining or sealing the matched
components or pipe joints in an
automobile cooling system with
the main purpose of stopping the
escape of a gas or liquid. And
usually these are made out of
rubber.

25. Shock Absorbers:
Shock absorbers are mechanical
devices having springs located in the
balance wheel bearings which are
used for preventing the vehicle from
getting bumps. Made up of Steel and
iron rods.
Suspension Springs:
Automotive or automobile suspension
and steering system make use of
many kinds of suspension springs that
help the vehicle to move comfortably
and adapt to the uneven road
conditions. These are made up of
tensile steel , irons in few cases.

26. Tires:
Tires are generally made up of rubber and polyisoprene.
The picture here shows the c/s of a tire.
And there are other materials used they are:
• Styrene-butadiene co-polymer
• Polybutadiene
• Halo butyl rubber
• Bromobutyl
• Chlorobutyl
• rubber compound.

27. Lights:
Polycarbonate (PC)
Polymethyl Methacrylate (PMMA)
Are the two plastic materials
used in lighting system.
Electrical system:
The armature is made out of Iron
The charging system inside the
auto is made out of plastic and lot
much of copper which is in the
form of coils

28. Acknowledgments
Now I hereby conclude this session by expressing my gratitude to my beloved teachers
and guide :
• Prof. R.M.Latthe sir
• Prof. V.B.Hippargi sir
Both of have been a very big inspiration under whose guidance I have been able to
start this, I also express my gratitude to :
• Shri.Baslingappa Beedi
(DTO, NEKRTC)
• Shri. M.Puranik
(Chassis inspector,NEKRTC)
• Shri.Santhosh Gogeri
(DME,NEKRTC)
I also thank each one of my group mates who have been all along with me and helped
me in completing this project successfully thank u one and all for giving me a chance
to present this in front of you.