Table Of Content

Materials for Lightweight Constructions This book presents the key concepts and methods involved in the develop- ment of a variety of materials for lightweight constructions, including metals, alloys, polymers, and composites. It provides case studies and examples to explain strategies adapted for specific applications of the materials and covers traditional to advanced manufacturing concepts of lightweight materials, including 3D printing. It also illustrates the fundamentals and usability of biodegradable materials for achieving a greener environment, as well as possibilities of green manufacturing. • Covers the fundamentals of a range of materials used for lightweight constructions • Discusses fabrication and testing of materials • Addresses relevant concepts of 3D printing and biodegradable materials • Explores analysis of the failure mechanism of materials used in various applications • Identifies the applicability of materials to a variety of situations Materials for Lightweight Constructions will suit researchers and gradu- ate students in materials science, mechanical engineering, construction, and composites. Materials for Lightweight Constructions Edited by S. Thirumalai Kumaran Tae Jo Ko S. Suresh Kumar Temel Varol First edition published 2023 by CRC Press 6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742 and by CRC Press 4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN CRC Press is an imprint of Taylor & Francis Group, LLC © 2023 selection and editorial matter, S. Thirumalai Kumaran, Tae Jo Ko, S. Suresh Kumar, Temel Varol; individual chapters, the contributors Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the conse- quences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged, please write and let us know so we may rectify in any future reprint. Except as permitted under US Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, micro- filming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, access www.copyright.com or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. For works that are not available on CCC, please contact [email protected]. Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for identifica- tion and explanation without intent to infringe. ISBN: 978-1-032-17173-9 (hbk) ISBN: 978-1-032-17174-6 (pbk) ISBN: 978-1-003-25210-8 (ebk) DOI: 10.1201/9781003252108 Typeset in Sabon by SPi Technologies India Pvt Ltd (Straive) Contents Preface vii Foreword ix Editors xi Contributors xiii 1 Introduction to lightweight materials 1 VIGNESHWARAN SHANMUGAM, RHODA AFRIYIE MENSAH, N. B. KARTHIK BABU, C. PRADEEP RAJA, J. RONALD ASEER, A. PUGAZHENTHI, D. SATISH KUMAR, AND OISIK DAS 2 Metals and alloys for lightweight automotive structures 17 K. PONAPPA AND YASH PANCHAL 3 Polymers for structural applications 39 K. ARUNPRASATH, M. VIJAYAKUMAR, PON JANANI SUGUMARAN, P. AMUTHAKKANNAN, V. MANIKANDAN, AND V. ARUMUGAPRABU 4 Chemical property and characteristics of polymer 61 A. SOFI, JOSHUA JEFFREY, AND ABHIMANYU SINGH RATHOR 5 Mechanical testing and its performance 83 M. ARUNA 6 Green manufacturing and environment 111 ALI SOHANI, JAROSLAV VRCHOTA, BURÇIN ATILGAN TÜRKMEN, MOHAMMAD MEHDI HOSSEINI, AND HITESH PANCHAL 7 Lightweight 3D printed materials 137 M. BHUVANESH KUMAR, K. ANAND BABU, P. SATHIYA, AND MILON SELVAM DENNISON v vi Contents 8 Biodegradable materials 161 AKESH B. KAKARLA, SATYA G. NUKALA, AND ING KONG 9 Sustainable composites for lightweight applications 191 A. SOUNDHAR, V. LAKSHMI NARAYANAN, M. NATESH, AND K. JAYAKRISHNA 10 Data-driven optimization of manufacturing processes 209 T. RAMKUMAR, M. SELVAKUMAR, S. K. ASHOK, AND M. MOHANRAJ 11 Conclusion and challenges 223 G. VELMURUGAN AND R. SUNDARAKANNAN Index 243 Preface The use of materials in the various fields is inevitable. However, develop- ing technologies have allowed for the use of lightweight materials for the desired applications. It is now becoming a part of the regular materials’ vocabulary. Because of the unique nature of the materials, more advanced research has continued in an effort to reduce the weight of structures. There is increasing demand for such lightweight materials in a variety of sectors that minimize energy consumption without compromising material quality. The use of polymer nanocomposites, such as polymer/carbon nanomateri- als, in the aerospace industry has grown in the last few years because of the strength of the components combined with their lightweight features. Each chapter in this book has been extended with new information, which goes from basic to in-depth discussion and conclusion. This book intends to maintain a balance between conventional processing of materials and design, as well as the recent developments vis-à-vis achieving the immediate needs. This book is intended for undergraduate students, postgraduate students, and research scholars who wish to acquire a broad knowledge of lightweight materials. In addition, industry personnel will also glean ample information from this book, as it will help them comprehend and apply the concepts to practical solutions in better ways. The references cited in this book will also help them find additional information to go deeper into topics that are of interest to them. S. Thirumalai Kumaran Tae Jo Ko S. Suresh Kumar Temel Varol vii Foreword MATERIALS FOR LIGHTWEIGHT CONSTRUCTION We stand today at a critical juncture. While the industrial revolution has given us a world of infinite possibilities, it has already created a world that is non-sustainable for the human race. Materials is at the heart of transfor- mation and particularly the dawn of one civilisation after next. The ages of copper, bronze, silver, gold, and iron are behind us. Today we stand face to face with a diversity of materials – mostly synthesized using molecular chemistries. These new age materials have excellent functional properties – however, are they sustainable and green. The core philosophy of going “green” is to reduce the impact of the material on the environment. It starts from the mining or synthesis of the starting blocks – be it a ore or a monomer. Then comes processing – either using furnaces driven by fossil rules or polymerisation using various toxic sub- stances often leaving behind a difficult set of residues. Finally the usage of the material as a product and its end of life. Recycle-Reuse-Retain is the new age mantra that is driving sustainable manufacturing processes. It is also noted that a new “sustainable” manufacturing process will be costly to start with. This is because the incumbent material enjoys a head start in terms of economies of scale, proven and sturdy supply chain and the established customer acceptance. It is imperative, therefore, to use modern tools such as 3D printing, Virtual reality and Artificial Intelligence to shorten the time to adoption of new materials and new processing technologies and make them commercially viable. In light of the above, I am encouraged to go through the 11 chapters of the book. The topics are very pertinent to the needs of sustainable manufacturing. It is refreshing to see the take on automotive and construction and the attempt by the authors to connect the state of the art research with the needs of these sectors. ix