International Topical Meeting on Nuclear Research Applications and Utilization of Accelerators
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AP/IA-04 Radiation Curing of Composites for Vehicle Component and Vehicle Manufacture M.R. Cleland1, R.A. Galloway1, D. Montoney2, D. Dispenza3, and A.J. Berejka4 1IBA Industrial Inc., Edgewood, New York, USA Corresponding Author: Marshall.Cleland@iba-group.com Uses of metals in vehicle components and vehicle manufacture, as steel (specific gravity .8) or aluminum
(specific gravity 2.7), can be replaced by carbon fiber composites (specific gravity 1.6) to provide weight
savings while maintaining structural integrity. The aircraft and aerospace industries have adopted this concept.
The motor vehicle industry is using composite materials for some non-structural components in automobiles, but
have not widely adopted this technology because of issues in high-volume manufacturing processes. A typical
steel auto body weighing ~750 kilograms would weigh only ~155 kilograms if replaced with carbon fiber
composites. Structural members, such as the vehicle chassis and body frame, could also be made out of carbon
fiber composites. With only 20% of the typical body weight, smaller, lighter, less powerful and more fuel
efficient engines could be used in such vehicles. Aircraft manufacturers have adopted large carbon fiber
structures in lieu of aluminum for a 40% weight reduction and estimate a 20% savings in fuel costs for large
planes. These aircraft still use conventional materials for motors, tires and interior components. The fuel
efficiency of an automobile could be doubled with an 80% weight reduction. As with aircraft, conventional
motors, tires and interior components could be used in automobiles. Radiation curing can simplify the
manufacture of carbon fiber composites. Penetrating X-rays generated with high-energy, high-power electron
beam (EB) accelerators can cure structural composites while they are constrained within inexpensive molds;
thus reducing cure times, eliminating heat transfer concerns and potentially hazardous volatile emissions during
the curing process. Since the power output of an EB accelerator can be tightly controlled, EB processing can be
used to produce “B” staged, fiber-reinforced composite materials for sheet molding compounds (SMC) and
prepregs. Such materials can significantly reduce the time-to-cure should alternative energy sources or
subsequent X-ray curing be used. In the EB mode, SMC materials can be made at more than 100 meters per
minute. The polymeric matrix systems are proprietary formulations based on common adiation responsive
materials which are used in a variety of radiation curing applications.
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