Mechanical Analysis of Different Composites Used in Automotive Chassis Design
Authors: Kulkarni Kalyani S. , Sawant Sanjay H. 
Published: December 2024

Background: In the rapidly changing automobile sector, the necessity for lightweight yet durable chassis materials is essential. The incorporation of composite materials offers the benefit of decreasing the total weight of vehicles while preserving adequate load-bearing capacity. This research examines three materials: ASTM A148 Gr 80-50 steel, P100/6061 aluminum alloy, and Graphite Al GA 7–230 Metal Matrix Composite (MMC). These materials were chosen for their ability to improve vehicle performance by optimizing strength, flexibility, and impact resistance. Methods: The chosen materials underwent stringent mechanical testing to evaluate their appropriateness for chassis applications. The evaluated key mechanical parameters comprised tensile strength, flexural strength, elongation, and percentage area reduction. Tensile and flexural tests were conducted to assess the materials capacity to endure various stress types, while elongation and area reduction measurements offered insights into their ductility and deformation properties under load. Results: ASTM A148 Gr 80-50 Steel demonstrated significant load-bearing capacity, featuring a tensile strength of 390 MPa and a flexural strength of 810 MPa. It exhibited commendable ductility, with 22% elongation and a 35% reduction in cross-sectional area, signifying its appropriateness for heavy-duty chassis applications. P100/6061 Aluminum alloy provides a balance of strength and weight, featuring a tensile strength of 320 MPa and a flexural strength of 640 MPa. It exhibited improved ductility with 30% elongation and a 41% reduction in area, rendering it suitable for applications where weight sensitivity is paramount. Despite possessing inferior tensile (76.9 MPa) and flexural strengths (159 MPa), graphite aluminum GA 7–230 MMC demonstrated superior ductility with 51% elongation and 68% area reduction. These characteristics demonstrate superior energy absorption during deformation, rendering it appropriate for impact-resistant applications. Conclusion: This study emphasizes the unique benefits of each material for car chassis applications. ASTM A148 Gr 80-50 steel has shown to be a viable option for severe load-bearing applications owing to its superior strength and commendable ductility. The P100/6061 aluminum alloy demonstrated efficacy as a lightweight chassis design choice, achieving a balance between structural integrity and weight reduction. Graphite Al GA 7-230 MMC, albeit exhibiting reduced strength, showcased enhanced energy absorption properties, rendering it appropriate for applications necessitating impact resistance. Future study may investigate the application of hybrid composites or the further optimization of these materials to improve vehicle performance while reducing weight.
Major Findings: The study compared three materials- ASTM A148 Gr 80–50 steel, P100/6061 aluminum alloy, and Graphite Al GA 7–230 MMC- for automotive chassis applications through rigorous mechanical testing. ASTM A148 Gr 80–50 exhibited superior strength and ductility, making it ideal for load-bearing applications. P100/6061 demonstrated a balance of strength and lightweight properties, suitable for weight-sensitive designs. Graphite Al GA 7–230 MMC showcased exceptional ductility and energy absorption, favoring impact-resistant applications. These findings underscore the materials' diverse advantages in enhancing chassis performance.