Text 3 a. Progress in Fiber Reinforced Resin Composite Technology

1. The lightweight but strong and stiff com­posites of fiber-reinforced resin had already made the transition from military aircraft structures to civilian ones,and race cars and exotic sports car prototypes featuring mass - efficient carbon-fiber bodies had started to appear. Yes, composites were still too expen­sive, but many experts believed that continued technical advancement would in due time yield low-cost, mass-produced auto chassis and bodies that could save fuel while enabling new designs that were never previously possible. That trend seems poised to change direction, however. Car structures are still made primarily of steel and other metals, and are likely to stay so for the foreseeable future. But many auto engineers are starting to realize the benefits of advancements in polymer composite technology to convince the auto industry that composites are up to the challenge.

Composites save weight

2. Potential weight savingsoffered by structural composite ma­terials are significant. Estimates of the relative weight savings and costs that could be achieved by replacing steel with current carbon-fiber- reinforced polymer composites (CFRPCs) range from 50 to 60% at two to ten times the cost. Substituting glass-fiber-reinforced polymer composites (GFRPCs) for steel could cut weight by a quarter to a third with a comparatively modest— 50%—cost rise. Composites can do the job, but it is a differ­ent material that requires careful predictive analysis as well as design with its special behavior in mind. Using finite elementanalysis, engi­neers designed the component to exhibit stiffness as well as modal and crash performance equivalent to that of a steel structure.

A new composites fabrication line

3. An even more ambitious effort is being mounted by MAG Industrial Automation Systems ¹, headquartered in Basic materials research at Oak Ridge National Laboratory is focus­ing on waysto reduce the cost of carbon-fiber precursors such as polyacrylonitrile (PAN), or lignin. Another pressing need is for lighter-weight interior cross­barbeams under the dashboard and in the floor, which are intended to pass crash energy from side impacts across to the other side of the vehicle to share the load. Composites might find early application in these tubular crossbeams. In addition, composite suspension components such as control arms could also find application. These parts need to be as lightweight as possible to reduce durabilityand noise issuescaused by large unsprang mass.

Notes: MAG - a group of leading machine tool and systems companies.

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Exercise 3. Complete the sentences

1	Strong and lightweight composites	a	realize the benefits of composite technology.
2	Many auto engineers	b	find application in civilian structures.
3	Structural composite materials	c	to reduce durability and noise issues.
4	Glass-fiber reinforced composites	d	equivalent to that of a steel structure.
5	Composite suspension components should be lightweight	e	interior crossbar beams intended to pass crash energy.
6	Composites exhibit stiffness	f	cut weight by a quarter.
7	Composites can be used in	g	offer weight savings.

1	2	3	4	5	6	7

Exercise 4. Answer the following questions. Find the answers in the right column.

1	Why are composite materials up to the challenge?	a	steel and other metals
2	What are car structures still made of?	b	weight reduction and cost savings
3	What are the benefits of advancements in polymer composite technology?	c	could yield low-cost auto chassis and bodies
4	What are the potential weight savings offered by structural composite materials?	d	stiffness equivalent to that of steel structure
5	What stiffness could composite materials have?	e	weight savings range from 50 to 60%
6	Why should composites find application in suspension components?	g	the lightweight parts reduce durability and noise issues

1	2	3	4	5	6

Exercise 5. Discuss advantages and disadvantages of different materials in car body design.

Materials in car body design

are… / are characterized by… / exhibit features …

fiber -reinforced composites

metal alloys

Pro

contra

Pro

contra

Useful language : stiff/ stiffness

durable/ durability

environmentally friendly

impact resistance/resistant

waterproofing (гидрофобный)

corrosion resistance/ resistant

easy to process

cost effective / cost savings

weight effective / weight savings

fuel efficient / fuel efficiency

recyclable

recoverable / recyclability

noise suppression

safety protection

Exercise 6. Open the brackets and put the verb in Active or Passive Voice

1. Recently the layers of woven Kevlar (to combine)____________ with the layers of resin, the resulting ‘rigid’ material is light and has twenty times the strength of steel.

2. Since its invention Kevlar _________ (to use) with 4 x 4 vehicles, especially when the vehicle is used off road and far away from recovery services.

3. Kevlar is ideal because it is lightweight and non-flammable and it ________ (to offer) protection from high temperatures and excellent impact resistance.

4. Kevlar is used as reinforcement material for some car tyres and bicycle tyres. This standard of tyre is more expensive than ordinary road tyres. They are of particular use with 4 x 4 vehicles, especially when the vehicle (to use) ___________ off road and far away from recovery services.

5. The first active suspension system with the ability to recapture energy (to develop) ____________ by the Levant Power Corp. It features modest power consumption, minimal complexity and affordable cost.

1	2	3	4	5

Exercise 7.Complete the following sentencesusing the words in the box

a. reduced / b.advancement / c. strength/ d.performance / e. durability/

1. Composites are still too expen­sive, but many experts believed that contin­ued technical ___________could bring low-cost, mass-produced auto chassis and bodies that could save fuel.

2. To improve car ____________ would require more powerful and more efficient combustion.

3. Composite materials allow engineers to create very complicated structures with _____________weight and increased strength at a lower-cost than can be achieved with conventional metal structures.

4.The shape of the material determines its stiffness without affecting its ultimate __________ .

5. The new and improved air suspension seating today provides drivers with a smooth vibration -free environment by focusing advancements in technology and _______________.

1	2	3	4	5

Exercise 8. Read thefollowing text without a dictionary and speak on the benefits of polymer composites in auto bodies and chassis.

Researchers continue to believe that further work on cheaper fibers, new resin systems such as liquid crystal polymers, and automated processing equipment will eventually cut costs and improve the final product.

Potential benefits derived from the adoption of structural composites are manifold. Improved crash safety could be achieved when engineers take advantage of the materials' higher specific energy absorption.

Composites contribute to simpler assembly opera­tions. Polymer composite structures offer better long-term durability than metal ones and supe­rior environmental sustainability through enhanced end-of- life recyclability.

(640 characters)

Exercise 9.Make reports supported by slides on the following topics (your speech should last for 5-7 minutes)