Thermoplastic Materials for the Metal Replacement of Non-Structural Components in Marine Engines

Abstract

Metal replacements for automotive and aerospace components are already a consolidated reality, in light of the advantages offered by fibre-reinforced polymers, consisting of reduced costs, weight, and environmental impact. As a result, engineering has been studying the possibility of replacing currently used metallic alloys with alternative materials, such as thermoplastic fibre-reinforced polymers, in the manufacturing of non-structural sections of marine engines. Given the peculiar characteristics of the working environment of such parts, i.e., ship engine spaces, and the strict requirements regarding safety, the selection of the polymer must be properly performed through a tailored material design process. Consequently, the redesign of the components must be carried out with the aim of exploiting the best of the materials’ properties while ensuring the correct resistance and simplifying installation operations. In this framework, finite element simulations may represent a suitable approach to validate the conformity of the proposed material and design. In this paper, this methodology is applied to a camshaft cover of a four-stroke marine engine, currently made of aluminium alloy. A 30% wt GFs/PA6,6 was identified as the most promising material and the novel plastic cover proved to guarantee the correct resistance while ensuring an important reduction in weight, processing costs, and required energy.