Desirable Materials that can be used for construction for solar vehicle

In this report, selection of different materials for the chassis and body works is done considering the physical properties of some selected materials. A right material is of utmost importance when it comes to designing a chassis because if a material of correct requirement is not chosen, the chassis could break on loads leading to fatal conditions of the driver. The following are the important considerations for the selection of proper material for the chassis. The material must have high yield strength, high machinability, easy weld ability, low cost, light weight and high elongation at failure.

Some of the materials under consideration include AISI 4130 (DIN 1.7218) chromyl steel (preannealed), AISI 1020 (DIN 1.0402) steel and Al-6063-T1. The problem with AISI 4130 (DIN 1.7218) steel was even though it gave good strength and lighter than mild steel (MS), it is expensive and not easily weld able. Welding AISI 4130 (DIN 1.7218)  steel is not only costly but could not be trusted as it has to be annealed before and after welding yet gives fractures without notice. 

AISI 1020 (DIN 1.0402) steel is cheap, easily available and weld able and with some decent specifications but when analysed for chassis and various components like rear axle, etc., it showed a high deflection of 2- 9mm with very less factor of safety and addition of members to improve strength makes the chassis heavy. Aluminium alloy 6063-T1 gives enough yield strength to withstand all subjected stresses and loads. Though expensive, we cannot compromise on the quality on material for chassis and it is advised to look for a competitive price. Thus, Al-6063 satisfies all other requirements.

Body Works is an important part of the vehicle design. External appearance is an important feature which not only gives grace and lusture to the vehicle but also dominates sale and marketing of it. Each product has a defined purpose. It has to perform specific functions to the satisfaction of customer. The functional requirement brings products and people together. However, when there are a number of products in the market having the same qualities of efficiency , durability and cost, the customer is attracted towards the most appealing and economical product. Three materials such as aluminium, carbon fiber and glass fiber can be considered for aesthetic considerations of the design.

Aluminium shows good properties like light weight, does not rust easily, and has good machinability but is costlier than steel and is very abrasive. Carbon fibre contains some ideal qualities like High stiffness, high tensile strength, low weight, high chemical resistance, high temperature tolerance and low thermal expansion. However, they are relatively expensive when compared to similar fibres, such as glass fibres or plastic fibres. Thus, budget exceeded in its place. Glass fibre is light weight, easily mouldable, easy machining, Fire resistant, Low maintenance, Anti- magnetic, good electrical insulator. However, it is costlier than aluminium but fits into economic range. Selection of glass fibre as the material for moulding the body of the vehicle is an educated choice since glass fibre is cost effective, light weight, has good strength, it fits into the requirement slot for manufacturing the solar vehicle.

Mechanical Prop.	Value (Metric)
Density	2700 kg/m3
Hardness (Brinell)	42
Ultimate Tensile Strength	152 MPa
Tensile Yield Strength	90 MPa
Elongation at Break	20%
Modulus of Elasticity	69 GPa
Poisson’s Ratio	0.33
Melting Point	616-654°C