Every year in July, the world’s most famous bike race competition, Tour de France, takes place. Ever since the 1998 winner rode a metal (aluminum)-frame bike for the competition, all of today’s Tour de France contestants compete in carbon-fiber bicycles. Although the quality and price might vary, carbon material has recently been widely used in ordinary bike riders’ bicycles.
Lightweight Material for Speed
For grown-ups, bikes bring riders back to the days of their youth. It reminds them of when they'd pretend to be heroes in gangster movies or princes on white horses in romance films, neighborhood pranks, biking through their neighborhoods and towns, and their school commute.
Bikes are making a comeback, even though they never left us. Bikes have always been present in our everyday lives, sports, and leisure. However, it's also true that bikes are making a comeback since we're seeing them as frequently as we did 30-40 years ago. There are some reasons for this.
Let’s talk about public bicycles first. “Ddareungi” (Seoul City), “Tashu” (Daejeon City), and “Pedallo” (Ansan City) are examples of public bikes that are not just for professional bikers only also for ordinary citizens and everyday use. They come to mind above all else because of their characteristic as a bike-sharing platform. In the past, if you wanted to use a bike, the only option was to buy one. It was difficult to keep a bike: more than half of the nation lives in apartments, and it's also easy for bikes to be stolen, even in a city like Seoul, which is famous for its security and safety. Bikes in Korea were mainly used by children. When they were used by adults, it was as a luxurious hobby, rather than a vehicle for daily use.
However, the bike-sharing system has revived bikes by relieving people from the burden of bicycle ownership. In large cities, bikes seemed to be a more effective means for the Last Mile Mobility that connects public transportation and destination. Also, bikes were a beneficial transportation tool in satellite cities where public transport is not as dense as in large cities.
The growth of the bike-sharing system began in Europe, which has a small and medium-sized city-based living environment, and public transportation is less developed than in Korea. This is true in Southeast Asia, too, where the car infrastructure and penetration rate are low. In Korea, Sangju City was famous for being the city of bikes (an average of two cycles per household). Even there, the introduction of the sharing system proliferated the use of bikes. In addition, as Kakao T, which aims at a mobility-integrated platform, also adds electric bikes to their service line, the bike-sharing system is expanding and accelerating.
Another reason for the revival of bikes is the Coronavirus pandemic. A bike is a transportation means, but it also serves as an exercise tool. People traveled on bikes, which freed them from the fear of the spread of infection. The bikes were also considered as a smart alternative work-out method for replacing exercise at the gym.
This trend has become an opportunity for the local bicycle industry. According to rumors, a bicycle manufacturer exhausted its long-accumulated stocks during the pandemic. Such an explosive demand also has led to a sharp price increase and production setbacks caused by Coronavirus-19.
The last reason concerns Last Mile Mobility, which is also related to the sharing system mentioned before. However, the point here is not a service platform but a new device, the electric bike. For example, I have experience commuting to and from 50 km. Although it felt great being away from the busy roads and enjoying the peaceful Han River, there was one big problem: I always got sweaty and needed a shower after every ride. However, as the electric bicycle came out, it served the purposes of both exercise and mobility when I needed them. As I will discuss later, the electric bikes' potential goes beyond even this.
To sum up, bikes have made a comeback in the public eye. This was made possible because bikes as tools for exercise have evolved through technology.
An image of a Pinarello bike made with carbon fiber for most of its parts including frame, fork, wheel-set, handlebar, and seat post. It is a model for the Tour de France.
©ShutterstockI was once a fan of cars and motorcycles, but I have not yet acquired a taste for bicycles. Then, a friend older than me told me, "You never know how precious a single gram can." As a bike fanatic, he insisted on the importance of lightening weight.
While a high-performance engine can increase a vehicle's performance, this option doesn't quite apply to bicycles. With a human serving as the engine, supplying half a horsepower, as a constant variable, the bike's performance depends on how efficiently this human power is used. Since the bike's output is fixed, the most critical factor was the bike's weight: performance can only be improved by lightening it. It is no exaggeration to say, "It costs 10,000 won to cut down 1 g." (In the world of bicycles, "Engine is the key," refers to a rider.)
Therefore, developing a bike's material was a natural yet fierce process to use this limited power more effectively. In particular, the evolution of the frame, which is the largest and heaviest of various bike parts, was noticeable.
The first material that should be mentioned is aluminum alloy, which is commonly and widely used for bike frames today. Unless it's a very cheap bicycle, most casual bicycles are produced with aluminum alloy material. Aluminum has a lot of advantages. The biggest benefit is that it does not rust, i.e., it still has excellent durability and is lightweight. Also, it is easy to process, so it's suitable for fits mass production and recycling. However, as aluminum alloy lacks strength compared to steel or carbon fiber, the frames need to be made thicker. Still, since the aluminum alloy is lighter than steel, it is a perfect fit for being an upper mid-level bicycle's frame material.
There are many factors to be considered in optimizing a high-performance bike. Fortunately, since there is a wide range of aluminum alloy, materials with various physical properties exist. According to cycles and the part's usage, one can choose different kinds of aluminum alloy, allowing for versatile material selection.
For example, aluminum alloy 6016 has excellent strength, so it provides both lightened weight and stiffness. Frames made in this way display outstanding effectiveness of power transmission, which is suitable for acceleration, but too much strength might lead to decreased shock absorption. This in turn may increase the rider's exhaustion level, which worsens on rough road surfaces. Therefore, the material is more appropriate for bike frames for short-distance sprint races. For reinforcement, securing a minimal shock absorption using a carbon-fiber fork and seat post is a common approach.
The second material that deserves our attention is carbon fiber. Recently, carbon fiber has become the most symbolic material for high-performance bicycles. More precisely, carbon fiber refers to carbon fiber reinforced plastic (CFRP). One can alternately overlap and bond the carbon sheet woven with carbon fiber and synthetic resin in the mold to create the desired shape. The greatest benefit of carbon fiber is that it can achieve both high stiffness and maximized weight lightening. As mentioned earlier, carbon fiber is good for absorbing vibration and shock to be used for the frame's fork and seat post. You can say that it is an ideal material with superior physical properties in many ways.
Carbon fiber can exert an impact on parts other than the frame. The bike's wheels are probably the most important of these. The wheel-set is lightweight and stiff when made with carbon fiber, so it has excellent acceleration, cruising performance, and shock absorption. With this in mind, carbon fiber is widely used for MTB, which requires incredible stiffness and shock absorption, and road bikes for races that do not have independent suspension. Since it's a complex material, a combination of the carbon fiber's type and weaving direction, resin's thickness, and physical properties can change the carbon fiber's physical properties. In other words, a wide variety of changes can be made in the production of carbon fiber so that it can suit different needs.
However, there are some weaknesses to carbon fiber as well. These originate from the internal structure, where the adhesion between carbon fiber and synthetic resin weakens. The bonding can get impaired when the air or distant subjects enter the complex form of the carbon fiber and resin, caused by surface damage from a thrown stone, etc. Such cases might lead to a sharp decrease in stiffness. This can lead to situations where the bike frame, which looks fine from the outside, can suddenly break.
For the most up-to-date frames for road bikes, in particular, one needs to be careful to find any damage on the surface. In road bike frames, for extreme light weight, the thinnest layer of paint is applied to the point where one can see the internal carbon fiber. Products from carbon fiber need extra care compared to those with other materials. Time permitting, it is advised that one conduct regular, non-destructive testing. This is why more and more quality management services have recently become available.
The next material we'll talk about is steel, which first led bicycles in its heyday. Just as human civilization evolved in the order of the Stone Age, Bronze Age, and Iron Age, steel, which is now ever present in everyday life, is an excellent material in various ways. Steel is inexpensive and has excellent workability and rigidity. So, steel has become widespread as a versatile material for structure as bicycle frames. Its disadvantage, however, is that it rusts easily.
Steel for bicycles mainly consists of high tensile strength steel and chrome molybdenum steel. As its name suggests, high tensile strength is used in inexpensive, daily-use bikes. Alloy chrome molybdenum steel, made by adding chromium and molybdenum to iron, has almost twice the strength of high tensile steel, so it can be made thin and light. It has been recently increasing again in popularity as a high-end bicycle material.
Chrome molybdenum steel has high tensile strength and fatigue limit, so the shock does not accumulate and does not deform the frame. Even if there is a deformation, it is comparatively easy to repair, so it has excellent durability and processability. Of course, this material still isn't perfect. It is heavy and easy to rust compared to aluminum. Despite those drawbacks, it is a suitable material for producing high-end bicycles with excellent riding comfort.
Although not very common, titanium or magnesium are used for bikes, too. Titanium has excellent heat resistance and rigidity, making it suitable for making a jet engine's turbine blade. It is absolutely best material for a bike frame, being stronger than steel and lighter than aluminum. However, it has weak processability and low conductibility because most manufacturing processes are manual.
Magnesium is also a lightweight and high-strength material. Since the production method uses sintering magnesium powder at high temperature and high pressure, it is possible to create a frame with seamless and uniform physical properties. However, it presents some major drawbacks, such as low mass productivity. and cracks can form from minor quality defects. These are why titanium and magnesium are not as popular as aluminum and steel for bicycle materials.
Integrating various elements such as weight reduction, rigidity, productivity, reliability, and price, aluminum is the most widespread and primary material for bicycle frames today. Steel keeps its place in some product groups, and carbon fiber is mostly seen in high-end models. This trend has settled as handlebars, forks, seat posts, and wheel-sets continued to be made with those materials. However, a change in the flow of bicycle materials has started. It started with the rise of e-bikes as the aforementioned personal mobility device.
A three-wheeled electric bike with ample cargo space
The electric bicycle finally removed the fundamental limit on the bicycle's engine power, which has long been humans. The bike's weight is less constrained by the electric motor's power. This is due to the efforts for weight reduction, based on the saying, "10,000 won per 1 g." Now, however, there is some flexibility in selecting materials for making bicycles.
In Europe, the bicycle as a means of single-person mobility transformed into an e-bike for freight. The e-bike has two front or rear wheels and a load in between the wheels. The electric powertrain was also reinforced by an electric motor with torque comparable to a motorcycle or scooter (two-wheeled vehicles with an engine), thereby increasing weight and load. This led to an increase in the battery capacity and increased weight once again. For e-bikes, however, the idea to use aluminum and steel came rather easily, expanding their usage scope again.
One can infer the change in the trend of bicycle materials in the era of electric mobility by comparing what has happened to automobiles. Cars used to be mainly designed as steel monocoque bodies, but in the 1990s, car parts began to be made with aluminum alloy to improve performance and reduce weight. At that time, technicians first applied it to aluminum subframes, suspension parts, and aluminum radiators. Gradually, the application scope enlarged, using aluminum for the exterior panels of the body, such as the bonnet and doors.
Eventually, the entire car body was made with aluminum. The first-generation A8, launched by Audi in 1994, is famous for its full aluminum construction for its body to reduce weight. To be more specific, the production involved a variety of aluminum alloys with various properties, such as the alloys mentioned above, 6016, 6060, and 6009. To make up for the material's weaker rigidity as compared to steel, the Space Frame Structure was adopted.
Most of today's Ferrari models also use aluminum space frames. For reference, some experts say it is surprising that Ferrari has achieved weight reduction and steering performance that were only possible when competitors extensively applied carbon fiber with aluminum alone.
As with high-end bicycles, high-end auto markets prefer carbon fiber materials. Automakers use a generous amount of carbon fiber for racing cars for motorsports (similar to professional athletes' bikes participating in the Tour de France) and for the highest models of supercar brands to construct the body parts. The approach of using carbon fiber to realize extreme weight reduction and high rigidity suitable for performance is in line with the carbon-fiber road bikes.
However, it is not worth it in terms of cost, mass production, and material recycling to construct the body of a large car (except for race cars) with only carbon fiber. The caveat here is “only” with carbon fiber. In other words, it does not mean that carbon fiber is the problem, but rather, it is too disadvantageous to limit construction to just a single material. The latest Audi A8, for example, uses an intelligent mix of steel, magnesium, carbon fiber, and an aluminum space frame.
Likewise, the recent trend inf the automobile field is the dynamic practice of using composite material platforms, based on a wide range of metals and carbon fiber materials, including high-strength steel. Even in the field of bicycles, which has entered the age of e-bikes, this trend of material diversity is sure to happen, moving away from "just" carbon fiber (just like the automobile industry).
Automakers intend to transform themselves into companies specializing in mobility devices during the paradigm shift that is happening right now. The bicycle industry is also trying to open a new path in personal mobility devices. This attracts curiosity about how the automobile and bicycle industries will unite and take over each other's domains in the future.