F1 Is Living in a Material World! (Part 1)

Over the past year, I have been lucky enough to go on two F1 Team factory tours; at Red

Bull, Milton Keynes and at the McLaren Technology Centre, Woking.

I was able to view the actual race cars from close up and was shown the complex machinery utilised, together  with a basic explanation of the process required to; envision, design, create and manufacture some of the fastest cars on the planet. After following F1 religiously for as long as I can remember, this was the first time I started to get a true understanding of the complexity and volume of work needed to just get a functioning F1 car on the track.

Whilst the overall process is fascinating, my interest was most piqued when we were told that some areas like the paint shop and aerodynamics section were out of bounds.

Having asked the simple question why, we were told about the importance of the choice and manner of use materials in various sections of the car. It seems that even the type of paint used can make the millisecond difference in winning and losing a race.

The most mind-blowing thing I heard during the tour was that the secrecy surrounding some to the technology used, like aerodynamics, means that even the team drivers aren’t allowed into these areas.

Following the tour, I started Googling about materials and their uses in F1. This took me down a rabbit warren of information, the sharing of which is my purpose behind this blog.

In developing a F1 car engineers segregate into 8 main sections on which to focus. These are:

1.      The Chassis and Body

2.      Engines and Power Units

3.      Suspension Systems

4.      Tires

5.      Braking Systems

6.      Safety

7.      Aerodynamics

8.      Data Sensors and Electronics

Whilst there are elements  of crossover and overlap between sections, some sections are unique in the engineers decisions as to the choice and purpose behind the materials used.

Chassis and Body Design

For this, engineers require the materials used to be strong, resistant to wear and most importantly, able to retain structure – something that is crucial when these parts are being put under immense pressure due to downforce and other forces.

Given these requirements,  there are two main groups of materials that are best suited to being; Carbon Fibre Composites and Aeroelastic Materials

Carbon Fibre Composites (or just carbon fibre) is basically carbon filament which can be thinner than human hair and gets its strength when from being twisted like yarn. It can then be woven into a fabric and moulded into different shapes. Its use is driven by; its high tensile strength, high strength-to-weight ratio – it is approximately 5x as light and 100x as strong as steel and its resistance to high temperatures. Due to these characteristics, you find it being used in common items like tennis rackets  In the case of high performance F1 cars, which need to be strong yet at the same time light, carbon fibre fits those needs perfectly.

Layers of carbon fibre are carefully arranged in specific directions to enhance strength in key areas while allowing flexibility where necessary. The chassis features a monocoque (single shell) structure, similar to an eggshell, where the outer surface supports the load. This design surrounds the driver for maximum protection. Before use, the carbon fibre chassis must pass strict FIA crash tests.

Aeroelastic materials are often used in the car's bodywork. These materials are designed such that they bend in controlled ways under aerodynamic forces. For instance, rear wings can flex slightly at high speeds to reduce drag, improving straight-line speed while maintaining downforce for cornering performance.

Engines and Power Units

During an F1 race, the car's engine can heat up to 100–120°C, so it's crucial to use materials that can handle such extreme temperatures. Titanium alloys are often chosen for engine parts like connecting rods and valves because they are both heat-resistant and lighter than alternatives like steel alloys.

Turbochargers and exhaust systems undergo thermal cycling, where they repeatedly shift between high and low temperatures. This makes them prone to cracking or deforming, so special nickel alloys are used to prevent these issues.

To maximize engine power during a race, heat loss must be minimized. This is achieved by coating components like pistons, cylinder heads, and exhausts with ceramics, which act as thermal barriers and improve efficiency.

Suspension Systems

Suspension systems in F1 cars endure intense and repeated forces during acceleration, cornering, and braking throughout a race. To handle these demands, materials like aluminium-lithium alloys are used because they are lightweight and resistant to fatigue, ensuring durability over the 300+ km of a Grand Prix.

Recent advancements have introduced carbon fibre suspension arms, which are both strong enough to handle these forces and lightweight. This reduces the mass that the springs and shock absorbers need to control, allowing the wheels to stay in steady contact with the track for longer. This improves grip, enhances stability, and ensures faster wheel responses to the track’s surface.

Tires

Pirelli is the exclusive and sole tyre supplier to all 10 F1 teams.

At the  start of each season they produce a range of tyres of different levels of hardness, with grade C0 being the hardest going down to grade C5 being the softest. The optimal working range temperature of the tyres varies depending on their level of hardness; hard tyres – 110 C to 145 C, medium – 105 C to 135 C and supersoft – 85 C to 115 C.

Each grade of tyre is carefully formulated to provide optimal grip and durability for specific track conditions.

The suitability of tyres for each Grand Prix is a function of the track design and construction, amongst the considerations being but not limited to; relative roughness of the track surface and extent of high-speed corners on the track

When choosing the tyres to use throughout each Grand Prix, F1 teams are faced with a tradeoff between hard tyres which are more durable, can be run for longer due to lower degradation as against soft tyres which give better grip and reach optimal working temperature much more quickly.

The tyres are made of a rubber compound consisting of over 100 ingredients which are rigorously tested after mixing.

Kevlar fabric reinforcements, normally associated with bullet proofing, are often used in the tire sidewalls as it helps to prevents deformation at high pressures and temperatures and so reducing the risk of blowouts.

Cover Image Credits: DiecastF1.com