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Reducing supply chain energy use in next-generation vehicle lightweighting
Vehicle lightweighting reduces the amount of fuel consumed in a vehicle's use phase, but depending on what lightweight materials replace the conventional materials, and in what amounts, the manufacturing energy may increase or decrease. For carbon fiber reinforced polymer (CFRP), a next-generation lightweighting material, the increase in vehicle manufacturing energy is greater than the fuel savings, resulting in a net increase in energy consumption over a vehicle's manufacturing and use relative to a standard non-lightweighted car. [1] This work explores ways to reduce the supply chain energy of CFRP lightweighted vehicles through alternative production technologies and energy efficiency improvements. The objective is to determine if CFRP can offer energy savings comparable to or greater than aluminum, a conventional lightweighting material. Results of this analysis can be used to inform additional research and development efforts in CFRP production and future directions in lightweight vehicle production. The CFRP supply chain is modeled using the Material Flows through Industry (MFI) scenario modeling tool, which calculates 'mine to materials' energy consumption, material inventories and greenhouse gas emissions for industrial supply chains. In this analysis, the MFI tool is used to model the supply chains of two lightweighted vehicles, an aluminum intensive vehicle (AIV) and a carbon fiber intensive vehicle (CFV), under several manufacturing scenarios. Vehicle specifications are given in [1]. Scenarios investigated cover alternative carbon fiber (CF) feedstocks and energy efficiency improvements at various points in the vehicle supply chains. The alternative CF feedstocks are polyacrylonitrile, lignin and petroleum-derived mesophase pitch. Scenarios in which the energy efficiency of CF and CFRP production increases are explored using sector efficiency potential values, which quantify the reduction in energy consumption achievable when process equipment is upgraded to the most efficient available. Preliminary analyses indicate that producing CF from lignin instead of polyacrylonitrile, the most commonly used feedstock, reduces energy consumption in the CFRP supply chain by 7.5%, and that implementing energy efficient process equipment produces an additional 8% reduction. Final results will show if these potential reductions are sufficient to make the CFV energy savings comparable with AIV energy savings. [1] Das, S., Graziano, D., Upadhyayula, V. K., Masanet, E., Riddle, M., & Cresko, J. (2016). Vehicle lightweighting energy use impacts in US light-duty vehicle fleet. Sustainable Materials and Technologies, 8, 5-13.
Vehicle lightweighting energy use impacts in U.S. light-duty vehicle fleet
In this article, we estimate the potential energy benefits of lightweighting the light-duty vehicle fleet from both vehicle manufacturing and use perspectives using plausible lightweight vehicle designs involving several alternative lightweight materials, low- and high-end estimates of vehicle manufacturing energy, conventional and alternative powertrains, and two different market penetration scenarios for alternative powertrain light-duty vehicles at the fleet level. Cumulative life cycle energy savings (through 2050) across the nine material scenarios based on the conventional powertrain in the U.S. vehicle fleet range from -29 to 94 billion GJ, with the greatest savings achieved by multi-material vehicles that select different lightweight materials to meet specific design purposes. Lightweighting alternative-powertrain vehicles could produce significant energy savings in the U.S. vehicle fleet, although their improved powertrain efficiencies lessen the energy savings opportunities for lightweighting. A maximum level of cumulative energy savings of lightweighting the U.S. light-duty vehicle through 2050 is estimated to be 66.1billion GJ under the conventional-vehicle dominated business-as-usual penetration scenario.
Vehicle Lightweighting: 40% and 45% Weight Savings Analysis: Technical Cost Modeling for Vehicle Lightweighting
The U.S. Department of Energy’s Vehicle Technologies Office, Materials area commissioned a study to model and assess manufacturing economics of alternative design and production strategies for a series of lightweight vehicle concepts. The strategic targets were a 40% and a 45% mass reduction relative to a standard North American midsize passenger sedan at an effective cost of $3.42 per pound (lb) saved. The baseline vehicle was an average of several available vehicles in this class. Mass and cost breakdowns from several sources were used, including original equipment manufacturers’ (OEMs’) input through U.S. Department of Energy’s Vehicle Technologies Office programs and public presentations, A2Mac1 LLC’s teardown information, Lotus Engineering Limited and FEV, Inc. breakdowns in their respective lightweighting studies, and IBIS Associates, Inc.’s decades of experience in automotive lightweighting and materials substitution analyses. Information on lightweighting strategies in this analysis came from these same sources and the ongoing U.S. Department of Energy-funded Vehma International of America, Inc. /Ford Motor Company Multi-Material Lightweight Prototype Vehicle Demonstration Project, the Aluminum Association Transportation Group, and many United States Council for Automotive Research’s/United States Automotive Materials Partnership LLC lightweight materials programs.
Green Principles for Vehicle Lightweighting
A large portion of life cycle transportation impacts happen during vehicle operation, and key improvement strategies include increasing powertrain efficiency, vehicle electrification, and lightweighting vehicles by reducing their mass. The probable energy benefits of vehicle lightweighting are large, given that 29.5 EJ was used in all modes of U.S. transportation in 2016, and roughly half of the energy spent in wheeled transportation and the majority of energy spent in aircraft is used to move vehicle mass. We collect and review previous work on lightweighting, identify key parameters affecting vehicle environmental performance (e.g., vehicle mode, fuel type, material type, and recyclability), and propose a set of 10 principles, with examples, to guide environmental improvement of vehicle systems through lightweighting. These principles, based on a life cycle perspective and taken as a set, allow a wide range of stakeholders (designers, policy-makers, and vehicle manufacturers and their material and component suppliers) to evaluate the trade-offs inherent in these complex systems. This set of principles can be used to evaluate trade-offs between impact categories and to help avoid shifting of burdens to other life cycle phases in the process of improving use-phase environmental performance.A large portion of life cycle transportation impacts occur during vehicle operation, and key improvement strategies include increasing powertrain efficiency, vehicle electrification, and lightweighting vehicles by reducing their mass. The potential energy benefits of vehicle lightweighting are large, given that 29.5 EJ was used in all modes of U.S. transportation in 2016, and roughly half of the energy spent in wheeled transportation and the majority of energy spent in aircraft is used to move vehicle mass. We collect and review previous work on lightweighting, identify key parameters affecting vehicle environmental performance (e.g., vehicle mode, fuel type, material type, and recyclability), and propose a set of 10 principles, with examples, to guide environmental improvement of vehicle systems through lightweighting. These principles, based on a life cycle perspective and taken as a set, enable a wide range of stakeholders (designers, policy-makers, and vehicle manufacturers and their material and component suppliers) to evaluate the trade-offs inherent in these complex systems. This set of principles can be used to evaluate trade-offs between impact categories and to help avoid shifting of burdens to other life cycle phases in the process of improving use-phase environmental performance.
Vehicle Lightweighting: Mass Reduction Spectrum Analysis and Process Cost Modeling
The U.S. Department of Energy’s Vehicle Technologies Office, Materials area commissioned a study to model and assess manufacturing economics of alternative design and production strategies for a series of lightweight vehicle concepts. In the first two phases of this effort examined combinations of strategies aimed at achieving strategic targets of 40% and a 45% mass reduction relative to a standard North American midsize passenger sedan at an effective cost of $3.42 per pound (lb) saved. These results have been reported in the Idaho National Laboratory report INL/EXT-14-33863 entitled Vehicle Lightweighting: 40% and 45% Weight Savings Analysis: Technical Cost Modeling for Vehicle Lightweighting published in March 2015. The data for these strategies were drawn from many sources, including Lotus Engineering Limited and FEV, Inc. lightweighting studies, U.S. Department of Energy-funded Vehma International of America, Inc./Ford Motor Company Multi-Material Lightweight Prototype Vehicle Demonstration Project, the Aluminum Association Transportation Group, many United States Council for Automotive Research’s/United States Automotive Materials Partnership LLC lightweight materials programs, and IBIS Associates, Inc.’s decades of experience in automotive lightweighting and materials substitution analyses.
Life Cycle Assessment of Vehicle Lightweighting: A Physics-Based Model To Estimate Use-Phase Fuel Consumption of Electrified Vehicles
Assessing the life-cycle benefits of vehicle lightweighting requires a quantitative description of mass-induced fuel consumption (MIF) and fuel reduction values (FRVs). We have extended our physics-based model of MIF and FRVs for internal combustion engine vehicles (ICEVs) to electrified vehicles (EVs) including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and battery electric vehicles (BEVs). We illustrate the utility of the model by calculating MIFs and FRVs for 37 EVs and 13 ICEVs. BEVs have much smaller MIF and FRVs, both in the range 0.04-0.07 L e /(100 km 100 kg), than those for ICEVs which are in the ranges 0.19-0.32 and 0.16-0.22 L/(100 km 100 kg), respectively. The MIF and FRVs for HEVs and PHEVs mostly lie between those for ICEVs and BEVs. Powertrain resizing increases the FRVs for ICEVs, HEVs and PHEVs. Lightweighting EVs is less effective in reducing greenhouse gas emissions than lightweighting ICEVs, however the benefits differ substantially for different vehicle models. The physics-based approach outlined here enables model specific assessments for ICEVs, HEVs, PHEVs, and BEVs required to determine the optimal strategy for maximizing the life-cycle benefits of lightweighting the light-duty vehicle fleet.
Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles
This project, Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles, develops Integrated Computational Materials Engineering (ICME) techniques for Carbon Fiber Reinforced Polymer (CFRP) composites and uses these ICME tools within a multi-disciplinary optimization scheme to design a carbon-fiber intensive front subframe for a passenger sedan. The subframe is a structural automotive component with stringent requirements for vibration, strength, durability and safety performance. CFRP composites, with a density of 1.55 g/cm3 and a tensile strength of up to 2,000 MPa in the fiber direction, have a high strength-to-weight ratio, making them one of the most promising candidates to replace the metals currently used for automotive structural components. By increasing the accessibility of CFRP component designs, reducing development-to-deployment lead time of CFRP components, and improving the robustness of initial designs, this project supports weight reduction in light-duty vehicles. These efforts can help mitigate greenhouse gas emissions from passenger vehicles and have the potential to improve national energy independence.
Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles
This project, Integrated Computational Materials Engineering Development of Carbon Fiber Composites for Lightweight Vehicles, develops Integrated Computational Materials Engineering (ICME) techniques for Carbon Fiber Reinforced Polymer (CFRP) composites and uses these ICME tools within a multi-disciplinary optimization scheme to design a carbon-fiber intensive front subframe for a passenger sedan. The subframe is a structural automotive component with stringent requirements for vibration, strength, durability and safety performance. CFRP composites, with a density of 1.55 g/cm 3 and a tensile strength of up to 2,000 MPa in the fiber direction, have a high strength-to-weight ratio, making them one of the most promising candidates to replace the metals currently used for automotive structural components. By increasing the accessibility of CFRP component designs, reducing development-to-deployment lead time of CFRP components, and improving the robustness of initial designs, this project supports weight reduction in light-duty vehicles. These efforts can help mitigate greenhouse gas emissions from passenger vehicles and have the potential to improve national energy independence.
Fixed-base simulator investigation of lightweight vehicles for lunar escape to orbit with kinesthetic attitude control and simplified manual guidance
Piloted simulator investigation of lightweight vehicles for emergency lunar escape to orbit with kinesthetic attitude control and simplified manual guidance
An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications
A bottom-up multi-scale modeling approach is used to develop an Integrated Computational Materials Engineering (ICME) framework for carbon fiber reinforced polymer (CFRP) composites, which has the potential to reduce development to deployment lead time for structural applications in lightweight vehicles. In this work, we develop and integrate computational models comprising of four size scales to fully describe and characterize three types of CFRP composites. In detail, the properties of the interphase region are determined by an analytical gradient model and molecular dynamics analysis at the nano-scale, which is then incorporated into micro-scale unidirectional (UD) representative volume element (RVE) models to characterize the failure strengths and envelopes of UD CFRP composites. Then, the results are leveraged to propose an elasto-plastic-damage constitutive law for UD composites to study the fiber tows of woven composites as well as the chips of sheet molding compound (SMC) composites. Subsequently, the failure mechanisms and failure strengths of woven and SMC composites are predicted by the meso-scale RVE models. Finally, building upon the models and results from lower scales, we show that a homogenized macro-scale model can capture the mechanical performance of a hat-section-shaped part under four-point bending. Along with the model integration, we will also demonstrate that the computational results are in good agreement with experiments conducted at different scales. The present work illustrates the potential and significance of integrated multi-scale computational modeling tools that can virtually evaluate the performance of CFRP composites and provide design guidance for CFRP composites used in structural applications.
Recycling and Life Cycle Issues for Lightweight Vehicles
This chapter addresses recycling and life cycle considerations related to the growing use of lightweight materials in vehicles. This chapter first addresses the benefit of a life cycle perspective in materials choice, and the role that recycling plays in reducing energy inputs and environmental impacts in a vehicle’s life cycle. Some limitations of life cycle analysis and results of several vehicle- and fleet-level assessments are drawn from published studies. With emphasis on lightweight materials such as aluminum, magnesium, and polymer composites, the status of the existing recycling infrastructure and technological challenges being faced by the industry also are discussed.
A method for determining optimal electric range by considering electric vehicle lightweighting on perceived ownership cost
The limited driving range due to high costs and low energy densities of batteries constraints the battery electric vehicle (BEV) market growth. Lightweighting in theory can reduce energy consumption rate and extend the driving range. The knowledge gap is to quantitatively link the cost-effectiveness of light-weight technologies with range extension and consumer acceptance of BEVs. In this study, a physics-based energy consumption model of BEVs is constructed and associated with a statistics-based model on the basis of travel surveys. A perceived cost of ownership (PCO) is then developed by adding intangible costs to traditional total cost of ownership models. We estimate, at the disaggregate vehicle model and driver level and the aggregate market level, 1) the extended range due to lightweighting for a given battery size; and 2) the optimal electric range based on lightweighting decisions. The cost-effectiveness of lightweighting for BEV range extension is found to vary with income-dependent daily range limitation value, driving patterns and lightweighting technology costs. In general, adopting lightweighting in BEVs is more cost-effective for consumers with higher daily limitation value, as well as for those with higher driving intensity or suitable daily driving patterns. When the lightweighting involves a higher vehicle production cost, less lightweighting could reduce the overall PCO for BEV owners. 4 of the selected top ten BEV models are found to benefit from additional 2.09%–4.45% lightweighting. Finally, the method built in this study can guide automakers in planning R&D investments in battery and lightweighting technologies.
Advanced Mg Matrix Composites For Lightweight Vehicles
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Process Integration and Optimization of ICME Carbon Fiber Composites for Vehicle Lightweighting: A Preliminary Development
Process integration and optimization is the key enabler of the Integrated Computational Materials Engineering (ICME) of carbon fiber composites. In this paper, automated workflows are developed for two types of composites: Sheet Molding Compounds (SMC) short fiber composites, and multi-layer unidirectional (UD) composites. For SMC, the proposed workflow integrates material processing simulation, microstructure representation volume element (RVE) models, material property prediction and structure preformation simulation to enable multiscale, multidisciplinary analysis and design. Processing parameters, microstructure parameters and vehicle subframe geometry parameters are defined as the design variables; the stiffness and weight of the structure are defined as the responses. For multi-layer UD structure, this work focuses on the discussion of different design representation methods and their impacts on the optimization performance. Challenges in ICME process integration and optimization are also summarized and highlighted. Two case studies are conducted to demonstrate the integrated process and its application in optimization.
Integrated Computational Materials Engineering Development of Advanced High Strength Steel for Lightweight Vehicles
The goal of the ICME 3GAHSS project was to successfully demonstrate the applicability of Integrated Computational Materials Engineering (ICME) for the development and deployment of third generation advanced high strength steels (3GAHSS) for immediate weight reduction in passenger vehicles. The ICME approach integrated results from well-established computational and experimental methodologies to develop a suite of material constitutive models (deformation and failure), manufacturing process and performance simulation modules, a properties database, as well as the computational environment linking them together for both performance prediction and material optimization. This is the Final Report for the ICME 3GAHSS project, which achieved the fol-lowing objectives: 1) Developed a 3GAHSS ICME model, which includes atomistic, crystal plasticity, state variable and forming models. The 3GAHSS model was implemented in commercially available LS-DYNA and a user guide was developed to facilitate use of the model. 2) Developed and produced two 3GAHSS alloys using two different chemistries and manufacturing processes, for use in calibrating and validating the 3GAHSS ICME Model. 3) Optimized the design of an automotive subassembly by substituting 3GAHSS for AHSS yielding a design that met or exceeded all baseline performance requirements with a 30% mass savings. A technical cost model was also developed to estimate the cost per pound of weight saved when substituting 3GAHSS for AHSS. The project demonstrated the potential for 3GAHSS to achieve up to 30% weight savings in an automotive structure at a cost penalty of up to $0.32 to $1.26 per pound of weight saved. The 3GAHSS ICME Model enables the user to design 3GAHSS to desired mechanical properties in terms of strength and ductility.
Lightweight Materials - Carbon Fiber and Polymer Composites, Integrated Computational Materials Engineering (ICME) Predictive Tools Development for Low-Cost Carbon Fiber for Lightweight Vehicles (University of Virginia) (Final Report)
This project aimed to develop low-cost alternative precursors and processing techniques through the implementation of an integrated computational materials engineering (ICME) framework to evaluate precursor conversion kinetics. Once established, this framework was then used to down-select precursors for laboratory- and pilot-scale production to validate resulting carbon fiber (CF) material properties and process cost-savings. The two most promising approaches to reduce the cost of CFs were to (1) use new low-cost precursors and (2) reduce the energy requirements of CF processing. These approaches were investigated over the course of three phases of work, spanning 3.5 years. This report describes the overall project objectives, approach, and the key accomplishments in each phase.
Corrosion Protection and Dissimilar Material Joining for Next Generation Lightweight Vehicles
The Arconic Technology Center working with Honda R&D Americas, LLC and the Ohio State University evaluated the corrosion performance of several multi-material conditions and demonstrated the production worthiness of the Resistance Spot Riveting (RSR™) process. RSR is a new technology being developed by Howmet Fastening Systems (formerly Arconic, Inc.) that employs a fastener that is installed using conventional resistance spot welding equipment to produce multi-material joints. The goal of the 3-year project was to demonstrate the use of RSR to join aluminum to steel and aluminum to carbon fiber composites on a prototype scale. Deployment of this technology would help the automotive industry achieve an additional 10 to 20% weight reduction over high strength steels. These weight-savings to the body in white generally translates to 2.5-5.0% of overall vehicle curb weight. The resulting total weight-savings could provide a 1.5% to 3.0% total improvement in fuel efficiency for vehicles that incorporate RSR for multi-material joining. The RSR technology addresses several production barriers to achieving DOE’s fuel efficiency targets including eliminating the need of additional capital for new joining technologies and the flexibility to process conventional steel and multi-material structures with the same equipment. Additionally, the trend towards ultra-high strength steels limits the availability of conventional joining technologies that can effectively process these multi-material combinations. In order to accomplish these goals, the following program milestones were completed by the team: 1) Developed RSR process parameters, producing multi-material joints for mechanical testing and corrosion assessments. 2) Conducted corrosion evaluation of RSR and baseline joints assembled between automotive type aluminum alloys, steels, and carbon fiber using several corrosion mitigation strategies. 3) Developed a production ready feed system and integrate into a robotic resistance spot welding station to simulate automotive production conditions. 4) Produced demonstration assemblies for testing and evaluation.