The Role of Light Metals in the Car of the Future

1. The Role of Light Metals in the Car of the Future Tobias Svantesson Kåvik Christian Eide Lodgaard

2. Contents • Emission Reducing Factors • Crashworthiness • End of Life Considerations • Future Trends

3. Emission Reducing Factors

4. Does CO2 Emissions cause climate changes?

5. Passenger Cars Part of Emissions Source; IEA (2000a)

6. Factors that influence car emissions Source; Automobiltechnische Zeitschrift 3/2002

7. More functions Modular approach Improved Crashworthiness Increased Stiffness Requirements on Body Structure Increased Loads from Road Gear Increased Performance Noise deadening Heavier Cars Maintain Performance Weight; Development Last 20 Years • Vicious Circle of increasing weight Increased Requirements on Road Gear & Brakes

8. One Car Model • VW Golf • Golf I (1977) Curb Weight; 750 kg • Golf II Curb Weight; • Golf III Curb Weight; • Golf IV (1998) Curb Weight; 1170 kg • Volvo 240 Curb Weight; 1240 kg • Same customer segment buys Golf today as 20 year ago.

9. 0,0046 l pr. Kg pr. 100 km • 18 000 km / year • 10 Years lifetime • 7 Years model life • 2.85 Kg CO2 pr l. fuel • 40% Weight saving by Al • 150 000 Tonnes Al Parts 0,0046 l x 18000 km x 10 years 100 km = 8.28 l fuel saved = 23.6 kg CO2 What does Weight Saving Imply? • EU mixed cycle 91/441/EEC • 1kg, one platform 18 888 000 kg CO2 eq saving • 1kg, one car 23.6 kg CO2 eq saving • Hydro Automotive yearly 828 000 000 kg CO2 eq saving Sources: IPAI; Life Cycle Inventory of the Worldwide Aluminium Industry with regard to Consumption and Emissions of Greenhouse Gases, BMW, VW

10. 0,0046 l x ~400 kg x 18000 km x 150 million cars 100 km European Fleet made Light Weight • All cars 30% lighter. Existing technology = 49 680 000 000 l = 141 588 000 tonnes CO2 x 1 656 000 Yearly

11. Emissions from Production • If Produced from Primary Aluminium • Real Recycling Level; • Automotive sheet 11% • Automotive extrusions 11% • Automotive castings 85% Emissions from Al. Production 12 kg -Emissions from Production of Replaced Steel 3 kg -Reduced Emissions from during use 16 kg Impact on Lifetime CO2 eq Emissions -7 kg Producing 1 kg Aluminium Emits 6 kg CO2eq Sources: IPAI; Life Cycle Inventory of the Worldwide Aluminium Industry with regard to Consumption and Emissions of Greenhouse Gases. Paper 1 Automotive

12. Effective Reduction of CO2eq Emissions 1 kg Aluminium = Reduction of 13 kg CO2eq

13. Other Benefits of Reduced Weight Pros • + Better kilometer reading • + Better handling • + Better driving dynamics • + Road wearing • + Safety if all cars’ weight is reduced Cons • - Safety if not all cars’ weight is reduced

14. Crash Worthiness

15. Level of Accidents in Road Traffic Sustainable? • 116 000 Fatalities in Road Traffic in OECD Countries in 2000 • 5 000 000 Injured • Proportions • 22 % Pedestrians • 6 % Bicyclists • 14 % Motorcyclists • 58 % Passenger Car Occupants • Cost on Society 1% of GDP • In Norway alone: NOK 15 Billion • Norwegian foreign aid: NOK 12.3 Billion Source: IRTAD April 2002 Issue

16. Crash Management • Considerations at different speeds; • Low speed; prevent damage of car • Mid speed; minimize damage of car • High speed; protect occupants

17. BMW 7 series • Crash management system

18. Comparison Aluminium to Steel • Energy absorbtion to weight ratio superior by aluminium

19. End of Life Considerations

20. Why Recycle? • Why not go for anything that saves weight, regardless of recycling friendliness?

21. Non ferrous Non ferrous Ferrous Ferrous Why Recycle Aluminium? • Only 5 % of primary production energy consumed • Only 5 % of CO2 emissions Average 12 year old US car

22. Global Supply 2002

23. Recycling Challenges Properties Metal in Use • Growing interdependency between primary and recycled Aluminium Primary Metal Recycled Tendency; High Purity Alloys Recycling Friendly Alloys Logistic Concepts Sorting Methods

24. The Aluminium Bank – Metal Stored in Use

25. Recycling in Hydro • Recycling Capacity 2002: 1 320 000 tonnes • Primary Metal Capacity: 1 640 000 tonnes • 10 Recycling facilities in Europe and USA • Only 5 % energy consumption compared to production of virgin material • Magnesium recycling in Europe and North America

26. Legislation Dilemma • Weight savings (emissions) during lifetime must be considered! • 87 % of total CO2e emissions over complete lifetime comes from car use • Production and shredding 13 % • EU directive require 85% by weight recycling

27. Future Trends

28. Are future demands different?

29. Turn Vicious Circle? More integration of functions • Circle of reducing weight More symbiotic approach Light metal applications Reduce weight of Body Structure Lighter Cars Reduce Stiffness Requirements on Body Structure Lighter Powertrain for same Performance Reduced Requirements on Road Gear & Brakes

30. Lightweight BIW Structures • Aluminium closures • MB E-class • Aluminium Spaceframes • Audi A2, A8, BMW Z8, Lotus Elise, • Aluminium sheet structures • Jaguar, Honda NSX • Hybrid Structures • Integrated Structures • Bolt-ons Mg Alu Steel

31. ‘No one are willing to pay more for reduced weight.’ (Dr. Wolfgang Ruch, Audi Aluminiumzentrum) Legislation Needs?

32. Bolt-ons • Engine Cradles • Suspension • IP Beams • Closures • Seats

33. New Vehicle Concepts • Is weight saving alone enough? 10% • Is hydrogen as energy carrier enough? 10% • Locally yes, globally? • Is fuel cell technology alone enough? 10% • Locally yes, globally? • Is fossil fuel / electric powertrain alone enough?10% • Does recycling solve this? No • New Mobility Concepts necessary in addition

34. New Mobility Concepts • Why private car? • VW 1 Litre car? Spacious enough? • Insight? Solves local emissions • Park & ride, car pools. Flexible enough? • Reduce Mobility Needs? • Highway chains?

35. Conclusions • We need all measures to reduce emissions from car use: • Light weighting • Hydrogen as energy carrier • Fuel cell technology • We need improved recycling systems • In addition, we need to challenge ourselves on new mobility concepts