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Sustainability advantage or not?

By: Alaeddine Mokri (MSE)Karim Mousa (ESM)Yomna Hassan (IT)

Course: UCC 501 - Spring 2010

Widespread adoption of aluminum in the

automotive industry

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Transportation & Environment Existing Solutions Why Aluminum Financial Analysis Environmental Analysis Conclusion

Outline

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The sector contributes to over 30% of U.S. emissions

Emissions expected to grow rapidly

Sector contributes to about 16% of worldwide emissions

Transportation & Environment

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Road Transport (Cars, Trucks & Buses)

Electricity Generation & Heating

Manufacturing & Construction

Fuel combustion for other uses

15.9%

18.2%12.2%

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Hybrid cars Electric cars Hydrogen Cars Taxing Congestion charges Car pooling Gasoline rationing

Existing Solutions

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Existing solutions are future solutions

Expensive Infrastructure problems Adaptation difficulties for customer

Policies are found “not very effective” or “moderately effective”.

Drawbacks

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A more immediate mitigation option would be to reduce the weight of the car

Every 10% reduction in total weight will give a 5% improvement in mpg.

Potential Short-term Solution?

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Replacing the body-in-white with an aluminum one to reduce weight Aluminum Body-in-White

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Density of Aluminum is 1/3 of Steel density. Aluminum rigidity is 1/3 of steel rigidity. To compensate:

- Increase wall thickness of the sheet of steel.- Optimize shaping.

The Space Frame Concept( An effective method of manufacturing car bodies which is feasible only when Aluminum is used).

maximum rigidity - maximum torsion stiffness - minimum welding spots - flexibility in shaping. [2]

[2] D. Carle, G. Blount, ”The sustainability of Aluminium as an alternative material for car bodies,” Materials and Design, pp 267-272, Issue 20, 1999.

Why Aluminum ? Steel Aluminum Module of elasticity in N/mm2 190 000- 220 000 60 000 – 80 000 Strength N/mm2 290 – 470 260 - 350 Density kg/dm3 7.85 2.7

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Density of Aluminum is 1/3 of Steel density. Aluminum rigidity is 1/3 of steel rigidity. To compensate:

- Increase wall thickness of the sheet of steel.- Optimize shaping.

The Space Frame Concept( An effective method of manufacturing car bodies which is feasible only when Aluminum is used).

maximum rigidity - maximum torsion stiffness - minimum welding spots - flexibility in shaping. [2]

[2] D. Carle, G. Blount, ”The sustainability of Aluminium as an alternative material for car bodies,” Materials and Design, pp 267-272, Issue 20, 1999.

Why Aluminum ? Steel Aluminum Module of elasticity in N/mm2 190 000- 220 000 60 000 – 80 000 Strength N/mm2 290 – 470 260 - 350 Density kg/dm3 7.85 2.7

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Density of Aluminum is 1/3 of Steel density. Aluminum rigidity is 1/3 of steel rigidity. To compensate:

- Increase wall thickness of the sheet of steel.- Optimize shaping.

The Space Frame Concept( An effective method of manufacturing car bodies which is feasible only when Aluminum is used).

maximum rigidity - maximum torsion stiffness - minimum welding spots - flexibility in shaping. [1]

[1] D. Carle, G. Blount, ”The sustainability of Aluminium as an alternative material for car bodies,” Materials and Design, pp 267-272, Issue 20, 1999.

Why Aluminum ? Steel Aluminum Module of elasticity in N/mm2 190 000- 220 000 60 000 – 80 000 Strength N/mm2 290 – 470 260 - 350 Density kg/dm3 7.85 2.7

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Calculation of the optimum thickness of the sheet of Aluminum so the body has the same mechanical properties as steel:

Density of steel: 7.85 g/cm³ Density of aluminium: 2.7g/cm³Area of panel = 739800 mm²

Volume of a 1.2mm thick AA6016 outer door panel = Area x thickness = 739800 x 1.2 = 88760 mm³

Volume of a 0.8mm thick BH210 outer door panel = Area x thickness = 739800 x 0.8 = 591840 mm³

Mass of a 1.2 mm thick AA6016 outer door panel = density of Al x volume = (2.7 x 10^-3) x (88760) = 2397 g = 2.397 kg Mass of a 0.8 mm thick BH210 outer door panel = density of steel x volume

= (7.85 x 10^-3) x (591840) = 4646 g = 4.646 kg

The mass calculation shows that the mass of the aluminium panel is around 50% less than that of steel, when the thickness of the aluminum panel is 1.5 times the thickness of the steel panel (this shows very good agreement with literature [2]).

[2] Masaaki Saito et al, ”Development aluminum bodies for fuel efficient vehicles,” Materials today, pp 30-34, Volume 4, Issue 1, 2001.

Why Aluminum ?

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Manufacturability of the body (Aluminum versus Steel): [1, 2]- punch riveting in Aluminum bodies is used: 30% stronger than spot

welding.- shielded arc welding in Aluminum bodies is used: economical.- one cast part made of Aluminum can replace several steel panels

( reduction of 15% in the number of parts).- easy shaping and production of Aluminum cast and extruded organs.- fewer parts in the Aluminum body, this results in fewer fixtures

( reduction of welding spot by 24%).- Body rigidity increases.- The amount of weight reduced due to replacing steel with aluminum is

enormous ( 47%) This results in less fuel consumption and less emissions.

Why Aluminum ?

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From the properties of aluminum better than steel is that it has the ability to be built in an “ASF” structure (not available in steel), which gives the car more rigidity. Due to plasticity.

One cast part can be shaped in different shapes so it can replace several steel panels, decreasing number of parts by 15%, and number of welding spots by 24%

Easy shaping and production, aluminum is more bendable by 13%.

The amount of weight reduced due to replacing steel with aluminum is enormous ( 47%), which will lead to a good amount of reduction in both cost and CO2 emissions as we will see later.

properties

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To carry out analysis, we need to consider and calculate several factors

Weight specifications Material Price / Raw Material Costs Distances travelled Fuel Consumption Fuel Costs

3 stages: Pre-manufacture, Manufacture, and Use.

Analysis

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Calculations should allow us to find:

$/kg of materials manufactured $/km of usage

Kg /kg materials manufactured Kg /km usage

Car that we will use for our analysis is the Toyota Camry

Financial and Environmental

Analysis

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Here we are discussing how our study will be affected by changing different variables.

Variables we considered through the analysis are:

1. Fuel Cost2. Aluminum Cost3. CO2 potential tax4. Distance covered by car yearly

Sensitivity Analysis

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0 1 2 3 4 5 6 7 80

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10

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30Chart Title

Fuel cost ($/gallon)

Number of Years to break even in

20US energy information Administration (EIA)

0 1 2 3 4 5 6 7 80

5

10

15

20

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30Chart Title

Fuel cost ($/gallon)

Number of Years to break even in

UAE

USA

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1 1.5 2 2.5 3 3.5 40

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2

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Aluminium price ($/kg)

Number of years to break even

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1 1.5 2 2.5 3 3.5 40

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Aluminium price ($/kg)

Number of years to break even

20082009

Using figures from World Bank Commodity Price Data

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0 50 100 150 200 250 3000

0.5

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1.5

2

2.5

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difference in tax value ( euro per year)

Number of years to break even

24UK public services governmental website

0 50 100 150 200 250 3000

0.5

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1.5

2

2.5

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difference in tax value ( euro per year)

Number of years to break even

By implementing the current tax system of UK and going from the band L to band J

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0 50 100 150 200 250 3000

2

4

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8

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Driving rate (Km/day)

Number of years to break even

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0 50 100 150 200 250 3000

2

4

6

8

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Driving rate (Km/day)

Number of years to break even

USA

UAE

The US Bureau of Transportation StatisticsBener,Crundall; Road traffic accidents in the United Arab Emirates compared to Western countries;2005

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Although CO2 emissions is higher in pre-manufacturing and manufacturing stage, during the usage, CO2 emissions are reduced by 5-6 % starting the first year of usage

C02 emissions effect

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On 50, 000 cars, we can save : around 0.3 billion kg of CO2 in 10 years.

0.7 billion in 20 years If implemented on 62 million cars

(registered cars in us, According to the U.S. Department of Transportation Statistical Records Office )

500 million kg =0.5 billion ton

Aluminum automotive

industry on a wider scale

29Paul R. Epstein, William Moomaw, Christopher Walker;Healthy Solutions for the Low Carbon Economy:Guidelines for Investors,

Insurers and Policy Makers

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We can remove half of this wedge if we implement our solution on a wide scale

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Is aluminum car sustainable??

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Questions & AnswersThank You