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

Contents Emission Reducing Factors Crashworthiness End of Life Considerations Future Trends

Emission Reducing Factors

Does CO2 Emissions cause climate changes?

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

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

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

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

What does Weight Saving Imply? EU mixed cycle 91/441/EEC  0,0046 l pr. Kg pr. 100 km  km / year  10 Years lifetime  7 Years model life  2.85 Kg CO2 pr l. fuel  40% Weight saving by Al  Tonnes Al Parts 1kg, one platform kg CO2 eq saving = 8.28 l fuel saved = 23.6 kg CO2 0,0046 l x km x 10 years 100 km 1kg, one car23.6 kg CO2 eq saving Hydro Automotive yearly 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

European Fleet made Light Weight All cars 30% lighter. Existing technology 0,0046 l x ~400 kg x km x 150 million cars 100 km = l = tonnes CO2 x Yearly

Emissions from Production If Produced from Primary Aluminium Real Recycling Level; Automotive sheet 11% Automotive extrusions 11% Automotive castings 85% Producing 1 kg Aluminium Emits 6 kg CO2eq Emissions from Al. Production12 kg -Emissions from Production of Replaced Steel3 kg -Reduced Emissions from during use16 kg Impact on Lifetime CO2 eq Emissions-7 kg Sources: IPAI; Life Cycle Inventory of the Worldwide Aluminium Industry with regard to Consumption and Emissions of Greenhouse Gases. Paper 1 Automotive

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

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

Crash Worthiness

Level of Accidents in Road Traffic Sustainable? Fatalities in Road Traffic in OECD Countries in 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

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

BMW 7 series Crash management system

Comparison Aluminium to Steel Energy absorbtion to weight ratio superior by aluminium

End of Life Considerations

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

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

Global Supply 2002

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

The Aluminium Bank – Metal Stored in Use

Recycling in Hydro Recycling Capacity 2002: tonnes Primary Metal Capacity: 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

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 Small Car 1000 kg Weight of non- recyclables Weight of recyclables Effect of legislation Conventional Build Accepted (15%) Light Weight Structure Not accepted (<15%)

Future Trends

Are future demands different?

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

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 Alu Mg Steel

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

Bolt-ons Engine Cradles Suspension IP Beams Closures Seats

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

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?

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