Modern vehicle concepts
Impact on material selection and recycling
Dr.-Ing. C. Haberling, AUDI AG, Environment Product & Material Development
1
Material requirements in automotive engineering
emissions /
environment
customers
CO2-reduction
weight
reduction
fuel
efficiency
lightweight
design
reduction of
friction
legislation
material ban
ressources
downsizing /
downspeeding
urbanisation
2
more derivates
alternative
drives
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
materials
customer
perceived
value
(optics / haptic
/ design)
economic feasibility sustainable /
recycled
and availability
materials
new BIW
structures
costoptimization
end of life
recycling
energy management
competitors
legislation
Material mix (whole car)
!!
Audi A6, 3.0 TDI
54 %
- BIW: steel
- Hang on parts: aluminium
!!
Audi TT, 2.0 TFSI
- BIW: mixed
front, mid.: aluminium
rear part: steel
!!
Audi A8, 4.2 TFSI
- BIW: aluminium
3
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
14 %
44 %
24 %
32 %
33 %
Progress in Lightweight Construction - difficult to achieve
Expected additional weight due
to requirements in:
!!legislation / safety
!!comfort / quality
Required
light weight
design
(weight)
!!concept / interior
!!efficiency
(i.e. recuperation, Start/Stop)
Achieved
weight reduction
previous
model
current
model
(timeline)
4
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
next
model
Audi Space Frame (ASF) - Body in white – why ?
••! 40 % weight reduction
••! fulfilling same requirements
••! 100 kg weight reduction
result in a reduction of up to 8.5 g CO2/km*
(* tank-to-wheel )
Weight reduction is the base for efficiency and dynamics
5
Dr.-Ing.
AG,OEA
I/EG-X1,
London
25/04/13 17. Januar 2011
Dr.-Ing. Christoph
Christoph Haberling,
Haberling, AUDI
I/EG-X1,
Recycling
Aluminium,
The reversal of the weight spiral
Starting with light weight design (BIW)
and downsizing of the engine
Secondary effects
smaller breaks,
tank etc.
Weight optimization
in all areas
Efficiency
and dynamics
6
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
The Audi Life Cycle Assessment
Use of sustainable materials
•!
Greenhouse gas emissions from various materials due to the use phase
Steel
Aluminum
Magnesium
CFRP *
lightweight
construction potential
lightweight construction
potential
lightweight construction
potential
- 40%
- 55%
- 55%
CO2eq emissions for movement
of functionally equivalent components
Lightweight design is always improving the balance of the use phase
* Carbon-fibre-reinforced polymer
7
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
Samples on CO2 legislation - worldwide
today:
today:
today:
today:
Actual law
in decision
Basis 2011
8
Dr.-Ing. Christoph Haberling, I/EG-X1, London 25/04/13; sources: Dr. S. Krinke, Volkswagen AG, G. Deinzer, AUDI AG 2011
The Audi Life Cycle Assessment
Scope of complete-vehicle assessment
Recycling
Production
•!
•!
•!
•!
•! Recovery of
- components
- materials
- energy
Use-phase
•! Fuel production (well-to-tank)
•! use (tank-to-wheel)
9
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
Raw material recovery
Transportation
Semi finished goods
Component production
Life Cycle Assessment - tracking Effects on the environment
Relevant industrial standards: ISO 14040 et seq.
Inventory
analysis
Extraction of
raw materials
Effect indicators
Estimated effect
CO2
Greenhouse
effect
CH4
Manufacture
Eutrophication
SO2
Summer smog
Production
NOX
Use/
traffic
Recovery/
recycling
10 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
HC
R11
Acidification
Ozone
breakdown
Cradle to grave CO2 Emissions
cars with internal combustion engine
Production
Use
Recycling
Output
emissions
waste
Input
energy
materials
~20%
cradle-togate
~79%
well-totank
(fuel
production)
(materials,
car production)
tank-to-wheel
(use)
well-to-wheel
(fuel production + use)
cradle-to-grave
11
Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
~1%
The Audi Life Cycle Assessment
Analysis of complete life cycle and influencing factors
Production
Use
Recycling
Input
Energy
Raw mat.
Output
Emissions
Waste
Influencing factors (examples)
•! Materials
•! Component
concepts
•! Weight-saving
degree
•! Production
•! Processes
•! Energy sources
•! Electricity gener.
mix
12 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
•!
•!
•!
•!
Weight of vehicle
Roll resistance
Aerodyn. (cw-coeff.)
Power unit
•! Type of fuel
•! Driveline efficiency
•! Production of fuel
•! Processes
•! energy
•! Recovery of
valuable materials
The Audi Life Cycle Assessment – procedure
Greenhouse gases [t CO2 equivalent]
Relevant industrial standards: ISO 14040 et seq.
Manufacture
and production
Recycling
Use
Conventional construction
Environmentally acceptable
lightweight construction
Net reduction in
greenhouse gases
Break-even
Additional manufacturing burden
by lightweight
design
Depreciation distance
0 km
200,000 km
In Life Cycle Assessment, all effects on the environment during the lifetime of the vehicle
are taken into account
13 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
The Audi Life Cycle Assessment
The challenge of electromobility
•!
The electric power generating mix in selected countries
China
CO2 eq. /kWh
1140 g
2%
17%
* Electric power generating mix of the 25 EU member states (2007)
14 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
EU 25*
560 g
Norway
46 g
The Audi Life Cycle Assessment
CO2 balance – internal combustion engine vs. electric motor
Internal combustion engine
~~ 20
20 %
%
~ 80%
< 1%
~ 80%
better
Production
Use (well-to-wheel)
Recycling
worse
Electric Vehicle
~ 25 %
~ 45 %
~ 80 %
~3%
~ 72%
~ 50%
~ 10% ~ 10%
~ 5%
Assumptions:
Compact-class car
Total mileage: 200,000 km
Fuel consumption: 5.5 l / 100 km
Electric power consumption: 15 kWh /
100 km
Climate impact of BEV only favorable if energy mix consists of significant amount of
renewable energy; importance of vehicle production increases
15 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
The Audi Life Cycle Assessment
Environmentally accaptable lightweight design and construction
Emissions
Additional
environmental
burden due to
manufacturing of
lightweight materials
Think of the extra expense in manufacturing when saving in use
Dr.-Ing.C.
Christoph
Haberling,
AUDI
AG, I/EG-X1,
London
25/04/13
16 Dr.-Ing.
Haberling,
AUDI AG;
F. Fraca,
RIMA; V.
Hasenberg,
PE-International, I/EG-X1, Xian 20/05/13
Source: Dr.-Ing. C. Haberling, AUDI AG
Reduced
environmental burden
Lower fuel consumption
due to lightweight
construction
The Audi Life Cycle Assessment
Use of sustainable materials
•!
Greenhouse gas emissions from various materials due to the manufacturing process
Steel
Aluminum
lightweight construction
potential
Magnesium
- 40%
lightweight construction potential
CFRP *
lightweight construction potential
0
5
10
15
20
25
30
35
[kg CO2 equivalent / kg component
]
[kg CO2 equivalent / functionally equivalent component
- 55%
- 55%
40
45
]
The scatter values (white bars) for the various materials are due to the different manufacturing
and recycling methods than can be used.
Improving the overall balance by choosing sustainable materials and
manufacturing processes
* Carbon-fibre-reinforced polymer
17
The Audi Life Cycle Assessment
Use of sustainable materials
•!
Greenhouse gas emissions from various materials due to use and manufacturing
use
manufacturing
Steel
Aluminum
Magnesium
CFRP *
0
5
10
15
20
25
30
35
[kg CO2 equivalent / use phase (incl. fuel production)
]
[kg CO2 equivalent / min. manufacturing
[kg CO2 equivalent / manufacturing (range)
]
assumptions: for a functionally equivalent component,
base is 1 kg steel and the movement of 1 kg component will cause
0.1 g CO2-eq/km (internal combustion engine, incl. fuel production )
Improving the overall balance by choosing sustainable materials and
manufacturing processes
* Carbon-fibre-reinforced polymer
18 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
]
40
45
LCA: Sphere of activity – engineering and car production
Concept and production
of components
!!
Material selection due to concept and component
!!
Determination of the potential of lightweight
construction due to concept and component
!!
Evaluation and optimization of manufacturing
processes (energy consumption and emissions)
Use the right material at the right place
requirements vs. potential of light weight design
Reduce emissions through all process steps
19 Dr.-Ing.
Dr.-Ing. Christoph
Christoph Haberling,
Haberling, AUDI
AUDI AG,
AG, I/EG-X1,
I/EG-X1, London
London 25/04/13
26/04/12
Solutions for castings
Outer
structure
Free room
for material
Optimized part
Diecasting offers possibilities for lokal opimization
Claus Haverkamp, Audi Leichtbau Zentrum Neckarsulm, 07.Mai 2010
20 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13, source: Haverkamp, Audi Leichtbau Zentrum Neckarsulm, 2010
Use of multiple or combinded set of castings
100%
source: DGS
multiple castings tools
100%
100%
1 part per shot
80%
6 parts per shot
>50%
60%
>80%
40%
20%
source: ALCOA
Combinded set of castings
0%
Component cost
Win-win: advantage in economics and CO2 emissions
21 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13, source: Haverkamp, Audi Leichtbau Zentrum Neckarsulm, 2010
Processing time per part
LCA: Sphere of activity – use phase
Use phase
!! drivetrain
scenarios
downsizing of engines
Reduce emissions „well-to-wheel“
Think of the energy mix used
Advantage by weight reduction
including secondary effects
light-weight design
-1 kg ~ -0,1 g CO2/km
(for internal combustion engine - well to wheel)
22 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
The aluminium cycle
Audi is looking at all steps of the Process chain
Primary production
Semi finished goods
Products
dismantling
secondary
castings
alloying
Shredder
and
sorting
smelting
sorting etc.
Aluminium fraction
Audi joined
Aluminium
Stewardship
Initiative
Optimized in house
recycling
23 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13
Tracking possibilities
of advanced EOL
techniologies
Secondary Aluminium is
mainly used for drive train
components and can be
recycled again and again
The Audi Life Cycle Assessment
Summary
!!Everybody focuses on reducing fuel consumption.
We look one step ahead – life cycle assessment analyzes effects
on the environment during the entire life cycle of the vehicle
!!The environmental impact can be considerably improved by
choosing sustainable materials and manufacturing processes
!!The overall environmental balance of an electric vehicle is
dominated by the energy generation factor. Renewable energy
has to be available if there is to be any ecological benefit.
24 Dr.-Ing. Christoph Haberling, AUDI AG, I/EG-X1, London 25/04/13