New Materials for Future Sustainable Mobility Trends and Challenges

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1 1st Public International Conference New Materials for Future Sustainable Mobility Trends and Challenges Rainer Mayer, M.B.A. (USA) Dr. Kord Pannkoke Dr. Marcus Seitz 12-Nov-2012 Cluster New Materials 1

2 Stimulating Innovation Material price Processes Functionality Emotion

3 Stimulating Innovation Material price Processes Functionality Emotion

4 Improved material cost - a driving force for material substitution Example: First-time application substititution of polyamide through polyproylene in an intake manifold application : Lower material price Fewer process steps, lower melting point and density offer a cost advantage of 15 % compared to polyamide ATZ, Röchling PP worldwide available Weight advantage of 15 % compared to polyamide Improved acoustic emission (especially at higher rpm and frequencies) due to lower density comp. to polyamide Target markets: Europe, China, Brazil 12-Nov-2012 Cluster New Materials 4

5 Stimulating Innovation Material price Processes Functionality Emotion

6 Reduction of process cost by selecting the best material combined with a suitable process Example: Tailgate of the Lamborghini Gallardo Spyder Material: Carbon fiber reinforced plastic, Process: RTM (Resin Transfer Molding) Volume: units/p.a. Advantage over aluminum as a result of lower tooling cost Quite demanding design can only be realized with CFRP Weight savings of 30 % over metal solution Images: Audi, ACE 12-Nov-2012 Cluster New Materials 6

7 Stimulating Innovation Material price Processes Functionality Emotion

8 Material and production innovations integrate several functions and reduce number of parts Example: Tail gate of BMW 5-Series GT Method: Aluminum die casting Weight reduction: 13 kgs Improved freedom / flexibility of design Reduction of joining necessities Reduced space requirements Sources: BMW Group, Heise, Rheinfelden, Auto News 12-Nov-2012 Cluster New Materials 8

9 Stimulating Innovation Material price Processes Functionality Emotion

10 New materials foster emotion Example: Superplastic Forming Extreme shaping of Al and Mg structures Technology: Superplastic forming properties of Al and Mg materials are being used through heat and pressure to generate extreme contours with a single-piece tool. Cycle-time: 2-10 minutes Source: Presentation Dr. Füller, Daimler, Nov-2012 Cluster New Materials Images: Magna/Daimler 10

11 Example: Metallic surfaces through IMD IMD IMD IMD Quelle: Vortrag Dr. Hagen, KURZ, Nov-2012 Cluster New Materials 11

12 Innovation Networks Megatrends

13 Megatrends establish the context for innovation SOCIETY Demographic change Women on the Rise Cultural Diversity New patterns of mobility CONSUMERS Next level of individualization New behavior patterns Health boom TECHNOLOGY Digital LIfe Convergence of technologies Learning from Nature Ubiquituous Intelligence GLOBALIZATION Globalization 2.0 Urbanisation New political world order Increasing security threats BUSINESS Knowledge-based economy Change of work environment Business eco-systems ENVIRONMENT Altered perspective of energy and resources Climate change Increasing pollution 12-Nov-2012 Cluster New Materials Source : 13

14 Sustainability Globalization Resources Megatrends

15 Sustainability Resources Megatrends

16 Source: Vision 2050 The New Agenda for Business 12-Nov-2012 Cluster New Materials 16

17 Source: Vision 2050 The New Agenda for Business 12-Nov-2012 Cluster New Materials 17

18 Example BMW i3 Renewable energy is being used exclusively for energy-intensive carbon fiber production (Moses Lake Site ) Recycling of carbon fibre production waste by returning the recycled semifinished parts into the carbon fibre production process chain or into the vehicle 25% of the weight of thermoplastic materials are being replaced by recycled and renewable materials. Devolopment / Use New Materials Environmental Impact Source: Lecture, Dr. Töpker, BMW Group, 2012 Image: BMW Group Cluster Neue Werkstoffe 18

19 Sustainability.requires a material-oriented and a process-oriented approach. sustainable product concepts are only feasible with appropriate material solutions and (closed) loops

20 Conception et fabrication du véhicule Utilisation du véhicule Fin de vie du véhicule Valorisation Fournisseurs de matière Equipementiers Gestionnaires distributeurs Récupération de véhicules Assureurs Particuliers Véhicules accidentés 0,5 M de VHU* Démolisseurs/Broyeurs non agréés Démolisseurs non agréés Déconstructeurs non agréés 0,05 M de VHU* Valorisation de pièces Constructeurs Industrie automobile 2,51 M de VEH Ventes de véhicules Concessionnaires Entreprises 0,12 M de VHU 0,99 M de VHU Démolisseurs/Broyeurs agréés Démolisseurs agréés 0,76 M de VHU Valorisation de matières Enfouissement Légende Matières Pièces Véhicules VHU Broyat * = Estimations Récupération de véhicules Garagistes Véhicules abandonnés Fourrières Détenteurs de VHU Découpage Stockage Dépollution Démontage Tri / Broyage 0,1 M de VHU Exportations Déconstructeurs agréés 0,1 M de VHU Stockage Valorisation énergétique BTP, Cimenterie, ferroviaire etc Débouchés Quelle: Pôle Véhicule du Futur 12-Nov-2012 Cluster New Materials 20

21 Resources Sustainability Megatrends

22 Resources Status quo: Complex process and value chains - from the mine to processed materials - are necessary to sustain worldwide production processes Changes in the technology base of society require re-evalution of resources Economic dependency on countries with a virtual monopoly position are viewed more critically

23 Raw Materials Annual mining of raw materials increased from 10 bill. to 15 bill. tons over the course of 25 years Threats: Limited availability Variety of materials Dissipation 12-Nov-2012 Cluster New Materials 23

24 Raw materials and supply risk 5,0 4,5 Nobel Earth 4,0 3,5 PGM Supply risk 3,0 2,5 2,0 1,5 1,0 0,5 Bariumsulfat Diatomit Talk Tone Borate Gips Silber Feldspat Lithium Antimon Beryllium Kalkstein Silika Kupfer Titan Bentonit Germanium Magnesium Gallium 0,0 Perlit Nickel 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0 Indium Cobalt Economic importance Flussspat Tantal Niob Wolfram Graphit Rhenium Magnesit Tellur Eisen Aluminium Molybdän Vanadium Chrom Mangan Zink Bauxit Source: EU-Commission, Critical Raw Materials for the EU 12-Nov-2012 Cluster New Materials 24

25 Example: Availability Production of primary aluminum: t Production of primary magnesium: t China Russland Kanada Australien USA Indien Brasilien Norwegen Deutschland sonstige China Israel USA Brasilien Russland Source: Presentation Dr. Blümlhuber, BMW, Nov-2012 Cluster New Materials

26 We appreciate your time and your interest

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