Automotive Steel Performance Advantages for Mass Reduction and Climate Change
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1 Automotive Steel Performance Advantages for Mass Reduction and Climate Change Jody Shaw United States Steel George Coates Phoenix AG, Inc.
2 Automotive Steel Performance Advantages Today s Agenda: 1) We ll discuss mass and cost reduction via Advanced High Strength Steels (AHSS) and 2) We ll introduce Life Cycle Assessment (LCA) to determine steel s impact on the environment compared to other material choices
3 Design Drivers Top Challenges Facing Automotive Design and Engineering Community, (by percent) Cost Reduction Fuel Economy Alternative Powertrain Alternative Fuel Vehicle Safety Advanced Electronics Emission Regulations
4 Aluminum Industry Statements A 6% to 8% fuel savings can be realized for every 10% reduction in weight from substituting steel with aluminum. Each kg of aluminum replacing 2 kg of steel will save 20 kg of CO 2 over the typical life time of a vehicle.
5
6 Theoretical Mass Reduction Calculations Mass Reduction Aluminium 50% mass savings over mild steel with 40% greater package space requirements High- Strength Steel provides a 25% mass savings over aluminium with 60% less package space
7 Mass Reduction Hood Comparison Transverse Stiffness:
8 Mass Reduction BIW Comparison - Aluminium
9 BIW Comparison Optimized Steel Mass Reduction
10 Mass Reduction BIW Comparison 11%
11 Weight Elasticity
12 Weight Elasticity
13 Weight Elasticity Average Car Trends (NHTSA data) Curb Wt. Interior Space Engine Displ.t HP/Curb Wt Ratio
14 Weight Elasticity
15 MIT Materials Systems Laboratory Study Manufacturing Cost
16 MIT Steel Design Comparisons Manufacturing Cost
17 Automotive Steel Performance Advantages Steel is part of the solution! in our ever-changing automotive landscape. Advanced High-Strength Steels (AHSS) Mass-efficient designs Improved crashworthiness Improved fuel economy Affordability Now let s consider the environment. w w w. a u t o 17s t e e l. o r g
18 Environmental impact - LCA Climate change is a critical issue... w w w. a u t o 18s t e e l. o r g
19 Environmental impact - LCA The argument for Life Cycle Assessment (LCA): To avoid unintended consequences. w w w. a u t o 19s t e e l. o r g
20 Greenhouse Gases (GHG) Environmental impact - LCA Substance Global Warming Potential Atmospheric Lifetime (GWP 100 in kg CO 2 eq) (years) Carbon Dioxide (CO 2 ) Methane (CH 4 ) Nitrous Oxide (N 2 O) CFC-12 (CCl 2 F 2 ) 6,200-7, HCFC-22 (CHClF 2 ) 1,300-1, Perfluoromethane (CF 4 ) 6,500 50,000 Perfluoroethane (C 2 F 6 ) 9,200 10,000 Sulphur Hexafluoride (SF 6 ) 23,900 3,200 Source: IPPC Radiative Forcing Report, 1996
21 Environmental impact - LCA Raw Materials Production
22 22 Environmental impact - LCA (GHG) CO 2 eq Use Phase Only greenhouse gas (GHG) emissions: AHSS Steel Vehicle use Aluminium Driven Distance Total Mileage
23 Environmental impact - LCA Environmental impact - LCA (GHG) CO 2 eq Total life cycle greenhouse gas (GHG) emissions: aluminium steel Material & vehicle production Vehicle use Driven Distance End-of-life recycling credits Total Life w w w. a u t o 23s t e e l. o r g
24 LCA GHG Parametric Model Dr. Roland Geyer The Donald Bren School of Environmental Science and Management University of California at Santa Barbara LCA GHG Model Credible model: validated by ISO Critical Review Panel: 2 university professors (Japan, U.S.) Automotive manufacturer (U.S.) International Aluminium Institute (Europe)
25 LCA GHG Model
26 LCA GHG Model Vehicle Mass Total GHG Emissions
27 AHSS Favorable Environmental Impact LCA GHG Model Up to 2.6% total life cycle CO2eq (GHG) improvement Vehicle Mass Total GHG Emissions Aluminium Aluminium
28 LCA GHG Model We tested the model over various input ranges. In conducting sensitivity analysis, we find: With most reasonable assumptions, across a broad vehicle spectrum, aluminium is responsible for increased total LCA GHG s. Aluminium shows comparable or improved GHG performance in only those cases where the most favorable (and unlikely) aluminium parameter inputs are chosen for the model. Let s test one theory...
29 Results Contribution Analysis (in kg CO 2 eq) Scenario 2 Material Use Total Baseline 1,621 34,821 36,442 AHSS (ULSAB-AVC) 1,620 34,810 36,430 Aluminum 1,624 34,798 36,422 Baseline - Aluminum AHSS (ULSAB-AVC) - Aluminum Aluminium Case Study 2 kg steel replaced by 1 kg aluminium Use 100% (instead of averaged) recycling credit Greatly increased weight elasticity value
30 LCA GHG Model The LCA Greenhouse gas model from UCSB is available for download from the WorldAutoSteel Website:
31 Slide 19 Automotive Steel Performance Advantages Steel is successfully reinventing itself! AHSS vs. Conventional Steel Little or no cost
32 Slide 20 Automotive Steel Performance Advantages Aluminium compared to AHSS
33 LCA GHG Model Life Cycle GHG Comparisons: Powertrains and Fuels aluminium
34 Steel No Regrets!
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