LIGHTWEIGHT VEHICLE TECHNOLOGYCASTLE BROMWICH, UK
02.05.2012
MARK WHITE CHIEF TECHNICAL SPECIALIST
3
Light Weight Vehicle rationale
XJ LWV Body Materials
Aluminium Sheet Strategy
Material Selection
Increased Recycling (REALCAR - REcycled ALuminium Car research project)
LWV Barriers - Aluminium Cost Considerations
LIGHTWEIGHT VEHICLE TECHNOLOGYAGENDA
4
LIGHTWEIGHT VEHICLE TECHNOLOGYLEADER IN AUTOMOTIVE INNOVATION
World-Firstdual-view screen
Design Enabling
Human/VehicleInteraction
Vehicle CapabilityLow Carbon Propulsion/KE recovery.
Light-weight Vehicles
Energy Efficiency/Parasitics
Product Life-cycle
What Makes Us Different
World-First Automatic Terrain ResponseSystem (in development)
World-first user-selectable terrain response system
World-first pyrotechnicdeployable bonnet protectspedestrians whistmaintaining sleek design
World-first aluminiumMonocoquebodyshell
World-firststop-startmid-size SUV
World-firstcapacitive senseinterior switches
World-First Adaptive Cruise Control
Limo-Green
World-firstfull electric drivepremium F-segmenttechnology demonstrator
Gen. 1Gen. 2
World-firstclosed-loop aluminium re-cycling
5
We must make cars that comply with future CO2 & FE requirements
From 2012 - 2019 a mass based CO2 limit will be applied to all new cars
OEM’s must address the CO2 challenge in a cost effective manner, whilst maintaining vehicle attributes to be a sustainable business & meet targets
LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 CHALLENGE FOR CAR MAKERS
6
Options available:
Propulsion:
Mild/micro hybrids
Full hybridisation
Weight:
Aimed at reducing BIW, PT & Chassis weight, but across whole vehicle
Parasitics:
Reduce heat, friction & pumping losses, increase combustion efficiency
Hybrid Elec VehiclesFlywheel [Kinetic]Plug in Hybrids
Electric VehiclesCombustionTransmissionDrivelinePowertrain Efficiency
Weight EfficiencyVehicle Architecture
BIW & ClosuresChassis partsMaterial applicationJoining technologyLCAWeight v attributes
Aerodynamics Rolling resistancePT & ThermalEnergy management- Chassis systems- ElectricalClimate systems
LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 CHALLENGE FOR CAR MAKERS
7http://ec.europa.eu/environment/co2/co2_home.htmEU CO2 Technology Roadmap
LIGHTWEIGHT VEHICLE TECHNOLOGYEU CO2 TECHNOLOGY ROADMAP
8
Cur
rent
Ste
el
Opt
imum
HS
Ste
el
Alu
min
ium
Mag
nesi
um
CF
RP
toda
y
CF
RP
?
100%-10-20%
-40%-50%
-60%-70%?
Relative cost
Will cost dominate function ?
LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT REDUCTION POTENTIAL
9Kerb weight (kg)
LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 EMISSIONS BY VEHICLE WEIGHT
PetrolDiesel
Hybrid
Modus
Citroen C2
Focus
Jaguar S 2.7
Jaguar XF 2.7
Insight
PriusCivic
Lexus GS450h
Lexus RX400h
Lexus LS600h
Citroen C1
50
100
150
200
250
300
500 1000 1500 2000 2500
CO
2g
/ k
m
10
What’s the CO2 benefit of 100 kg weight reduction?Certified CO2 figures are calculated using categories which cover a range of vehicle weights (typically 115 kg)
Due to the certified FE test being static, vehicle weight has no real effect. Resistance on rollers is used & is a constant value in each category
Therefore, we get steps in the certified CO2
values for a range of weights within a category
If we are at the top of a category & save100 kg we have the same CO2 figure
1 lower category is worth circa 2% CO2
Equating to 3.6 grams of CO2 on an XJ
LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & THE EU CERTIFIED CYCLE
CO 2
M as sHigh Lo w
High
Low
115kg d r o p p er T es t W e ig ht
Clas s
2% CO 2 d r op p er Te s t
W e igh t Clas s
11
100 kg weight reduction effect per vehicle on LCA
Production 650 kg
FE Improvement (certified) 720 kg
Fuel production 86 kg
Total LCA save per vehicle 1,456 kg (using ISO 14040/44)
Real world FE 110 kg
Total Carbon Impact of 100 kg save 1,566 kg
Therefore, every 1 kg reduction results in 16 kg CO2 per vehicle
But it ‘s on every car we make so it’s actually 2,56Kt of CO2 per 1kg
For every 100 kg that’s over a quarter of a million tonnes saved by JLR!
LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & LIFE CYCLE CO2
100 kg weight reduction effect per vehicle on LCA
Production 650 kg
FE Improvement (certified) 720 kg
Fuel production 86 kg
Total LCA save per vehicle 1,456 kg (using ISO 14040/44)
Real world FE 110 kg
Total Carbon Impact of 100 kg save1,566 kg
Therefore, every 1 kg reduction results in 16 kg CO2 per vehicle
But it ‘s on every car we make so it’s actually 2,56Kt of CO2 per 1kg
For every 100 kg that’s over a quarter of a million tonnes saved by JLR!
LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & LIFE CYCLE CO2
13
LIGHTWEIGHT VEHICLE TECHNOLOGYJAGUAR XJ MATERIALS – COMPLETE BODY
6%
1%
1% 1%2%
5%
5%
58%
19%
% by mass
Al sheet 6xxx
Al sheet 5xxxAl casting
Al extrusion
Mg casting
Mild steel
AHS steelHSS steelPHS steel
11%
66%
9%
9%
2% 3%
Al Sheet 6xxx
Al Sheet 5xxx
Al Casting
Al Extrusion
Mild Steel
AHS
Previous generation XJ
Current XJ
14
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ COMPLETE BODY OVERVIEW
% by part count
Al sheet 5xxx58% by mass
1%-Other
5%4%Profiles
6%5%Castings
88%91%Stampings
Current XJPrevious generation XJComponent type
15
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ DIE CAST PARTS
Castings used in key areas for:
– Complex geometry
– Local stiffness in high load input areas
– Part integration
– Reduce multiple sheet stack-up issues
– Self pierce rivet joining to other parts
16
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ EXTRUDED PROFILE PARTS
Bolt-on
Bolt-on– Use of high strength extruded alloys
to minimise weight & meet package requirements
– Bolt-on parts to support vehicle repair strategy
– Support manufacturing Bill Of Process (BOP)
17
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ BODY STRUCTURE MATERIALS
Al sheet 6xxx
Al sheet 5xxx
Al casting
Al profile
Mg casting
Mild steel
AHS steel
HSS steel
PHS steel
18
LIGHTWEIGHT VEHICLE TECHNOLOGYBODY STRUCTURE SHEET MATERIALS
Alloy Types
AA6xxxBAKE-HARDENINGALLOYS
MEDIUM STRENGTH OR
BAKE-HARDENINGALLOYS
Alloy Types
AA6xxx
AA5xxx
Requirements - BIW
– Good formability
– Corrosion resistance
– Good crash performance
– Long term stability of properties
Requirements – Outer skins
– Good formability
– High strength after paint bake
– Corrosion resistance
19
LIGHTWEIGHT VEHICLE TECHNOLOGYEXTERIOR SHEET MATERIALS
6111-T4 meets the following requirements:
– Suitable for all Class A exterior panels
– Sufficient formability to achieve style
– Compatibility with deep draw lubricants
– Dent resistance via strain & bake hardening
– Bake hardening without body shop oven
– Minimum gauge provides max weight save
– Weight save 20%+ over previous generation XJ
– 20% Material cost savings
New XJ bodyside material selected AA6111 T4PD Panel thickness = 1.2mm
Previous generation XJ used NG5754Panel thickness = 1.5mm
20
LIGHTWEIGHT VEHICLE TECHNOLOGYSTRUCTURAL CRASH ALLOY - Ac300 T61 – Typical in-service strength circa 225 MPa versus 140MPa for NG5754
– Ac300 in the T61 condition offers higher specific energy absorption
than strain hardening 5xxx series alloys
– Gauge for gauge the alloy absorbs 30% more energy per unit length
– Weight for weight more effective than DP600 steel
– Opportunity to down gauge NG5754 components by 20% of the original gauge
in crash crush applications - saving both weight and piece cost
– Ac300 T61 is resistant to stress corrosion cracking and can be used in environments
with elevated temperatures
21
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ JOINING TECHNOLOGY
– Self-Piercing Rivets (SPRs) are the main joining technology
– Adhesive bonding used for NVH & durability
– 1K adhesive used for sheet joints
– Blind rivets for single sided joint access
– Low speed & high speed ‘bolt-on’ structures
– No welding in the body shop
– Elimination of previous generation XJ roof joints
- zero MIG welding in house
Adhesive bonding (body & closures) = 154m
22
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ JOINING TECHNOLOGY
Nu
mbe
r of
SP
R’s
PreviousXJ
NewXJ
3000~11% reduction
– New XJ body is larger & meets increased functional requirements
– 11% reduction in SPR count in body structureover previous generation
– Savings in both direct & investment costsStandard wheelbase XJ (BSLD) has 2840 SPRscompared to over 5000+ spot welds for an equivalent steel body. SWB Body Complete has 3118 SPR’s
23
LIGHTWEIGHT VEHICLE TECHNOLOGYXJ BODY COMPLETE WEIGHT
Fro
nt D
oors
Rea
r D
oors
Bon
net
Tai
lgat
e
Fen
ders26
2017
11 4 324
246
Bod
y S
truc
tureM
ass
[Kg]
Unl
aden
Veh
icle
Wei
ght
Bo
dy
Com
ple
te(
bod
y +
clo
sure
s)
1843
A B New XJ D
Wei
ght [K
g]
Competitor data based upon LWB derivative data[1] - A2mac1 data[2] - JLR Teardown data
[1]
[1]
[2]
Steel body complete equivalent ~ 454KgData based upon mounting parts included in module, SWB 3.0L V6 Diesel
24Waste
Production Use Disposal
Raw material
Waste WasteEmissions to air and water
Production Use Disposal
Energy Energy Energy
Disposal, 1%
Production, 14%
Use, 85%
LIGHTWEIGHT VEHICLE TECHNOLOGYPRODUCT LIFE CYCLE ANALYSIS
Emissions to air and water
Emissions to air and water
0
100
200
300
400
500
600
Steel Aluminum Magnesium CDRC
Production End of Life
(MJ/kg)
0
100
200
300
400
500
600
Steel Aluminum Magnesium CDRC
Production End of Life
(MJ/kg)
25
LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR - RECYCLED SOURCESAluminium Recycling Opportunities
26
LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – ALUMINIUM SOURCES
End-of-life (ELV) vehicles
– Application of aluminium in vehicles
increasing
– Assess current industry material
separation
– Need to assess aluminium quality
– Avoid downcycling
Post-consumer waste
– Mechanical Biological Treatment plants
– Waste to energy plants
– Material quality impacts
– Cost opportunities
Recycled Aluminium Opportunities
AluminiumRemelter
Mechanical Biological
Treatment (MBT)
Energy from Waste (EfW)
Industrial Shredder
Separated Aluminium Shred
Scrapped Vehicles
End-of-Life vehicle processing
Post consumer aluminium waste
Note: 2009 = 40,500 tonnes land-filled in UK (Source: Alupro)
27
LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – ALUMINIUM SOURCES
Opportunity identified….assessment of aluminium in general wastePost-Consumer Waste Studies
Aluminium extracted from domestic household waste
Aluminium (3101)Aluminium (UBC) Aluminium (Foil)Aluminium (Areosol)
56.5% 23.7% 6% 6%
Actual MBT aluminium study conducted….further study in progress– Trial to separate and melt aluminium content
– Assess chemistry and suitability for 5XXX sheet
– Assess potential to reduce cost vs. primary aluminium
– Reduce aluminium lost to landfill Typical consumer aluminium waste
28
LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – IMPROVED RECYCLING
– Whitley and Gaydon Engineering Sites
– Heritage Motor Centre
– Purchase of Ecopacteur bins
– Actively investigating roll-out across business
– Increase awareness of recycling/reduce landfill
– JLR video can be viewed at www.everycancounts.co.uk
‘Every Can Counts’ Initiative – Adoption at Jaguar Land Rover
Can Crushing Bin
Every Can Counts – Video of introduction at Jaguar Land Rover JLR Case Study
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LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – NEXT STEPS
Alloy development
– Rigorous testing and validation
– Design rules
Recyled aluminium sources
– Vehicle ELV + post consumer
– Improved segregation
– Improvements in infrastructure
Recycling promotion
– Avoid materials going to landfill
– Responsible approach in the workplace
– Help educate/social responsibility
TSB application to develop a further recycled tolerant alloy ‘REALCAR 2’
30Market Rates - Al LME vs. HR Steel
0
500
1000
1500
2000
2500
3000
Jan-75 Jan-80 Jan-85 Jan-90 Jan-95 Jan-00 Jan-05 Jan-10
$/M
T Al LMEHR Steel
LIGHTWEIGHT VEHICLE TECHNOLOGYCOST CONSIDERATIONS
Raw Material Volatility
– Need to address the LME volatility cycle
31
1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 20081980 1990 2000
PriceUSD
2,200
2,400
2,600
2,800
1,200
1,400
1,600
1,800
2,000
Strategic weight save only – Luxury/ Sports
Premium sector Sports/ Saloons/ SUVs
Executive sector – all Models
D & C/D Segment High Volume & Mixed Metal Cars
10 - 20KT per year maximum
50 - 100KT per year maximum
100 - 250KT per year maximum in Eu
250KT - 500Kt per year plus in Eu
LIGHTWEIGHT VEHICLE TECHNOLOGYVOLATILITY EFFECT ON LWV MIGRATION
10 - 20KT per year maximum
32
G W P p e r B IW ( k g C O 2 e )
0
1 0
2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
1 0 0
R S W S P R
C o n s u m a b le p ro d u c t io n
E x tra c t io n h e a t lo s s e s
E le c t r ic ity
LWV Body saves 40% relative to steel, enabling secondary weight saves (power train down sizing)
Joining technology gives significant energy save v welding & reduces waste (water & air extraction)
Significant improvement in Fuel Economy & CO2
reduction when combined with Power Train down sizing
Up to 50% recycled aluminium in LWV body, World-First Closed-Loop Aluminium Re-Cycling
Steel Diesel V8 SUV
Steel Petrol V8 SUV
LWV Diesel V6 SUV
LWV Diesel V8 SUV
LWV Diesel V6 HEV
Steel Diesel V8 SUV
Steel Petrol V8 SUV
LWV Diesel V6 SUV
LWV Diesel V8 SUV
LWV Diesel V6 HEV
LIGHTWEIGHT VEHICLE TECHNOLOGYLWV TECHNOLOGY SUMMARY
Thank you Vielen Dank
MerciGrazie
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