Presenting Lightweight Construction In Modern Vehicles To Evaluate And Address Its Challenges From A Lifecycle Perspective
GALM 2016, Birmingham Dr. Christoph Haberling, Audi AG
2
Mission – Light weighting Comfort and efficiency: weight and requirements
Titel oder Name, Abteilung, Datum
luxury SUV with a total vehicle weight less than 2000 kg
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
3
Lightweight design Approach in different steps
Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
4
Production concept Joining technologies cell and hang on parts
Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
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Goals of body in white development and production Material logic in the Audi Spaceframe Multi Material Mix
Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
6
Lightweight design Material mix and structure concept
Titel oder Name, Abteilung, Datum
Structure: 41 % Aluminium 59 % Steel
Complete Body: 50 % Aluminium 50 % Steel
Aluminium sheet Aluminium extrusion
Steel conventional
Aluminium casting
Steel hot formed
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
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Results Weight comparison to predecessor
Titel oder Name, Abteilung, Datum
Wholistic lightweight approach = ultra®–lightweight design
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16 source: F. Venier, Audi
8
Optimizing transmissions
Optimizing combustion engines
Lightweight design, aerodynamics, rolling resistance
CO2-reduction potentials: ICE options
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Global trends and general constraints
Challenges for the automotive industry
Climate change Urbanization
Political framework
Scarcity of resources Markets in upheaval
New technologies Shifting values Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Global trends: Influencing and interacting factors
1 – Technology ► Characteristic properties
of different drivetrain technologies.
► effects of renewable fuels (e-fuels, „green“ power)
4 – Market and Customer ► Technological requirements
of the customers ► acceptance of additional
costs ► competition
2 – Infrastructure ► Kind of production
(CNG, power, hydrogen) ► Economic feasibility ► Government aid
3 – Legislation ► CO2-legislation ► Limitation of
emissions (NOx…) ► Energy-Legislation ► Incentives for alternative drives ► Resource efficiency
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Risk of oversimplification … Su
stai
nabi
lity
issu
es
Climate change
loss of species
overfishing
shortage of ressources
regional scarity of potable water
desertification
destruction of rain forest
erosion of top soil
Clim
ate
chan
ge CO2-footprint
NOXe
methane
particulate matter
…
CO
2-
foot
prin
t
tank-to-wheel (tailpipe)
cradle-to-cradle
tailp
ipe
well-to-wheel
source: „Grüne Lügen“, Friedrich Schmidt-Bleek
acidification
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Systematic Holistic
Networked
Life cycle
Thinking in cycles Orientation to nature
To implement sustainable development, you need a wider perspective
LCA – A Method for Sustainable Product Development
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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LCA – Decision-making Tool for Sustainable Development The Life Cycle Assessment
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Production
Use
Cycle concept
Recycling
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
14
Inventory analysis
Extraction of raw materials
Manufacture
Production
Use/ traffic
Recovery/ recycling
Effect indicators
CO2
CH4
SO2
NOX
HC
R11
Estimated effect
Global warming
Eutrophication
Summer smog
Acidification
Ozone breakdown
Life Cycle Assessment - tracking Effects on the environment
Relevant industrial standards: ISO 14040 et seq.
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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cradle-to-grave
~20% ~1%
tank-to-wheel (use)
cradle-to-gate (materials and car production)
well-to-tank (fuel
production)
well-to-wheel (fuel production + use)
Production Use Recycling
Input energy
materials
Output emissions
waste
Cradle to grave CO2 emissions Cars with internal combustion engine
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Recycling
0 km 200,000 km
Gre
enho
use
gase
s [t
CO
2 equ
ival
ent]
In Life Cycle Assessment, all effects on the environment during the lifetime of the vehicle are taken into account
Net reduction in greenhouse gases
Break-even
Depreciation distance
Additional manu- facturing burden
by lightweight design
Conventional construction Environmentally acceptable
lightweight construction
Use Manufacture and production
The Audi Life Cycle Assessment – procedure
Relevant industrial standards: ISO 14040 et seq.
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Manufacturing Recycling Use
- 16%
0
10,000
20,000
30,000
40,000
50,000
60,000
0 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000
GW
P (g
loba
l-war
min
g po
tent
ial)
[kg
CO
2 equ
ival
ent]
Operating life [km]
Audi Q7 3.0TDI quattro 180kW tiptronic (MJ2015)
Audi Q7 3.0TDI quattro 200kW tiptronic (MJ2016)
Break-even point ~ 34,000 km
Additional Manufacturing burden
Improvements in greenhouse gas emissions of 16% compared to the previous model over the life cycle
LCA – Decision-making Tool for Sustainable Development LCA for the AUDI Q7 - result for greenhouse gas emissions
16 Uwe Heil, I/EG-X1, 2015-03-19
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Alternative drives
Optimizing transmissions
Optimizing combustion engines
Lightweight design, aerodynamics, rolling resistance
CO2-reduction potentials: further options – alternative drives
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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The new Audi Q7 e-tron
► Drivetrain of the Audi Q7 e-tron quattro Material mix:
3.0 TDI engine
8 speed Automatic transmission High-voltage-battery
Charging point
Power electronics Electric motor
Electric motor
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Greenhouse gas emission value of the Audi Q7 e-tron quattro in compared with the Audi Q7 3.0 TDI over the entire life cycle
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
The additional costs associated with the hybrid drive system on the Audi Q7 e-tron quattro are offset after approximately 128,000 km when running the vehicle on the EU power mix and after just approximately 38,000 km when running the vehicle on electricity generated from hydroelectric power.
21
Distribution of CO2 equivalents to the LCA for different vehicles
~ 80% ~20% Petrol engine
Assumptions: Compact-class car Mileage: 200,000 km Petrol engine: 5.5 l / 100 km PHEV: 1.5 l/100 km BEV: 15 kWh / 100 km CO2 equivalent: 11 g/kWh
~ 5% ~ 95 % BEV*
~ 50% ~ 50 % PHEV*
Use (well-to-wheel) Manufacturing
Using traction batteries makes the production phase increasingly more significant in terms of the environment
LCA – Decision-making Tool for Sustainable Development
Comparison of different vehicle concepts
* electricity from renewable sources
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Effects of light - weighting (efficiency - CO2 reduction) ICE vs. BEV
Significantly lower compared to an ICE vehicle
Significantly lower compared to an ICE vehicle
BEV ICE
100 kg
Weight reduction: CO2 savings: Additional range:
100 kg
The efficiency improvement of weight reduction measures is most important for ICE
Weight reduction:
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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BEV: The need for Light weighting for weight compensation will increase compared to ICE
reference vehicle
CO2 impact of
Light weighting
CO2 impact caused
by additional features /
performance needed
CO
2 pro
duct
ion
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
reference vehicle
Light weighting
additional features /
performance needed
Vehi
cle
wei
ght
24
Recycling
0 km 200,000 km
Gre
enho
use
gase
s [t
CO
2 equ
ival
ent]
In the future there will be a stronger need also to optimize the manufacturing burden
Net reduction in greenhouse gases
Break-even ? Additional manu- facturing burden
by lightweight design
Conventional construction lightweight construction
Use Manufacture and production
Life Cycle Assessment – procedure
Relevant industrial standards: ISO 14040 et seq.
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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The Audi Life Cycle Assessment Use of sustainable materials – on component basis
* Carbon-fibre-reinforced polymer
• Greenhouse gas emissions from various materials due to the manufacturing process
The scatter values (red bars) for the various materials are due to the different manufacturing and recycling methods that can be used.
[kg CO2 equivalent / kg component ] [kg CO2 equivalent / functionally equivalent component ]
0 5 10 15 20 25 30 35 40 45
CFRP *
Magnesium
Aluminum
Steel - 40%
lightweight construction potential
- 55% lightweight construction potential
- 55% lightweight construction potential
Dr.-Ing. Christoph Haberling, AUDI AG, London 25/04/13 Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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The Audi Life Cycle Assessment - CO2 balance share of the material groups for the manufacturing process
A6 A8
proportional weight CO2eq. proportional weight CO2eq.
other materials
polymers
other metals
light metals
steel / iron
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Solutions for castings
Diecasting offers possibilities for local opimization
Outer structure
Free room for material
Optimized part
source: Mr Haverkamp, Audi Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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multiple castings tools
Use of multiple or combinded set of castings
Win-win: advantage in economics and CO2 emissions
0%
20%
40%
60%
80%
100%
Component cost Processing time per part
1 part per shot 6 parts per shot
Combinded set of castings
source: DGS
source: ALCOA
source: Mr Haverkamp, Audi Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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The aluminium cycle Audi is looking at all steps of the process chain
alloying smelting
secondary castings
Semi finished goods Primary production Products
Audi is participant Aluminium Stewardship Initiative
sorting etc.
Optimized in house recycling
Secondary Aluminium is mainly used for drive train components and can be recycled again and again
Tracking possibilities of advanced EOL
technologies
Shredder and sorting
Aluminium fraction
dismantling
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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LCA – A Method for Sustainable Product Development
Renewable fuels – Audi e-fuels
The principle behind Audi e-fuels: CO2 is used as the raw material to manufacture e-fuels and is used in the cycle
Customer fills up with renewably produced fuel
CO2 used as raw material
In fuel production:
Binding CO2
Fuel production
vehicle
CO2 collector
Petrol station
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Vehicle production*
Fuel production* Total*
Compact-class car
Vehicle use*
Conventional vehicle (petrol) 113 30 25
BEV (Renewable energy mix)
0
43
3
95 Construction of
e-gas plant
33 Audi A3 g-tron (with Audi e-gas)
-75
Construction of e-gas plant
∑ 168
∑ 46
∑ 53
-75 95
Construction of e-gas plant
*g CO2 equivalent per km over 200Tkm
A vehicle running on Audi e-gas overall emits a similar volume of CO2 as an e-vehicle running on renewable energy.
LCA – A Method for Sustainable Product Development Comparison of CO2 emissions over the life cycle
Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
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Conclusion:
► Choose an appropriate balance sheet calculation to evaluate a system
► Light weighting will be more a weight compensatory measure than today
► Environmental impact by production will come more and more into the focus
► The Recycling of process and end-of-life scrap has to be optimized for all new lightweight materials on a high material quality level
► The use of more “green” energy and recycled material for production of new materials can decrease the environmental impact of light weight materials dramatically
Titel oder Name, Abteilung, Datum Dr. C. Haberling, Audi AG, I/EG-X2, GALM 2016, 26/04/16
Thank you.
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