Life-cycle energy and greenhouse gas emission benefits of lightweighting in automobiles: review and harmonization

Lightweighting in the automotive industry as a measure for energy efficiency: Review of the main materials and methods

The increasing emissions of greenhouse gases (GHG) and pollutants like particulate matter and nitrogen oxides (NOx) have led to environmental concerns. Hybrid and electric powertrains are being introduced as means to reduce pollutant emissions, especially at the local level. Additionally, the finite availability of fossil fuel sources, which are used to produce gasoline and diesel, highlights the need for alternative technical solutions. One approach to partly address these issues is lightweighting, which involves reducing the weight of vehicles to minimize their impact during the use phase. Mathematical models are employed to simulate the longitudinal dynamics of vehicles and estimate the energy required to accomplish driving missions. Appropriate metrics have been developed to quantify energy-saving effects that, in addition, can support the decision making, design, and development phase of future vehicles. To facilitate this process, it would be useful to build a database of ERV (Energy Reduction Value) and FRV (Fuel Reduction Value) figures derived through a unified procedure. Such a database would be useful in evaluating the effectiveness of vehicle lightweighting and its impact on energy consumption and pollutant emissions. The last phase of the analysis is the assessment of the overall reduction in the environmental impact of the vehicle throughout its life cycle by using the LCA (Life Cycle Assessment) approach. From this study, it was possible to conclude that lightweighting can be an appropriate solution to improve the energy efficiency of vehicles and that appropriate metrics, can support the development of new car models. The potential to integrate enhanced energy efficiency, lower emissions, and higher safety features into our everyday vehicles would represent a significant advancement in the automotive industry. There is a gap in the scientific literature on the effects of lightweighting on vehicle dynamics and energy usage which deserves to be investigated.

Circularity of new composites from recycled high density polyethylene and leather waste for automotive bumpers. Testing performance and environmental impact

New composite materials (suitable for automotive bumpers), composed of recycled high-density polyethylene (rHDPE) and leather buffing dust waste (BF) ranging from 20 to 50 wt%, were produced and investigated for mechanical properties. Optimal mechanical performance was achieved with composites containing 30 % wt BF. The environmental performance of automotive bumper production from both virgin and recycled HDPE reinforced with 30 % wt BF (HDPE-BF, rHDPE-BF) composites was compared to that of conventional polypropylene (PP) by performing a cradle to gate life cycle assessment. A component-based approach, instead of a comprehensive LCA assessment for the entire car was adopted using various functional units (FU) such as mass (FU1), volume (FU2), and volume of raw material fulfilling a specific impact strength requirement (FU3), thus enriching the paper with methodological discussions. The rHDPE-BF system provided better environmental performance compared to the virgin PP system, when considering both mass and volume-related functional units, mainly due to the avoidance of virgin polymer production. Even with the inclusion of the use phase in FU2 and a slightly higher density (+1.7 %) of composites than PP-based bumpers, the rHDPE system still provides better environmental performance (10 % less impact). The sensitivity analysis highlighted the significance of car type and final density of the bumper on the impact results. Finally, when using FU3, due to its higher impact strength, HDPE-BF system is clearly the best environmental alternative (50 % less impact) followed by rHDPE-BF system. In all cases, rising the content of recycled materials in the bumpers increases its circularity. The paper illustrates the importance of selecting a suitable functional unit, based on a specific application (i.e., automotive bumpers), to evaluate the environmental impact of new composite materials in comparison to traditional options. Expanding the assessment to encompass multiple functions provides a more accurate portrayal of reality but also introduces greater result uncertainty.

Corrosion-Fatigue Performance of 3D-Printed (L-PBF) AlSi10Mg

Additive manufacturing (AM) allows for optimized part design, reducing weight compared to conventional manufacturing. However, the microstructure, surface state, distribution, and size of internal defects (e.g., porosities) are very closely related to the AM fabrication process and post-treatment operations. All these parameters can have a strong impact on the corrosion and fatigue performance of the final component. Thus, the fatigue-corrosion behavior of the 3D-printed (L-PBF) AlSi10Mg aluminum alloy has been investigated. The influence of load sequence (sequential vs. combined) was explored using Wöhler diagrams. Surface roughness and defects in AM materials were examined, and surface treatment was applied to improve surface quality. The machined specimens showed the highest fatigue properties regardless of load sequence by improving both the roughness and removing the contour layer containing the highest density of defect. The impact of corrosion was more pronounced for as-printed specimens as slightly deeper pits were formed, which lowered the fatigue-corrosion life. As discussed, the corrosion, fatigue and fatigue-corrosion mechanisms were strongly related to the local microstructure and existing defects in the AM sample.

Cradle-to-Gate and Use-Phase Carbon Footprint of a Commercial Plug-in Hybrid Electric Vehicle Lithium-Ion Battery

Increased use of vehicle electrification to reduce greenhouse gas (GHG) emissions has led to the need for an accurate and comprehensive assessment of the carbon footprint of traction batteries. Unfortunately, there are few lifecycle assessments (LCAs) of commercial lithium-ion batteries available in the literature, and those that are available focus on the cradle-to-gate stage, often with little or no consideration of the use phase. To address this shortfall, we report both cradle-to-gate and use-phase GHG emissions for the 2020 Model Year Ford Explorer plug-in hybrid electric vehicle (PHEV) NMC622 battery. Using primary industry data for battery design and manufacturing, cradle-to-gate emissions are estimated to be 1.38 t CO2e (101 kg CO2e/kWh), with 78% from materials and parts production and 22% from cell, module, and pack manufacturing. Using mass-induced energy consumptions of 0.6 and 1.6 kWh/(100 km 100 kg) for charge-depleting and -sustaining modes, respectively, the mass-induced use-phase emission of the battery is estimated to be 1.04 t CO2e. We show that battery emissions during the cradle-to-gate and use phases are comparable and that both phases need to be considered. A holistic and harmonized LCA approach that includes battery use is required to reduce carbon footprint uncertainties and guide future battery designs.

A Power-Based Framework for Quantifying Parameter Uncertainties in Finite Vibroacoustic Metamaterial Plates

Vibroacoustic metamaterials (VAMMs) are artificial materials that are specifically designed to control, direct, and manipulate sound waves by creating a frequency gap, known as the stop band, which blocks free wave propagation. In this paper, a new power-based approach that relies on the active structural intensity (STI) for predicting the stop band behavior of finite VAMM structures is presented. The proposed method quantifies the power loss in a locally resonant finite VAMM plate in terms of percentage, such as STI_99% and STI_90%, for stop band prediction. This allows for the quantitative analysis of the vibration attenuation capabilities of a VAMM structure. This study is presented in the context of a two-dimensional VAMM plate with 25 resonators mounted in the middle section of the plate. It has been demonstrated that this method can predict the stop band limits of a finite VAMM plate more accurately than using negative effective mass, unit cell dispersion analysis, or the frequency response function methods. The proposed approach is then implemented to establish a framework for investigating the influence of parameter uncertainties on the stop band behavior of the VAMM plate. Based on the STI_99% method, which aims for significant vibration reduction, stricter tolerances in the mass fabrication process are required to ensure the robustness of VAMM. Conversely, the STI_90% method suggests that larger fabrication tolerances can be leveraged to achieve a broader stop band range while still meeting the desired performance level, leading to cost savings in manufacturing.

Autogeddon or autoheaven: Environmental and social effects of the automotive industry from launch to present

The automotive industry is one of the most significant and increasing sources of pollution worldwide. Previous studies examining its impacts focus on the post-1950 era as data available before this period is scarce. This study carefully reconstructs six datasets from the early 20th century to 2019 for the UK: annual number of motor cars, road lengths, road fatalities, NOx and CO emissions, and fuel consumption. Interpolation was prudently used to fill gaps in the data sets. Results highlight changing health, social and environmental effects throughout the growth of the automotive sector. Ratios of fatalities to cars indicate social ingraining of the car and rapid response to legislation. Significant emissions resulted from the early industry. Successful remediation of emissions occurred in the late 20th century. All variables studied were interrelated, but expansion of road networks particularly contributed to a range of both positive and (unintended) negative consequences. World War 2 appears to have been a landmark for the automotive industry, producing capacity for mass production, personal mobility and research and therefore a struggle between impacts and social policies. We have demonstrated that technological developments and regulatory interventions relating to the motor industry, alongside events that have catalysed societal change, have been crucial in terms of subsequently providing benefits to society whilst also acting to mitigate (but not prevent) the adverse and frequently devastating impacts of motor vehicles on human health and the environment. A periodic, regular, overarching, independent review (~ every 5 years) of the collective positive and negative impacts of the motor vehicle industry and appropriate interventions are essential to maintain and improve social benefits and public and environmental health, as well as supporting delivery of the United Nations' Sustainable Development Goals by 2030 and beyond.

Engineering, Recyclable, and Biodegradable Plastics in the Automotive Industry: A Review

The automotive industry has used plastics almost since the beginning. The lightness, flexibility, and many qualities of plastics make them ideal for the automotive industry, reducing cars' overall weight and fuel consumption. Engineering plastics in this industry belong to the high-performance segment of non-renewable resources. These plastics exhibit higher properties than commodity plastics. Fortunately, unlike recycled commodity plastics, the super properties and high-performance characteristics make engineering plastics effectively reused after recycling. The substitution of these fossil-fuel-derived plastics adds to the solution of lightweighting, a much-needed solution to waste management, and solves industrial and ecological issues surrounding plastic disposal. All major vehicle manufacturers worldwide use bioplastics and bio-based plastics, including natural-fiber composites and engineering plastics reinforced with natural fibers. Changing the source of plastics to raw materials from renewable resources is the logical approach to sustainability. Thus, high-quality plastics, recycled plastics, bio-based plastics, and biodegradable plastics could be exploited from design, making sustainability an integral concept of mobility development. This review analyzes that switching from fossil-fuel- to renewable-sources-derived plastics is a step toward meeting the current environmental goals for the automotive industry, including electric cars.

Carbon Fiber Reinforced Plastics in Space: Life Cycle Assessment towards Improved Sustainability of Space Vehicles

Composite materials, specifically carbon fiber reinforced plastics (CFRPs), are used in various applications such as the automotive, aerospace, and renewable energy industries, thus increasing their global production and volume consumption and creating a subsequent increase in CFRP waste. Especially in space applications and Vega launcher construction, the use of CFRP components to replace metal envisages significant benefits in the use phase by reducing weight and fuel consumption requirements. The current and future waste management and environmental legislation, considering the actual and impending EU framework on waste management, requires all engineering materials to be properly recovered and recycled from EoL products. In this study, the potential of recycling and the subsequent environmental benefits have been assessed by investigating the EoL of CFRPs through a life cycle assessment (LCA). LCA is a valuable tool for evaluating a composite material’s environmental ecological burdens over its lifetime. Therefore, it is important to the composites industry as a material selection tool when determining the applicability of recycled composites in the design phase. Particularly, the benefits from recycling methods were systematically studied in order to assess the environmental impacts of EoL scenarios, to underline the importance and necessity for the maturity increase in recycling technologies for CFRPs.

Review of life cycle models for enhancing machine tools sustainability: lessons, trends and future directions

The life cycle models are critical in the assessment of the performance of a product from the design phase to its end of life (EoL). With the quest for manufacturing sustainability with respect to energy, process, material, and environment friendliness as well as the clamour for circular economy which emphasizes zero tolerance for waste, there is a need for a critical review of the life cycle of machine tool employed for machining operations and product development. The objective of this study is to evaluate the efficient way of managing the machine tools throughout its lifecycle. Several studies have been conducted in analysing the life cycle of the machine tools and different strategies were employed for its design, manufacture, use, maintenance and recovery at the end of life. The common approach to ensure environmental sustainability was established when comparing the literature studied. From the articles reviewed 60% applied life cycle assessment (LCA) methodology to reduce energy consumption and enhance environmental sustainability, while 40% employed other assessment tools. In this study an integrated life cycle and cyber physical machine tool model is proposed.

An Integrated Computational Materials Engineering Framework to Analyze the Failure Behaviors of Carbon Fiber Reinforced Polymer Composites for Lightweight Vehicle Applications

A bottom-up multi-scale modeling approach is used to develop an Integrated Computational Materials Engineering (ICME) framework for carbon fiber reinforced polymer (CFRP) composites, which has the potential to reduce development to deployment lead time for structural applications in lightweight vehicles. In this work, we develop and integrate computational models comprising of four size scales to fully describe and characterize three types of CFRP composites. In detail, the properties of the interphase region are determined by an analytical gradient model and molecular dynamics analysis at the nano-scale, which is then incorporated into micro-scale unidirectional (UD) representative volume element (RVE) models to characterize the failure strengths and envelopes of UD CFRP composites. Then, the results are leveraged to propose an elasto-plastic-damage constitutive law for UD composites to study the fiber tows of woven composites as well as the chips of sheet molding compound (SMC) composites. Subsequently, the failure mechanisms and failure strengths of woven and SMC composites are predicted by the meso-scale RVE models. Finally, building upon the models and results from lower scales, we show that a homogenized macro-scale model can capture the mechanical performance of a hat-section-shaped part under four-point bending. Along with the model integration, we will also demonstrate that the computational results are in good agreement with experiments conducted at different scales. The present study illustrates the potential and significance of integrated multi-scale computational modeling tools that can virtually evaluate the performance of CFRP composites and provide design guidance for CFRP composites used in structural applications.

Automotive Lightweight Design: Simulation Modeling of Mass-Related Consumption for Electric Vehicles

A thorough assessment of Life-Cycle effects involved by vehicle lightweighting needs a rigorous evaluation of mass-induced consumption, on which energy and sustainability benefits during use stage directly depend. The paper proposes an analytical calculation procedure to estimate the weight-related energy consumption of pure Electric Vehicles (EVs), since existing literature leaves considerable room for improvement regarding this research area. The correlation between consumption and mass is expressed through the Energy Reduction Value (ERV) coefficient, which quantifies the specific consumption saving achievable through 100 kg mass reduction. The ERV is estimated for a number of heterogeneous case studies derived from real 2019 European market EV models and according to three drive cycles, to consider different driving behaviors. For the case studies under consideration, ERV ranges from 0.47 to 1.17 kWh/(100 km × 100 kg), with the variability mainly depending on vehicle size and driving cycle. Given the high uncertainty of mass-related consumption on car size, an analytical method is refined to estimate accurately the ERV for any real-world EV model, starting from vehicle technical features. Along with energy assessment, the research also evaluates the environmental implications of lightweight design by means of the Impact Reduction Value (IRV), which is estimated for three distinct electricity grid mixes. Finally, the ERV/IRV modeling approach is applied to a series of comparative lightweight case studies taken from the literature. Such an application demonstrates the effective utility of the work to reduce the uncertainty for all cases where no physical tests or computer-aided simulations are available.

Design of a Lightweight Rear Crash Management System in a Sustainable Perspective

The paper presents an innovative lightweight design solution for the rear crash management system of a C-class car, developed within the AffordabLe LIghtweight Automobiles AlliaNCE (ALLIANCE) EU research project. The innovation provides that the reference version of the module, based on conventional steel components, is revolutionized through the introduction of extruded 6000/7000 series aluminum alloys. The two competing alternatives are described and compared in relation to design and technological solutions, including also a sustainability analysis which assesses the entire Life Cycle (LC) of the system on the basis of a wide range of environmental indicators. The lightweight solution allows achieving a large mass reduction (almost 40%), while providing improvements in terms of strength, production efficiency and design freedom. On the other hand, the introduction of new materials and manufacturing technologies entails contrasting sustainability effects depending on impact category, thus not allowing to affirm that the novel alternative is unequivocally preferable under the environmental point of view. However, the comprehensive evaluation of all sustainability aspects through a multi-criteria decision analysis (TOPSIS method) reveals that the environmental profile of the innovative design is slightly preferable with respect to the conventional one.

Research on Carbon Emissions of Electric Vehicles throughout the Life Cycle Assessment Taking into Vehicle Weight and Grid Mix Composition

To study the impact of the promotion of electric vehicles on carbon emissions in China, the full life carbon emissions of electric vehicles are studied on the basis of considering such factors as vehicle weight and grid mix composition, and fuel vehicles are added for comparison. In this paper, we collect data for 34 domestic electric vehicles, and linear regression analysis is used to model the relationship between vehicle weight and energy consumption. Then, a Hybrid Life Cycle Assessment method is used to establish the life cycle carbon emission calculation model for electric vehicles and fuel vehicles. Finally, the life cycle carbon emissions of electric vehicles and fuel vehicles under different electrical energy structures are discussed using scenario analysis. The results show that under the current grid mix composition in China, the carbon emissions of electric vehicles of the same vehicle weight class are 24% to 31% higher than that of fuel vehicles. As the proportion of clean energy in the grid mix composition increases, the advantages of electric vehicles to reduce carbon emissions will gradually emerge.

Regional Heterogeneity in the Emissions Benefits of Electrified and Lightweighted Light-Duty Vehicles

Electrification and lightweighting technologies are important components of greenhouse gas (GHG) emission reduction strategies for light-duty vehicles. Assessments of GHG emissions from light-duty vehicles should take a cradle-to-grave life cycle perspective and capture important regional effects. We report the first regionally explicit (county-level) life cycle assessment of the use of lightweighting and electrification for light-duty vehicles in the U.S. Regional differences in climate, electric grid burdens, and driving patterns compound to produce significant regional heterogeneity in the GHG benefits of electrification. We show that lightweighting further accentuates these regional differences. In fact, for the midsized cars considered in our analysis, model results suggest that aluminum lightweight vehicles with a combustion engine would have similar emissions to hybrid electric vehicles (HEVs) in about 25% of the counties in the US and lower than battery electric vehicles (BEVs) in 20% of counties. The results highlight the need for a portfolio of fuel efficient offerings to recognize the heterogeneity of regional climate, electric grid burdens, and driving patterns.

Energy Efficiency or Conservation for Mitigating Climate Change?

Given that global energy use today is still dominated by fossil fuels, there is an urgent need to rapidly reduce its use in order to avert serious climate change. However, the alternatives to fossil fuels—renewable and nuclear energy—are more expensive, and have so far done little to displace fossil fuels. Accordingly, reducing energy use must play an important part in both averting climate change and avoiding the depletion of high energy return easily recoverable fossil fuel reserves. This paper examined both the potential and barriers to the adoption of energy reduction measures, with particular attention to domestic energy and passenger transport. The main finding was that energy efficiency approaches alone are unlikely to deliver anywhere near the energy reductions needed in the limited time available. Instead, most energy reductions will have to come from energy conservation, involving less use of energy-using devices, including private vehicles. Achieving such reductions will require changes in lifestyles, especially for residents of OECD nations.

The Technological Progress of the Fuel Consumption Rate for Passenger Vehicles in China: 2009–2016

China has set stringent fuel consumption rate (FCR) targets to address the serious environmental and energy security problems caused by vehicles. Estimating the technological progress and tradeoffs between FCR and vehicle attributes is important for assessing the viability of meeting future targets. In this paper, we explored the relationship between vehicle FCR and other attributes using a regression model with data from 2009–2016. We also quantified the difference in the tradeoff between local and joint venture brands. The result showed that from 2009 to 2016, if power and curb mass were held constant, 2.3% and 2.9% annual technological progress should have been achieved for local and joint venture brands, respectively. The effectiveness of fuel-efficient technologies for joint venture brands is generally better than that of local brands. Impacts of other attributes on FCR were also assessed. The joint venture brands made more technological progress with FCR improvement than that of local brands. Even if 100% of technological progress (assume the technological progress in the future were the same as that of 2009–2016) investment were used to improve actual FCR after 2016, it would be difficult to meet 2020 target. Accelerating the adoption of fuel-efficient technologies, and controlling weight and performance, are both needed to achieve the 2020 and 2025 targets.

Microstructural characterization and film-forming mechanism of a phosphate chemical conversion ceramic coating prepared on the surface of 2A12 aluminum alloy

Phosphate chemical conversion (PCC) ceramic coatings on the surface of 2A12 aluminum alloy substrate have been fabricated by a simple and inexpensive chemical conversion process in CrO₃–NaF–H₃PO₄ solution. Microstructure characterization showed that the average diameter of micro-pores and the thickness of the PCC ceramic coating were about 50 nm and 4 μm, respectively, and the ceramic coating was compact and uniform when the conversion time was 60 min. Meanwhile, we found that the PCC ceramic coating mainly consisted of AlPO₄, AlOOH, AlF₃, and a few amorphous phases (CrPO₄ and CrOOH) via EDS, XRD, XPS analyses. TG-DSC results indicated that the PCC ceramic coatings had excellent thermal stability. Significantly, the adhesion strength (178.55 N) between the PCC ceramic coatings and 2A12 Al substrate was remarkably improved owing to the strong chemical bond between the PCC ceramic coating and 2A12 Al substrate and the increase of surface roughness. Furthermore, a lower corrosion current density (1.382 × 10⁻⁷ A cm⁻²) and a higher corrosion inhibition efficiency (99.91%) confirmed that PCC ceramic coatings had fantastic corrosion resistance because of the presence of crystalline AlPO₄/AlF₃/AlOOH and amorphous CrPO₄/CrOOH as a barrier layer. Additionally, a possible film-forming mechanism of the PCC ceramic coating was proposed during the chemical conversion process, which could be divided into four stages: dissolution of 2A12 aluminum substrate and hydrogen evolution; crystallization of insoluble phosphates and formation of an amorphous phase; growth of insoluble phosphates and dissolution of PCC ceramic coatings; growth and dissolution of PCC coatings to dynamic equilibrium.

Phosphate chemical conversion (PCC) ceramic coatings on the surface of 2A12 aluminum alloy substrate have been fabricated by a simple and inexpensive chemical conversion process in CrO₃–NaF–H₃PO₄ solution.

Green Principles for Vehicle Lightweighting

A large portion of life cycle transportation impacts occur during vehicle operation, and key improvement strategies include increasing powertrain efficiency, vehicle electrification, and lightweighting vehicles by reducing their mass. The potential energy benefits of vehicle lightweighting are large, given that 29.5 EJ was used in all modes of U.S. transportation in 2016, and roughly half of the energy spent in wheeled transportation and the majority of energy spent in aircraft is used to move vehicle mass. We collect and review previous work on lightweighting, identify key parameters affecting vehicle environmental performance (e.g., vehicle mode, fuel type, material type, and recyclability), and propose a set of 10 principles, with examples, to guide environmental improvement of vehicle systems through lightweighting. These principles, based on a life cycle perspective and taken as a set, allow a wide range of stakeholders (designers, policy-makers, and vehicle manufacturers and their material and component suppliers) to evaluate the trade-offs inherent in these complex systems. This set of principles can be used to evaluate trade-offs between impact categories and to help avoid shifting of burdens to other life cycle phases in the process of improving use-phase environmental performance.

A Dynamic Fleet Model of U.S Light-Duty Vehicle Lightweighting and Associated Greenhouse Gas Emissions from 2016 to 2050

Substituting conventional materials with lightweight materials is an effective way to reduce the life cycle greenhouse gas (GHG) emissions from light-duty vehicles. However, estimated GHG emission reductions of lightweighting depend on multiple factors including the vehicle powertrain technology and efficiency, lightweight material employed, and end-of-life material recovery. We developed a fleet-based life cycle model to estimate the GHG emission changes due to lightweighting the U.S. light-duty fleet from 2016 to 2050, using either high strength steel or aluminum as the lightweight material. Our model estimates that implementation of an aggressive lightweighting scenario using aluminum reduces 2016 through 2050 cumulative life cycle GHG emissions from the fleet by 2.9 Gt CO₂ eq (5.6%), and annual emissions in 2050 by 11%. Lightweighting has the greatest GHG emission reduction potential when implemented in the near-term, with two times more reduction per kilometer traveled if implemented in 2016 rather than in 2030. Delaying implementation by 15 years sacrifices 72% (2.1 Gt CO₂ eq) of the cumulative GHG emission mitigation potential through 2050. Lightweighting is an effective solution that could provide important near-term GHG emission reductions especially during the next 10-20 years when the fleet is dominated by conventional powertrain vehicles.

Are functional fillers improving environmental behavior of plastics? A review on LCA studies

The use of functional fillers can be advantageous in terms of cost reduction and improved properties in plastics. There are many types of fillers used in industry, organic and inorganic, with a wide application area. As a response to the growing concerns about environmental damage that plastics cause, recently fillers have started to be considered as a way to reduce it by decreasing the need for petrochemical resources. Life cycle assessment (LCA) is identified as a proper tool to evaluate potential environmental impacts of products or systems. Therefore, in this study, the literature regarding LCA of plastics with functional fillers was reviewed in order to see if the use of fillers in plastics could be environmentally helpful. It was interesting to find out that environmental impacts of functional fillers in plastics had not been studied too often, especially in the case of inorganic fillers. Therefore, a gap in the literature was identified for the future works. Results of the study showed that, although there were not many and some differences exist among the LCA studies, the use of fillers in plastics industry may help to reduce environmental emissions. In addition, how LCA methodology was applied to these materials was also investigated.

Evaluation of Alternatives for the Passenger Road Transport Sector in Europe: A Life-Cycle Assessment Approach

The road passenger transport is responsible for a large share of energy consumption and pollutants emission in Europe. Efforts have been made in the definition of new policies to reduce the environmental impacts of this sector. However, an integrated and consistent assessment of the most promising policies is required, using specific European indicators. For that matter, a life-cycle analysis was applied to the road passenger transport, for the European Union with 27 countries (EU27) in 2010, following a basket-of-products methodology and considering three main stages: production, use, and end-of-life of vehicles. Simapro 8 software was used, along with Ecoinvent 3 database and the impact assessment method International Reference Life Cycle Data System (ILCD) 2011 Midpoint+. Changes in vehicle production processes, vehicle constitution, and energy sources for vehicle propulsion were analyzed. The policies resulting in a decrease in all impact categories are the use of smaller or lightweight vehicles by positively influencing use, production, and end-of-life of vehicles. The use of more recent vehicles technology or diesel vehicles show substantial reductions in, respectively, five and eight impact categories (out of 15), justifying their adoption in the European fleet. Generally, the most notorious policies compared to the actual transport paradigm, like compressed natural gas (CNG), biofuels, or electric vehicles use, show the greatest reduction in climate change (up to 46%) but also a very significant rise of impacts in the categories that in the conventional basket-of-products already resulted in the worst indicators after normalization.

Review of the Fuel Saving, Life Cycle GHG Emission, and Ownership Cost Impacts of Lightweighting Vehicles with Different Powertrains

The literature analyzing the fuel saving, life cycle greenhouse gas (GHG) emission, and ownership cost impacts of lightweighting vehicles with different powertrains is reviewed. Vehicles with lower powertrain efficiencies have higher fuel consumption. Thus, fuel savings from lightweighting internal combustion engine vehicles can be higher than those of hybrid electric and battery electric vehicles. However, the impact of fuel savings on life cycle costs and GHG emissions depends on fuel prices, fuel carbon intensities and fuel storage requirements. Battery electric vehicle fuel savings enable reduction of battery size without sacrificing driving range. This reduces the battery production cost and mass, the latter results in further fuel savings. The carbon intensity of electricity varies widely and is a major source of uncertainty when evaluating the benefits of fuel savings. Hybrid electric vehicles use gasoline more efficiently than internal combustion engine vehicles and do not require large plug-in batteries. Therefore, the benefits of lightweighting depend on the vehicle powertrain. We discuss the value proposition of the use of lightweight materials and alternative powertrains. Future assessments of the benefits of vehicle lightweighting should capture the unique characteristics of emerging vehicle powertrains.

The impact of reducing car weight on global emissions: the future fleet in Great Britain

Current European policies define targets for future direct emissions of new car sales that foster a fast transition to electric drivetrain technologies. However, these targets do not consider the emissions produced in electricity generation and material production, and therefore fail to incentivise car manufacturers to consider the benefits of vehicle weight reduction. In this paper, we examine the potential benefits of limiting the average weight and altering the material composition of new cars in terms of global greenhouse gas emissions produced during the use phase, electricity generation and material production. We anticipate the emissions savings for the future car fleet in Great Britain until 2050 for various alternative futures, using a dynamic material flow analysis of ferrous metals and aluminium, and considering an evolving demand for car use. The results suggest that fostering vehicle weight reduction could produce greater cumulative emissions savings by 2050 than those obtained by incentivising a fast transition to electric drivetrains, unless there is an extreme decarbonization of the electricity grid. Savings promoted by weight reduction are immediate and do not depend on the pace of decarbonization of the electricity grid. Weight reduction may produce the greatest savings when mild steel in the car body is replaced with high-strength steel.This article is part of the themed issue 'Material demand reduction'.

Regional distribution and losses of end-of-life steel throughout multiple product life cycles-Insights from the global multiregional MaTrace model

Substantial amounts of post-consumer scrap are exported to other regions or lost during recovery and remelting, and both export and losses pose a constraint to desires for having regionally closed material cycles. To quantify the challenges and trade-offs associated with closed-loop metal recycling, we looked at the material cycles from the perspective of a single material unit and trace a unit of material through several product life cycles. Focusing on steel, we used current process parameters, loss rates, and trade patterns of the steel cycle to study how steel that was originally contained in high quality applications such as machinery or vehicles with stringent purity requirements gets subsequently distributed across different regions and product groups such as building and construction with less stringent purity requirements. We applied MaTrace Global, a supply-driven multiregional model of steel flows coupled to a dynamic stock model of steel use. We found that, depending on region and product group, up to 95% of the steel consumed today will leave the use phase of that region until 2100, and that up to 50% can get lost in obsolete stocks, landfills, or slag piles until 2100. The high losses resulting from business-as-usual scrap recovery and recycling can be reduced, both by diverting postconsumer scrap into long-lived applications such as buildings and by improving the recovery rates in the waste management and remelting industries. Because the lifetimes of high-quality (cold-rolled) steel applications are shorter and remelting occurs more often than for buildings and infrastructure, we found and quantified a tradeoff between low losses and high-quality applications in the steel cycle. Furthermore, we found that with current trade patterns, reduced overall losses will lead to higher fractions of secondary steel being exported to other regions. Current loss rates, product lifetimes, and trade patterns impede the closure of the steel cycle.

Life Cycle Assessment of Vehicle Lightweighting: A Physics-Based Model To Estimate Use-Phase Fuel Consumption of Electrified Vehicles

Assessing the life-cycle benefits of vehicle lightweighting requires a quantitative description of mass-induced fuel consumption (MIF) and fuel reduction values (FRVs). We have extended our physics-based model of MIF and FRVs for internal combustion engine vehicles (ICEVs) to electrified vehicles (EVs) including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and battery electric vehicles (BEVs). We illustrate the utility of the model by calculating MIFs and FRVs for 37 EVs and 13 ICEVs. BEVs have much smaller MIF and FRVs, both in the range 0.04-0.07 L_e/(100 km 100 kg), than those for ICEVs which are in the ranges 0.19-0.32 and 0.16-0.22 L/(100 km 100 kg), respectively. The MIF and FRVs for HEVs and PHEVs mostly lie between those for ICEVs and BEVs. Powertrain resizing increases the FRVs for ICEVs, HEVs and PHEVs. Lightweighting EVs is less effective in reducing greenhouse gas emissions than lightweighting ICEVs, however the benefits differ substantially for different vehicle models. The physics-based approach outlined here enables model specific assessments for ICEVs, HEVs, PHEVs, and BEVs required to determine the optimal strategy for maximizing the life-cycle benefits of lightweighting the light-duty vehicle fleet.

Variation Trend and Driving Factors of Greenhouse Gas Emissions from Chinese Magnesium Production

As the largest magnesium producer in the world, China is facing a great challenge of greenhouse gas (GHG) emissions reduction. In this paper, the variation trend and driving factors of GHG emissions from Chinese magnesium production were evaluated and the measures of technology and policy for effectively mitigating GHG emissions were provided. First, the energy-related and process-oriented GHG inventory is compiled for magnesium production in China. Then, the driving forces for the changes of the energy-related emission were analyzed by the method of Logarithmic Mean Divisia Index (LMDI) decomposition. Results demonstrated that Chinese magnesium output from 2003 to 2013 increased by 125%, whereas GHG emissions only increased by 16%. The emissions caused by the fuels consumption decline most significantly (from 28.4 to 6.6 t CO2eq/t Mg) among all the emission sources. The energy intensity and the energy structure were the main offsetting factors for the increase of GHG emissions, while the scale of production and the international market demand were the main contributors for the total increase. Considering the improvement of technology application and more stringent policy measures, the annual GHG emissions from Chinese primary magnesium production will be controlled within 22 million tons by 2020.

Impacts of Vehicle Weight Reduction via Material Substitution on Life-Cycle Greenhouse Gas Emissions

This study examines the vehicle-cycle and vehicle total life-cycle impacts of substituting lightweight materials into vehicles. We determine part-based greenhouse gas (GHG) emission ratios by collecting material substitution data and evaluating that alongside known mass-based GHG ratios (using and updating Argonne National Laboratory's GREET model) associated with material pair substitutions. Several vehicle parts are lightweighted via material substitution, using substitution ratios from a U.S. Department of Energy report, to determine GHG emissions. We then examine fuel-cycle GHG reductions from lightweighting. The fuel reduction value methodology is applied using FRV estimates of 0.15-0.25, and 0.25-0.5 L/(100km·100 kg), with and without powertrain adjustments, respectively. GHG breakeven values are derived for both driving distance and material substitution ratio. While material substitution can reduce vehicle weight, it often increases vehicle-cycle GHGs. It is likely that replacing steel (the dominant vehicle material) with wrought aluminum, carbon fiber reinforced plastic (CRFP), or magnesium will increase vehicle-cycle GHGs. However, lifetime fuel economy benefits often outweigh the vehicle-cycle, resulting in a net total life-cycle GHG benefit. This is the case for steel replaced by wrought aluminum in all assumed cases, and for CFRP and magnesium except for high substitution ratio and low FRV.

Life Cycle Assessment of Vehicle Lightweighting: Novel Mathematical Methods to Estimate Use-Phase Fuel Consumption

Lightweighting is a key strategy to improve vehicle fuel economy. Assessing the life-cycle benefits of lightweighting requires a quantitative description of the use-phase fuel consumption reduction associated with mass reduction. We present novel methods of estimating mass-induced fuel consumption (MIF) and fuel reduction values (FRVs) from fuel economy and dynamometer test data in the U.S. Environmental Protection Agency (EPA) database. In the past, FRVs have been measured using experimental testing. We demonstrate that FRVs can be mathematically derived from coast down coefficients in the EPA vehicle test database avoiding additional testing. MIF and FRVs calculated for 83 different 2013 MY vehicles are in the ranges 0.22-0.43 and 0.15-0.26 L/(100 km 100 kg), respectively, and increase to 0.27-0.53 L/(100 km 100 kg) with powertrain resizing to retain equivalent vehicle performance. We show how use-phase fuel consumption can be estimated using MIF and FRVs in life cycle assessments (LCAs) of vehicle lightweighting from total vehicle and vehicle component perspectives with, and without, powertrain resizing. The mass-induced fuel consumption model is illustrated by estimating lifecycle greenhouse gas (GHG) emission benefits from lightweighting a grille opening reinforcement component using magnesium or carbon fiber composite for 83 different vehicle models.

A facile electrochemical approach for the deposition of iron–manganese phosphate composite coatings on aluminium

Cathodic electrochemical treatment is a facile approach for the deposition of iron–manganese phosphate composite coatings on Al.

Global carbon benefits of material substitution in passenger cars until 2050 and the impact on the steel and aluminum industries

Light-weighting of passenger cars using high-strength steel or aluminum is a common emissions mitigation strategy. We provide a first estimate of the global impact of light-weighting by material substitution on GHG emissions from passenger cars and the steel and aluminum industries until 2050. We develop a dynamic stock model of the global car fleet and combine it with a dynamic MFA of the associated steel, aluminum, and energy supply industries. We propose four scenarios for substitution of conventional steel with high-strength steel and aluminum at different rates over the period 2010-2050. We show that light-weighting of passenger cars can become a "gigaton solution": Between 2010 and 2050, persistent light-weighting of passenger cars can, under optimal conditions, lead to cumulative GHG emissions savings of 9-18 gigatons CO2-eq compared to development business-as-usual. Annual savings can be up to 1 gigaton per year. After 2030, enhanced material recycling can lead to further reductions: closed-loop metal recycling in the automotive sector may reduce cumulative emissions by another 4-6 gigatons CO2-eq. The effectiveness of emissions mitigation by material substitution significantly depends on how the recycling system evolves. At present, policies focusing on tailpipe emissions and life cycle assessments of individual cars do not consider this important effect.

Life cycle assessment of vehicle lightweighting: a physics-based model of mass-induced fuel consumption

Lightweighting is a key strategy used to improve vehicle fuel economy. Replacing conventional materials (e.g., steel) with lighter alternatives (e.g., aluminum, magnesium, and composites) decreases energy consumption and greenhouse gas (GHG) emissions during vehicle use, but often increases energy consumption and GHG emissions during materials and vehicle production. Assessing the life-cycle benefits of mass reduction requires a quantitative description of the mass-induced fuel consumption during vehicle use. A new physics-based method for estimating mass-induced fuel consumption (MIF) is proposed. We illustrate the utility of this method by using publicly available data to calculate MIF values in the range of 0.2-0.5 L/(100 km 100 kg) based on 106 records of fuel economy tests by the U.S. Environmental Protection Agency for 2013 model year vehicles. Lightweighting is shown to have the most benefit when applied to vehicles with high fuel consumption and high power. Use of the physics-based model presented here would place future life cycle assessment studies of vehicle lightweighting on a firmer scientific foundation.