SAMPLE: Vehicle lightweighting intelligence service. Generated: July 9, 2018

Transcription

1 SAMPLE: Vehicle lightweighting intelligence service Generated: July 9, 2018

2 Table of contents Table of contents Introduction... PESTER Analysis... Political... For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to factors such as the increasing impact of passenger and pedestrian safety requirements.... Increasingly, strict global environmental standards and fuel economy regulations have intensified the need to reduce vehicle mass by using lightweight materials in place of high-tension steel or aluminium.... Economic... Automakers are driven to design lightweight cars that will meet increasing fuel efficiency requirements miles per gallon by and satisfy consumer appetite for high-quality vehicles.... Lightweight structures are now more important than ever given the trend toward future-oriented drive technologies such as electric mobility... The automotive market is one of the largest and fastest-growing market sectors for aluminium producers.... The use of plastics, aluminium, magnesium and different grades of steel are all under scrutiny by the vehicle makers in a bid to optimise factors.... Social... As vehicles become smaller, we continue to see a trend towards thinner seats. These are the kind you see in concept cars at auto shows. Not just because they look sleeker, but because they add interior space to the cabin.... The vehicle exterior remains an important element in brand differentiation of vehicle makers and a business card for its owner. Choice of car colour also matters, too.... Technological... Aluminium use in electric and other alternative powertrain vehicles helps offset heavy battery weight, increasing driving range or fuel economy and improving performance... Carbon fibre reinforced plastics (CFRP) have been drawing industry attention as their lightness and strength can help the fuel efficiency of vehicles, but the time-consuming work required to produce the materials is a drawback.... Interest in polycarbonate (PC) automotive glazing is gaining momentum but it s not a gold rush.... Magnesium is the lightest structural metal. It weighs only around a quarter as much as steel and is 35 percent lighter than aluminium.... The use of organic materials in cars is not new. For some time, component suppliers and automakers have focussed on promoting environmentally friendly technologies in all product segments... The use of performance materials such as high strength steel and aluminium is on the rise and heavier traditional materials, such as steel and iron, are being replaced whenever possible.... Environmental... The automotive sector's requirement to meet future emission and CO2 regulations sees engine technology at the centre of most automakers' R&D efforts at present.... The environmental and economic requirements for reduced fuel consumption have also led to an increase in the use of lightweight materials for components that bolt on to a conventional steel vehicle, but at a cost.... Regulatory... Material suppliers are affected by the same challenges as the rest of the industry.... Reduction of copper content in vehicle friction materials is required with the passage of environmental legislation in California and Washington.... Body & exterior... Body-in-white... Aluminium... Carbon fibre...

3 Table of contents Magnesium... Doors and front-end modules... Aluminium... Magnesium... Organic materials... Plastics and composites... Steel... Glazing... Plastics and composites... Roofs... Magnesium... Plastics and composites... Steel... Chassis... Suspension and braking components... Aluminium... Carbon ceramic disc brakes... Organic materials... Plastics and composites... Steel... Tyres... Wheels... Companies... Aluminium... Accuride Corporation... Alcoa Inc... Aleris... Bodine Aluminum... Constellium... Martinrea International... Nemak... Novelis... Shiloh Industries Inc... Showa Denko... Stadco...

4 Table of contents Plastics and composites... 3M... Asahi Kasei Plastics... Autoneum... BASF... Biomer... CIE Automotive SA... ContiTech... Cooper-Standard Automotive... Covestro... Dow Automotive Systems... DuPont... Evonik... Faurecia... Freudenberg... Henkel... Honeywell... Lanxess... LG Chem... Magna International... Minda Corporation... Novares... Oerlikon Balzers... PPG Industries... PT Astra Otoparts... Ricardo... Saint-Gobain... Samvardhana Motherson Group... Solvay... Toray Industries... Toyo Tire & Rubber... Toyoda Gosei... Trelleborg AB... Trinseo... Woodbridge Group... ZF...

5 Table of contents Steel... Aichi Steel... Benteler Automotive... Gestamp Automocion... GF Linamar... JFE Steel... Kobe Steel... NanoSteel Company... Posco... Sumitomo Corporation... Tata Steel... ThyssenKrupp... Forecasts... Aluminium... Glass... Iron... Other materials... Plastics... Steel... Fuel systems... Overview... Plastics and composites... Steel... Future developments... Concept cars... Audi TT Sportback... Citroën C1 Urban Ride... Citroën C4 Cactus... Ford Mondeo... Infiniti Q80 Inspiration... Magna's MILA Blue... Renault Eolab... Toyota C-HR... Other future vehicle lightweighting developments...

6 Table of contents Composite materials... Exhausts... Lotus Engineering... Smart materials... Tubes... Ultra-lightweight sports car... Volvo s lightweight structural energy storage components... Production cars... BMW i3 electric vehicle... Volkswagen XL1 Super Efficient Vehicle (SEV)... Interior... Cockpits... Magnesium... Organic materials... Plastics and composites... Other... Passive safety systems... Seating... Carbon fibre... Magnesium... Organic materials... Plastics and composites... Steel... Material development... Overview... Aluminium... Carbon fibre... Magnesium... Organic materials... Plastics and composites... Steel... Other... Adhesives... Airbags...

7 Table of contents Batteries... Brake pedals... Floor mats... Foam... Glazing... Power electronics... Starter motors... Wiring harnesses... Powertrain... Engines... Driveline... Aluminium... Carbon fibre... Magnesium... Organic materials... Plastics and composites... Steel... Recycling initiatives... Batteries... Doors & front-end modules... Glass... Plastics and composites... Seating... Steel... Tyres... Wheels...

8 Introduction Introduction For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to factors such as the increasing impact of passenger and pedestrian safety requirements and the competitive intensity caused by globalisation and manufacture in low cost economies. Governmental pressure in Europe and North America to reduce the CO2 emissions has also prompted automakers and their supply base to develop automotive technology to meet those strict emission limits. Consequently, more and more vehicles are incorporating components aimed at mass reduction, parts consolidation to reduce assembly costs and more efficient recycling. The automaker's need to improve overall fuel economy in vehicles has led to the trend toward minimising vehicle weight. The use of performance materials such as high strength steel and aluminium is on the rise and heavier traditional materials, such as steel and iron, are being replaced whenever possible. The VW Golf VII is a prime example of the trend for lightweighting, weighing in X kg lighter than its predecessor. As this report highlights, the latest generation Golf offers a carbon fibre roof as an option on performance models. The roof saves approximately X kg which helps clearly improve performance and fuel economy. This move further demonstrates how far the use of carbon fibre in vehicle manufacture has come. Indeed, it is no longer the preserve of the luxury class but could soon become common place in mid range segments. The car body itself is said to be X kg lighter than the last generation Golf. The weight loss here is due to the use of new materials and manufacturing processes, including the use of laser stir welding, also known as the wobble method. Other notable new models that have shed some weight include: The Ford F-X is about 315kg lighter than its predecessor; The 2015 Mazda MX-X roadster is 100kgs lighter compared to its predecessor; Depending on the engine version, the new Audi A3 weighs up to 80kg less than its predecessor; The new Skoda Fabia five-door hatchback is shorter than its predecessor but roomier and weighs an average 65kg less; The new BMW M4 is 54kg lighter than the old M3; And thanks to some advances in battery technology, the 2016 Chevrolet Volt is about 10kg lighter than its predecessor. Next generation models are expected to shed even more weight. For instance, the Ford Mondeo concept weighs in at X,195kg, equivalent to the current diesel-powered Fiesta. The concept features parts such as carbon fibre seats and X-inch wheels, high-strength steels, aluminium in the chassis and composite springs for the front suspension. The net result of such efforts to reduce vehicle weight are faster acceleration and improved fuel economy over the X.4mpg offered by today's car... 1

9 PESTER Analysis PESTER Analysis Political For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to factors such as the increasing impact of passenger and pedestrian safety requirements. Governmental pressure in Europe and North America to reduce the CO2 emissions has also prompted automakers and their supply base to develop automotive technology to meet those strict emission limits... Economic Automakers are driven to design lightweight cars that will meet increasing fuel efficiency requirements miles per gallon by and satisfy consumer appetite for high-quality vehicles. Adopting lightweight polymers and polyurethane composites to replace traditional materials such as glass and metal in exterior applications, including window glazing and body panel components, clearl... Social As vehicles become smaller, we continue to see a trend towards thinner seats. These are the kind you see in concept cars at auto shows. Not just because they look sleeker, but because they add interior space to the cabin. As manufacturers attempt to add more features and create more interior space in the small car segment, designers and material suppliers are being urged to come up with new ideas, such as slimline sea... Technological Aluminium use in electric and other alternative powertrain vehicles helps offset heavy battery weight, increasing driving range or fuel economy and improving performance....

10 PESTER Analysis Environmental The automotive sector's requirement to meet future emission and CO2 regulations sees engine technology at the centre of most automakers' R&D efforts at present. While other elements such as the drivetrain, body materials, aerodynamics and tyres can all be further optimised for fuel economy the engine is by far the biggest contributor to energy losses in a... Regulatory Material suppliers are affected by the same challenges as the rest of the industry. Everybody in the supply base faces reduced global demand at the moment and is anticipating the return of consumer confidence, economic recovery and new car sales in North America and Europe. China&rs...

11 Body & exterior Body & exterior

12 Chassis Chassis

13 Companies Companies This section is not intended to include all material manufacturers. Instead, it draws attention to a growing list of companies - broadly categorised by material - which have developed or advanced the use of materials used in vehicle manufacture.

14 Forecasts Forecasts This section sets out our estimates and forecasts of the use of the main materials used in vehicle manufacture, namely steel, iron, aluminium, plastics and glass across X of the world s largest light vehicle markets - which collectively account for more than X per cent of world light vehicle production. Our forecasts range is from 2008 through to 2020 with spot forecasts for 2025 and For each material, our forecasts set out the percentage of the total kerb weight of a medium-sized passenger car, e.g. VW Golf, Ford Focus. Today, such cars in Europe weigh in at around X,X kg (or X.X metric tons) compared to about X kg in the 1970s. In North America, an average sized passenger cars weighs approximately X,X kg. Smaller European cars, such as the Fiat Punto currently weigh about 1000 kg whereas larger cars, such as a 4x4, typically weigh approximately X,X kg. Despite its impact on fuel consumption, the average mass of vehicles has increased over the past X years. For example, a Ford Escort weighed in at around X pounds in By 1998, a Ford Focus weighed approximately X,X pounds. As the slide opposite shows, the VW Golf GTI has gained weight too. According to the European Aluminium Association, the weight increase across all vehicle models is due to more stringent legislative requirements and changing customer demands (i.e. growing vehicle size, extra comfort and safety features) and that, in turn, has caused an increase in weight of other components, such as brakes, engines and transmissions...

15 Fuel systems Fuel systems Overview Fuelled by the need to save weight and reduce evaporative emissions, a great deal of innovative design and materials work is going into vehicle fuel tanks. For instance, TI Automotive believes that the main driver for fuel tank systems designs are the legislative requirements in regards to permeation. An executive told us: In addition, space is at a premium within a vehicle body and it becomes more and more critical to get the space necessary for a fuel tank meaning fuel tank producers must be more creative when it comes to design. In addition, components that reduce tailpipe emissions and hybrid vehicles are taking away the space that was traditionally reserved for the fuel tank. In hybrid vehicles, fuel slosh noise reduction is getting more focus. This is especially needed for start-stop vehicles where the car becomes very silent - while standing at a traffic light for example. To address these issues, TI Automotive is developing and producing plastic fuel tanks in complex shapes and sizes, which enables self-damping, reduces emissions and weight and allows for the insertion of slosh walls to reduce noise and improve stiffness in hybrid vehicles. This section further illustrates the ways in which manufacturers are using steel and plastic to make lighter fuel tanks.

16 Future developments Future developments Concept cars draw attention by showcasing new styling and/or technologies. For instance, the Swiss manufacturer and tuning designer Rinspeed attracted a lot of attention at the 2013 Geneva motor show for its so-called micromax commuter electric vehicle concept which is designed to travel short distances in urban environments. The model is X.X metres long, X.X metres tall - equivalent size to a BMW Mini - and has acoustic pedestrian safety system. On the glazing front, the windows are made of Plexiglas with a non-scratch coating. Both help keep the weight low. Rinspeed s CEO, Frank Rinderknecht told us: We chose this material due to its lightweight, particularly for an electric car. From a design perspective, we wanted to have this ability for vehicle occupants to see all around them. In this section, we highlight a number of other concept cars shown recently that demonstrate some measures being taken to push back the lightweighting boundaries. In explaining the difference between a functional concept car and an engineering prototype, Paul Cerisola, Quality Manager at Envisage told just-auto: Engineering prototypes are built with much greater budgets, later in the programme when significant funding has been approved so they can be much closer to production intent and generate useful engineering data. Functional concept cars do not compete with engineering prototypes but form part of the decision-making process to go ahead with a project. They can also give early warning of potential issues directly improving the quality of prototype designs. So we asked how does a functional concept car help to identify potential issues? He added: Complex styled surfaces often introduce challenges such as door sealing and shut lines, requiring careful hinge design and adjustment. Creating a functional concept car introduces the discipline of 'design for manufacture and assembly' which helps to avoid unforeseen issues downstream, at which point they are more expensive to fix. As more complex body-in-white material combinations are introduced, our approach helps identify any feasibility concerns regarding bonding between aluminium and composite components, the location of rivets and joint lines and other manufacturability issues, before the concept is approved.

17 Interior Interior

18 Material development Material development Overview According to VCD Verkehrsclub Deutschland, reducing the weight of a vehicle by X kilograms lowers fuel consumption by X.X litres over a distance of X kilometres and cuts carbon dioxide emissions by X.X kilograms over the same distance. Lightweight structures are now more important than ever given the trend toward future-oriented drive technologies such as electric mobility. Although the car is built from many different materials, its main structure known as the body in white (BIW) is usually made of steel pressings welded together to form a strong and stiff frame. According to Corus, this method of construction accounts for X.X percent of all cars produced in the world. The remaining X.X percent are mostly constructed with an aluminium BIW, while a very small number (fewer than X.X percent) are constructed from carbon fibre composite. The BIW of a vehicle accounts for X percent of the vehicle mass, says Corus. The weight of the closures (doors, bonnet and boot/rear hatch), chassis (suspension parts) and driveline bring the total amount of steel and other ferrous metals to more than X percent. Tata Steel (formerly Corus) reports that, in recent years, the amount of ferrous metal has declined, mostly driven by manufacturers replacing iron with aluminium for engine castings. The percentage of sheet steel per car has also dropped, mainly due to: higher levels of equipment, trim and sound-proofing; more aluminium used in wheels and suspension parts; more moulded plastics, especially under the bonnet. The environmental and economic requirements for reduced fuel consumption have also led to an increase in the use of lightweight materials for components that bolt on to a conventional steel vehicle, but at a cost. The following table indicates the potential weight savings of using alternative materials to steel and the additional cost involved...

19 Other Other

20 Powertrain Powertrain Engines The automotive sector's requirement to meet future emission and CO2 regulations sees engine technology at the centre of most automakers' R&D efforts at present. While other elements such as the drivetrain, body materials, aerodynamics and tyres can all be further optimised for fuel economy the engine is by far the biggest contributor to energy losses in a conventional driveline and, therefore, the biggest target for reducing CO2 emissions. Depending on operating load conditions, the engine contributes anywhere between X and X percent of the energy losses in a vehicle. ZF, the transmission and driveline supplier, estimates that the engine contributes X percent of losses followed by the driveline (X percent), rolling resistance and aerodynamics (each with X percent), weight (X percent) and auxiliary systems (X percent). While work on improving driveline losses, reducing vehicle weight etc. is all ongoing in automakers' R&D departments, engine development remains key to meeting future emission legislation and also for maintaining automakers' brand attributes in terms of performance, driver feedback, comfort and control. During an interview with just-auto, Gian Maria Olivetti, Vice President of pistons, rings and liners was asked for his opinion of alternative materials and lightweighting? He told us: I don't see a revolution in the direction of lightweight material. I see a trend continuing to downsize the engine. Look at how many three cylinders will be in the market in the coming years. I think people are [prepared] to pay for consumption and also it means environmentally-friendly because consumption means CO2. Driveline Aluminium Alcoa has developed a new lightweight alloy, called MagnaForce. The supplier claims it is, on average, X.X percent stronger than the industry standard, Alcoa's 6061 alloy, in similar applications. Alcoa will use the material to manufacture wheels for commercial vehicles...

21 Recycling initiatives Recycling initiatives