Developing aluminium sheet making use of wider scrap sources. Adrian Tautscher Materials Engineering Jaguar Land Rover

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1 Developing aluminium sheet making use of wider scrap sources Adrian Tautscher Materials Engineering Jaguar Land Rover

2 Range Rover History 2

3 New Range Rover JLR LIGHT WEIGHT VEHICLE STRATEGY 3

4 New Range Rover 4

5 New Range Rover Solihull Manufacturing Plant Manufacture of Defender, New Range Rover, Discovery & Range Rover Sport Models Total Plant Capacity 210k to 320k per Annum 5

6 New Range Rover The All-New Range Rover: Body Less Doors Overview Component Type % Part No. Stampings 88% Castings 5% Profiles 3% Tubes 3% Other 1% 6

7 New Range Rover The All-New Range Rover: Materials & Components: 6xxx alloys applied for improved strength & weight reduction AC600T61 Crash Alloy One Piece Bodyside in AC170PX Post Form Heat Treated (PFHT) 6111T4 alloy Castings used for part integration & stiffness Aluminium Rolled Section & Profile applications Friction Stir Welded Sub-frame Reinforcement 7

8 New Range Rover Body Complete: Material Breakdown 6% 1% 4% 15% 37% Al sheet 6xxx Al sheet 5xxx Al casting Al extrusion HSS steel PHS steel by mass 37% 8

9 New Range Rover Process of Self-Pierce Riveting (SPR). Punch Blankholder Rivet 2T joint Die Place two or more layers of materials on top of a die Clamp the layers of materials between the blankholder and die Drive a semitubular rivet piercing through the top layer(s) Flaring into the bottom layer to form a mechanical interlock Lift the blankholder 3T joint 9

10 New Range Rover LWV Strategy: Virtuous Circle of Weight Reduction Reduced body weight creates a virtuous circle of weight reduction Every 100kg saved in the vehicle mass saves around 2% in fuel consumption Target at least 400kg vehicle save 8% better fuel efficiency overall as a direct result of the 420kg weight save 10

11 New Range Rover LWV Strategy: Vehicle Weight Reduction Previous Range Rover All-New Range Rover Achieved weight saving of 420kg 2580kg 300kg Aluminium body & closures, smc tailgate aluminium suspension & subframes 120kg TDV6 powertrain systems 420kg 2160kg Reduced weight improves vehicle dynamics Aluminium and other Light Weight parts reduce overall carbon footprint BIW 40% 190kg LIGHTER THAN THE STEEL EQUIVALENT 11

12 New Range Rover LWV Strategy: System Weight Reduction Aluminium Body & Closures Aluminium intensive Suspension & Sub-frames Magnesium castings (Cross Car Beam & Front End Carrier) Composite plastic upper tailgate Aluminium brake callipers Aluminium space saver wheel Optimised part & systems for maximum weight save 12

13 A leader in Automotive Innovation World-First Full Electric Drive Premium F-Segment Technology Demonstrator. World-First Adaptive Cruise Control World-First Automatic Terrain Response System. (in development) World-First Stop-Start Mid-size SUV. Limo-Green World-First User-Selectable Terrain Response System. World-First Dual-View Screen Low Carbon Propulsion/ KE recovery. Vehicle Capability Gen. 1 Gen. 2 Energy Efficiency/ Parasitics Light-weight Vehicles Product Life-cycle What Makes Us Different Human/Vehicle Interaction Design Enabling World-First Capacitive Sense Interior Switches. World-First Aluminium monocoque bodyshell World-First Closed-Loop Aluminium Re-Cycling World-First Pyrotechnic Deployable bonnet protects Pedestrians whist maintaining Sleek Design. 13

14 Product Life Cycle Analysis Production, 14% Use, 85% Disposal, 1% Raw material Energy Energy Energy Production Use Disposal (MJ/kg) Waste Emissions to air and water Waste Emissions to air and water Waste Emissions to air and water 0 Steel Aluminum Magnesium CDRC Production End of Life 14

15 REALCAR Recycled Sources Recycling Opportunities MaDE - ELV 15

16 REALCAR Project Technology Strategy Board REALCAR Recycled Aluminium Car Jaguar Land Rover research project Technologies for Low Carbon Vehicles TSB project Consortium Partners 16

17 REALCAR Project Technology Strategy Board Project Summary Technology Strategy Board Low Carbon Vehicle call Budget 2m Partners: JLR (lead), Novelis, Innoval, Norton Aluminium, Brunel University, Stadco, Zyomax Duration: 3 years TSB funding completed Nov. 11 REALCAR has delivered a high iron tolerant alloy that allows all 5754 series aluminium press shop scrap to be recycled back into the alloy (50%) TSB Low Carbon Call

18 REALCAR Materials Characterisation Self-Pierce Rivets Crush Tube Corrosion Plaque Stampings: Tyre Tub Stampings: Dash Panel Stampings: Bracket 18

19 REALCAR Production Scrap Press shop scrap strategy: Scrap rate from stamping process approximately 50% Closed loop of press shop scrap for re-melting into new sheet Separation between 5xxx & 6xxx alloys Ensure separation of steel in mixed metal press shops Castle Bromwich press shop current Jaguar Land Rover model for scrap segregation Planned adoption with external stamping suppliers I54 Engine Plant Study ongoing to assess swarf segregation New aluminium alloy: Fully characterised Allows higher Fe content Material inputs, process scrap & primary metal Press Shop Segregation 19

20 REALCAR 2 Project Technology Strategy Board REALCAR 2 Recycled Aluminium Car Jaguar Land Rover research project Technology Inspired Innovation TSB project Consortium Partners 20

21 REALCAR 2 Project Technology Strategy Board Project Summary Technology inspired innovation call Category Advanced Materials 500 applications (10% success rate) Budget 1m Partners: JLR (lead), Novelis, Innoval, Aleris Recycling, Warwick University Duration: 2 years REALCAR 2 target is to supplement our process scrap with post consumer non-auto scrap to achieve higher recycling rates (and reduce cost) for our 5xxx series body sheet; up to a further 25% TSB Technology Inspired Call

22 REALCAR 2 Project Aluminium Sources Recycled Aluminium Opportunities Post consumer waste: Mechanical Biological Treatment plants Waste to energy plants Material quality impacts Cost opportunities Energy from Waste (EfW) Aluminium Remelter Mechanical Biological Treatment (MBT) End-of-Life vehicle waste: Closed loop use of materials from vehicle shredding Post consumer aluminium waste Responsible materials use: Ethical sourcing of materials EU legislation by 2020 Note: 2009 = 40,500 tonnes land filled in UK (Source: Alupro) Scrapped Vehicles Industrial Shredder End-of-Life vehicle processing Separated Aluminium Shred 22

23 REALCAR 2 Project Alloy Development Scrap separation & melt trials (Aleris) Post consumer scrap sourcing Separation trials from MBT waste Melt trials to achieve a suitable chemistry Laboratory strips (Novelis): Production of rolling blocks/narrow strips at Novelis Production coils (Novelis): Full size coils produced by Novelis Main Project Deliverables Materials characterisation (JLR/Warwick): Track all testing against project plan Alupro study: MBT aluminium cost and sourcing opportunity 23

24 MaDE ELV Project Materials & Design Exchange End-of-Life Vehicles Jamie Shaw Marie Parsons Linda George Kat Rawlings Adrian Tautscher Nat Spencer Pat Winfield MaDE ELV is improving links and understanding between materials selection and vehicle/component design and their impact on CO 2 life cycle. Specific focus is on end-of-life vehicles including options with recycling, disassembly, reuse and disposal Richard Winsor Julian Reichman Merih Kunur Brian Knott Linda Barron Geoff Hollington Alison Prendiville 24

25 MaDE - ELV Project ELV Recycling Opportunities: Up front use of LCA to influence materials selection/design Increased use of recycled materials Materials with increased tolerance to a higher recycled content Vehicles Post Crushing Closed loop of shredder waste Re-use/disassemby options (high value parts) Reduced part complexity/reduced range of materials Future impact of EV s & modular construction Vehicle Shredding 25

26 MaDE - ELV Project JLR vehicle component teardown: Presentations from JLR and the vehicle shredding company SIMS JLR supplied 8 components for study: Front Seats Front Doors Centre Console Instrument Panel Controlled vehicle component teardown to assess construction, materials and ease of disassembly Conducted by students from Oxford Brookes University, Royal College of Art and Loughborough University 26

27 MaDE - ELV Project Seat Granular Study: 1988 Range Rover seat - very few parts + limited selection of materials 2010 Range Rover seat - high feature and complexity + high value components Opportunities: Use less material More recycled materials Part integration Innovative Design solutions High value parts re-use 27

28 MaDE - ELV Project 1988 Range Rover Seat 2010 Range Rover Seat 28

29 REALCAR - Improved Recycling Every Can Counts Initiative Adoption at Jaguar Land Rover: 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 Can Crushing Bin Every Can Counts Video of introduction at Jaguar Land Rover JLR Case Study 29

30 THANK YOU Adrian Tautscher 30