2008 dec.bettercar webinar

AluminumBuildsaBetterCar

TheAluminumAssociationAuto&LightTruckGroup(ALTG)

Webinar

Tuesday,December9,2008

www.autoaluminum.org


BuddyStemple,ChairmanoftheALTG,VP/GMofSpecialtyProductsforNovelis

•  ALTGOverview•  AutoAluminum’sResearchOn:

•  FuelEconomy

•  Environment•  Safety• Growth

•  Q&A•  WrapUp

Today’sAgenda

WhatIsTheALTG?

AluminumandFuelEconomy

MichaelBull,directorofAutomotiveTechnologyNovelisInc.

RicardoStudyObjectives

•  Quantifyimpactofvehicleweightreduction(5%,10%,20%)–  Fueleconomy

–  Performance•  Quantifyimpactofweightreductionwithengine

downsizing

–  Maintainvehicleperformancelevel•  Evaluateweightreductionwithdifferentenginetypes

–  Gasoline–  Diesel

•  Fivevehicleclasses–  Representativerangeofvehicleweightsandengines–  Passengerandlight‐dutytruck

•  VehicleClass/ComparatorVehicle

Small Car/Mini Cooper Mid-Size Car/Ford Fusion Small SUV/Saturn Vue

Truck/Toyota Tundra Large SUV/Ford Explorer

VehicleSelection

ModelInput–VehicleParameters

SimulationModel–GeneralDescription

•  Physics‐basedmodelforeachvehicleconfiguration

–  Vehicle–  Engine–  Drivingschedule

•  Simulatesacceleratorand/orbrakingtoachievedrivingschedule

•  Runsonamillisecond‐by‐millisecondbasis•  Simulatesspeedandfuelusage

•  Vehicle–  Configuration(FWD,RWDor

AWD)

–  Weight(front/reardistribution)

–  Wheelbase–  Frontalarea

–  Coefficientofdrag(Cd)–  Centerofgravity

•  Wheels/Tires–  Rollingradius(tiresize)–  Rollingresistancecoefficients

–  Rotationalinertia–  Maximumfrictioncoefficient

–  Slipatpeaktireforce

•  Finaldrive–  Gearratio–  Efficiency–  Rotationalinertia–  Spinlosses–  Spinlosses‐4‐WDoperatingin2WD

SimulationModel–VehicleParameters

•  Engine–  Torquecurves‐fullload,closedthrottlemotoring–  Fuelconsumption‐entirespeedandloadrange–  Idleandredlinespeeds–  Rotationalinertia–  Turbo‐lagmodel(turbochargeddieselengines)–  Parasiticloads:

•  Alternator•  Powersteering•  Coolingfan–electric,beltdriven

•  Transmission–  Torqueconvertercurves–  Gearratios–  Shiftandlock‐upmaps–  Efficiencyandpumpinglosses‐eachgear–  Rotationalinertias

SimulationModel–Engine/TransmissionParameters

VehicleSimulations

•  Vehiclefueleconomy(MPG)–  EPAFTP75(city)–  EPAHWFET(highway)–  ECE(European)–  SteadyState30,45,60and75MPH

•  Vehicleperformance(sec.)–  0–10MPH–  0–60MPH

–  30–50MPH

–  50–70MPH

•  Eachvehicle:–  Baseline–  Baseengine:weightreducedby5%,10%and20%–  Reducedweightandenginedownsizedtomatchthebaselinevehicle

performance

Source:

SimulationDriveCycles

Source:

VehiclePerformanceMatching

ModelValidation

•  Simulationresultscomparedtopublisheddataforthecomparatorvehicle

–  Noattemptto“calibrate”models

VEHICLE

Simulation Roadload Force Simulated Fuel Economy vs. Comparator (% diff)

Maximum Variation vs. Comparator

EPA City EPA Highway Combined

Small Car 0.2% 2.5% -0.6% 1.3%

Mid-Size Car 2.5% 0.2% -1.4% -0.4%

Small SUV 1.1% 1.8% -4.4% -0.4%

Large SUV 1.7% 5.9% -1.1% 3.5%

Truck -1.3% 2.2% -1.9% 0.7%

Mid‐SizeCar–3.0L‐4VGasEngineWithVariableIntakeCamTiming

•  VehiclePerformanceSimulationResultsatFullEngineLoad(WOT)

FuelEconomySimulationResults:

Mid‐SizeCar3.0L‐4VGasEnginewithVariableIntakeCamTiming

Gasoline

PercentFuelEconomyImprovementvs.PercentWeightReduction

Simple weight reduction 10% 3-4%

Gasoline

Weight reduction & resizing 10% 6-7%


Gasoline


ModelInput‐DownsizedGasolineEngines

Whatdoes5,10and20%weightsavingsmeanintermsofaluminum?

Gasoline


AIV

AIV RESIZED

PART SUB.

RicardoStudyFindings

•  Excellentcorrelationbetweensimulationandactualvehicle

•  Fueleconomyimprovementwith10%weightreduction–  Withnoenginedownsizing:

3.5%increaseinEPAcombinedMPG (9%improvementinperformancelevel)

–  Enginedown‐sizedtomaintainbasevehicleperformance:

6.5%increaseinEPAcombinedMPG•  Similarresultsforgasolineanddieselenginevehicles

WeightandCostSummaryFromIBIS

CostandMPGSummary

Midsize Steel Hybrid

Midsize Steel Diesel

Midsize Aluminum Diesel

Midsize Aluminum Baseline

Midsize Aluminum Hybrid

Source: IBIS ’07

CombinedMPGImprovementvs.Costof1MPGImprovement

FuelEfficiency:KeyTakeaway

Byreducingpowerrequirementswithaluminum,vehiclesaremoreaffordableandreducefuelconsumptionwithoutthelossof

performancecapabilities.

AluminumandTheEnvironment

KenMartchek,managerofLifeCycle&EnvironmentalSustainabilityAlcoa

•  Environmentalissuessuchasclimatechangeareagrowingsubjectofconcernandcustomerchoice

AluminumandtheEnvironment

•  TheAluminumindustryhasestablishedandreportsannuallyonglobal,voluntaryimprovementobjectivestoaddressenvironmentissues

•  Learnmoreathttp://www.world‐aluminium.org/Sustainability

AluminumandtheEnvironment

Global,VoluntaryObjectivesInclude:

•  By2010:

–  An80%reductioninPFCgreenhousegasemissionspertonofAL

–  Aminimumofa33%reductioninfluorideemissionspertonofAL

–  A10%reductioninaveragesmeltingenergyusagepertonAL

–  ImplementationofISOEnvironmentalManagementSystemsin95%ofIAImembersplants

•  MonitorannualALshipmentsforuseintransporttotrackaluminum’scontributionthroughlightweighting

•  ReportregularlyonglobalALrecyclingperformance

Thealuminumindustryistheworld’slargestuserofrenewableenergy

AluminumandtheEnvironment:Production

London,UK(October2007)“TheInternationalAluminiumInstitutereportedtodayindustrysurveyresultsshowinga14percentreductionintotaldirectgreenhousegasemissionsfromtheproductionprocessesofprimaryaluminum,between2000and2005,despitea20percentgrowthinprimaryaluminumproductioncoveredinthesurvey.“

Makingprogressinreducingits“carbonfootprint”


Theenergyrequiredtoproducealuminumissmallrelativetoenergyusedbyvehicles(USAMP)

55%ofaluminumusedtoproducetoday’scarsisproducedfromrecycledmetal

Recycledaluminumuses95%lessenergytoproducethanprimaryaluminum


Usinghighstrengthtomassaluminumreducesweightandimprovesfueleconomy

AluminumandtheEnvironment:UseinVehicles

• Over90%ofaluminumisrecoveredfromscrapvehicles

AluminumandtheEnvironment:EndofVehicleLife

• Aluminumisoneofthemostdurableandrecyclablematerials.

•  “ImprovingSustainabilityintheTransportSector”peer‐reviewedstudypublishedearly2008

•  “Theapplicationofaluminuminpassengervehiclesandlighttrucksmanufacturedinmodelyear2006willleadtopotentialsavingsof:–  14.5billiongallonsofgasolineand–  Approximately140milliontonsofCO2eqemissionsoverthelifecycleofthesevehicles.

AluminumandtheEnvironment:FullCycleAssessment

Source: IAI Study 2008

TransportModelDeveloped

Weight Reduction of 1125 Kg (10%)

7% Fuel Efficiency

90 mt of CO2

Lifetime

Example:ChinaCityBus

Value–Ecological•ReductioninCO2emissions•Reducedroadsurfacewearandtear

Value–Financial•7%lessfuel•Maintenancesavings(tires,brakes,suspension)•Improvedcorrosionresistance•Paybackof2‐3years

Partnership with Yutong bus of ZhengZhou, China Launched in Beijing Early 2008

The“TransportModel”canbeassessedhttp://www.world‐aluminium.org/Downloads/Publications/Most+recent

•  InputYourOwnCaseStudyandAssumptions!

TransportModel

Environment:KeyTakeaway

Aluminumproducersarereducingtheirecologicalimpacts.

Utilizingaluminuminvehiclesinplaceofmoredensematerialscanhelpreducethecarbonfootprintofvehicles.

AluminumandSafety

RandallScheps,marketingdirectorofGroundTransportationAlcoa

AFewBasicSafetyFacts

•  Aluminumcanbuildasafercarthansteel‐ AudiA8–oneofthesafestvehiclesontheroad

•  Secondarybenefits:‐ Handling(accidentavoidance)advantages

‐ Brakingdistancereduction•  Directbenefits:

‐  Absorbsmoreenergy,poundforpound,thansteel

‐  Predictabledeformation‐ Notstrain‐ratesensitive‐ Extrudedstructures–designflexibility‐ Bettercrashcompatibility–reduceweight,notsize

1 2 3 4 5 6 7

Mas

s Sp

ecifi

c EA

(kJ/

kg)

Aluminum

Steel

W/t = 60...80 W = width t = wall thickness

t

W

•  ObjectiveoftheDRI(DynamicResearchInc.)study:

‐ Interplayofvehicleweightvs.sizeinoccupantprotection

•  Methodology:

‐ Real‐worldcrashdatafrom3500collisions

‐ CartoSUV,SUVtoSUV,andSUVtofixedobstacle

‐ NCAPpulseandNASS/CDSdescriptors

‐ ELU(InjuryIndex)asproxyforoccupantsafety

•  Scenarios:‐ 20%weightreduction–nolengthreduction

‐ 4inchlengthincrease–noweightincrease

DRIStudyOverview

• AddingcrushspacewithoutaddingweightimprovesELU27%

• Reducingweightfurtherimprovesfleetsafety

SUV to Car Crashes

DRIResults

20% Reduced Weight SUV and Conventional Cars

DRIResults

38.88

• 56%masssavingsvs.mildsteel–(38%vs.HSS)

• Lowerpeakloads• Consistentcrushperformanceatallspeeds

Crush Distance (mm)

Cru

sh L

oad

(kN

)

Aluminum Rail Steel Rail

CrushRailExample

• 35‐50%highermeancrushload

• Lowpeakloads• Nearly100%utilizationofcrushraillength

• Allowsshorterfrontend• Crushloadoptimizedindependentoftherailthickness

• Notpossibleinsteel

50

100

125

50 100 150 200 250

Load due to Taper (This level is not present during crash) Taper-Flare Steady Sate Load

Axial Folding of Same Section Cru

sh F

orce

(kN

)

Crush Distance (mm)

TaperandFlareExample

TaperandFlareExample

Example:

• Extrudedkneebolsterconsolidates3partsinto1

• 48%weightreductionvs.steel

• 50thpercentilemaleunbeltedsledtestpassedforaN.AmericanOEM

KneeBolsterExample

Aluminumcanplayakeyrolein

energymanagementinvehicleinteriors

• Size–notweight–isbestdeterminantofvehiclesafety

• Aluminumcansafelytakeweightout

• Aluminumperformsaswell,ifnotbetterthansteelincrash

• Aluminumoffersdesignflexibilityandinnovativesolutionsforenergymanagement

Safety:KeyTakeaways

Growth

BuddyStemple

AutomakersLightenUp

DaimlerAG“EverynewMercedes‐Benzmodelwillbe5percentlighterthanitspredecessor.”

Nissan“Nissanwillcuttheweightofitsvehiclesbyanaverageof15%overthenextsevenyearsasitseekstoimprovefuelefficiency.”

Ford“EachFordMotorCo.modelwilllose250to750poundsdependingonitsmarketsegment.CuttingweightwillbemoreimportanttoCAFEcompliancethansometoutedfuel‐savingtechnologies.”

GM“Thecompanywillusedifferentmaterials,suchasmoremagnesiumandaluminum,tomakeitsvehicleslighterandmorefuel‐efficient.”

LandRover“TheLRXwasengineeredtomakeitoneofthecleanestvehiclesinitsclass‐‐itslowerweightandreducedaerodynamicdragaidfuelefficiencyandreduceC02emissions.”

Volkswagen“Automakersaresubstitutingaluminumorplasticsforsteelwhereverpossibletoreducevehicles'weight.”

AutoAluminumUseClimbs

***2006 model year


Jaguar XJ

Audi A8

Thefutureofferslighter,cleanerandbetter‐performingvehiclesforallconsumers.

Chevy Tahoe Hybrid Audi TT

Nissan 370Z


BMW X6

Source:DuckerWorldwide

NorthAmericanLightVehicleAluminum

ContentContinuestoClimb


Growth:KeyTakeaway

Aluminumcontinuestoproveitsvalueintheautomotivemarketwithrisingvehiclecontent

formorethanthreedecades.

Question&Answer

Pleasesubmitanyquestionsthroughthequestionmarkonyourscreen.

SoWhatLiesAheadForAutoAluminum?


www.autoaluminum.org