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Vehicle Technologies Program Will Joost Energy, Materials, and Vehicle Technology Area Development Manager Weight Reduction Lightweight Materials Vehicle Technologies Program 1 | Program Name or Ancillary Text eere.energy.gov Vehicle Technologies Program Program Manager Administration Patrick Davis Maxine Robinson Bernadette Jackson Johnathan Wicker FreedomCAR and Fuel Partnership 21st Century Truck Partnership Director – Christy Cooper Director – Ken Howden Yury Kalish Analysis Chief Scientist Phil Patterson James Eberhardt Jake Ward Education and Outreach Budget Program Analyst Connie Bezanson Noel Cole Supervisory General Engineer Supervisory General Engineer Steve Goguen Ed Owens Fuels Technology Advanced Combustion Engine R&D Hybrid Electric Systems Materials Technology Team Lead – Kevin Stork Team Lead – Gurpreet Singh Team Lead – Dave Howell Team Lead – Carol Schutte Advanced Petroleum Based Fuels Combustion & Emission Controls Vehicle Systems Lightweight Materials Steve Przesmitzki Ken Howden Lee Slezak Will Joost Non-Petroleum Fuels Roland Gravel David Anderson Propulsion Materials Dennis Smith Solid State Energy Conversion Energy Storage Jerry Gibbs Technology Integration/ John Fairbanks Tien Duong HTML Clean Cities Brian Cunningham Carol Schutte Dennis Smith Peter Faguy Linda Bluestein Power Electronics & Electric Motors Shannon Shea Susan Rogers Mark Smith Steven Boyd Legislation/Rulemaking Dana O’Hara 2 | Vehicle Technologies Program eere.energy.gov The Plan • Why reduce vehicle weight? • What does weight reduction look like today? • How can we move forward? 3 | Vehicle Technologies Program eere.energy.gov U.S. Total Energy Flow (QBtu) - 2010 Transportation accounts for ~28% of U.S. energy consumption Energy Information Administration (www.eia.gov) 4 | Vehicle Technologies Program eere.energy.gov U.S. Petroleum Flow (Mbpd) - 2010 94% of transportation 71% of petroleum is used energy is from petroleum in transportation Energy Information Administration (www.eia.gov) 5 | Vehicle Technologies Program eere.energy.gov Transportation Energy Consumption by Mode - 2009 Military Rail Water 3% 2% 5% Non-highway On-highway consumption ~10.6 mbpd Air Buses 10% U.S. domestic production 1% Light Trucks Med. Trucks 34% ~5.3 mbpd 3% Heavy Trucks 13% Highway Cars 29% Energy Information Administration (www.eia.gov) 6 | Vehicle Technologies Program eere.energy.gov Energy flow in a typical ICE vehicle 100% 62% Energy to the wheels - Aerodynamic Engine 12% Drag Loss - Rolling (Heat) Resistance - Inertia (acceleration) Engine Loss Drive Train (Mechanical) Loss (Mechanical) 7 | Vehicle Technologies Program eere.energy.gov Mass and Fuel Consumption b = Specific Fuel Consumption (Heat/Mech Loss) Fuel FT = Tractive Forces (Drag, Inertia, Rolling) Consumed η = Drivetrain Efficiency (Mechanical Loss) Cheah, L. Cars on a Diet: The Material and Energy Impacts of Passenger Vehicle Weight Reduction in the U.S., 2010. 8 | Vehicle Technologies Program eere.energy.gov The Mass Effect • We know that mass affects tractive forces – Rolling resistance, inertial forces • The relationship between mass and energy consumption is complicated by a variety of factors – Averages/fleet mix – Mass compounding – Vehicle design – Powertrain resizing – Material energy content • So how does vehicle mass affect vehicle efficiency? 9 | Vehicle Technologies Program eere.energy.gov What can weight savings do for you? Improve performance Increase freight efficiency Extend electric range • Fuel economy • Freight efficiency when • Increase range with • Acceleration weight limited existing battery • Gradability • Fuel efficiency when • Maintain range with volume limited smaller battery • Handling/Feel • Optimize for • Safety? requirements 10 | Vehicle Technologies Program eere.energy.gov Weight Reduction and Fuel Economy Fuel Economy vs. Mass Fuel Economy vs. Mass Conv Conv w/Resizing Conv Conv w/ Resizing 32.0 50.0 45.0 31.0 40.0 30.0 35.0 30.0 29.0 25.0 Fuel Economy (mpg) Economy Fuel Fuel Economy (mpg) Economy Fuel 20.0 28.0 15.0 27.0 10.0 75% 80% 85% 90% 95% 100% 0% 50% 100% 150% 200% 250% Percent of Baseline Vehicle Mass Percent of Baseline Vehicle Mass Ricardo Inc., 2008 FAST Model, NREL 2011 Conv. Midsize Sedan: 6.8% improvement in Conv. Midsize Sedan: 6.9% improvement in fuel economy for 10% reduction in weight fuel economy for 10% reduction in weight 11 | Vehicle Technologies Program eere.energy.gov Weight Reduction and Performance Acceleration vs. Mass Gradability vs. Mass Conventional Conventional 9.8 10 9.6 9 9.4 8 9.2 9 7 8.8 6 60 Time (seconds) 60 - 0 8.6 Max Grade in Top Gear (%) Gear Top in Grade Max 5 8.4 8.2 4 75% 80% 85% 90% 95% 100% 50% 60% 70% 80% 90% 100% Percent of Baseline Vehicle Mass Percent of Baseline Vehicle Mass Ricardo Inc., 2008 Conv. Midsize Sedan: 7% improvement in Conv. Midsize Sedan: 25% improvement in 0-60 time for 10% reduction in weight gradability for 10% reduction in weight Performance improvements compete with resizing design objectives 12 | Vehicle Technologies Program eere.energy.gov Heavy Duty Vehicles + = 80,000 lbs Empty Trailer Tractor Cargo 13,000 lbs (16%) 16,000 lbs (20%) 51,000 lbs (64%) Fixed Load Added Load Ricardo Inc., 2009 - 100.0 • 50% reduction in tractor/trailer weight 98.0 23% reduction in total weight 96.0 • You can’t “lightweight” cargo 94.0 92.0 miles/gallon) You can increase freight efficiency 90.0 Freight Efficiency (Ton Efficiency Freight 88.0 86.0 92% 94% 96% 98% 100% Percent of Baseline Vehicle Mass Without Cargo 13 | Vehicle Technologies Program eere.energy.gov Weight Reduction and “Electric Vehicles” EV Range vs. Mass Fuel Economy vs. Mass Kan, Y et. al JISSE-10, 2007 Conv Conv w/Resizing 290 HEV HEV w/Resizing 270 70.0 250 60.0 230 210 50.0 190 Electric Range (km)Electric 40.0 170 150 30.0 60% 70% 80% 90% 100% Fuel Economy (mpg) Economy Fuel Percent of Baseline Vehicle Mass (%) 20.0 BEV Midsize Sedan: 13.7% improvement in 10.0 electric range for 10% reduction in weight 0% 50% 100% 150% 200% 250% Percent of Baseline Vehicle Mass FAST Model, NREL 2011 Battery Cost Savings HEV Midsize Sedan: 5.1% improvement in • $/kWh fixed fuel economy for 10% reduction in weight • Fewer kWh to maintain range … Design balance including cost! 14 | Vehicle Technologies Program eere.energy.gov The Mass Effect • Directly calculating the impact of vehicle weight reduction on energy consumption is difficult – Complicated by mass compounding, design, material energy content, etc. • Mass reduction does provide improvements – Typical ICE Vehicles Efficiency, performance, and optimization – Heavy Duty Vehicles Freight Efficiency – HEV/PHEV/BEV Range, battery size, and cost • Impact on Energy Consumption – Nearer term: 30% light duty wt. reduction, 15% heavy duty wt. reduction Potentially more than 2 QBtu per year saved! – Longer term: 45% light duty wt. reduction, 25% heavy duty wt. reduction Potentially more than 3.5 QBtu per year saved! 15 | Vehicle Technologies Program eere.energy.gov Weight Reduction Potentials Relative Cost Lightweight Material Material Replaced Mass Reduction (%) Per Part Magnesium Steel, Cast Iron 60 - 75 1.5 - 2.5 Carbon Fiber Composites Steel 50 - 60 2 - 10+ Aluminum Matrix Steel, Cast Iron 40 - 60 1.5 - 3+ Composites Aluminum Steel, Cast Iron 40 - 60 1.3 - 2 Titanium Steel 40 - 55 1.5 - 10+ Glass Fiber Composites Steel 25 - 35 1 - 1.5 Advanced High Strength Mild Steel 15 - 25 1 - 1.5 Steel High Strength Steel Mild Steel 10 - 15 1 16 | Vehicle Technologies Program eere.energy.gov Example Component Lightweighting - Mg engine cradle for Corvette Z06 - AHSS rear cradle for RWD vehicles - 35% lighter than Al - 27% lighter than conventional design, no - Single piece Mg casting vs. multi-piece loss of stiffness steel assembly - Cost neutral - Carbon Fiber Composite seat structure - 58% lighter than standard design - Mg engine block, bedplate, oil pan, and engine cover - 28% lighter than Al version 17 | Vehicle Technologies Program eere.energy.gov Example System Lightweighting EU Super Energy Light Car Foundation - Lotus - Multi-material vehicle, Al intensive - AHSS intensive vehicle - 30% weight reduction for BIW - 16% weight reduction for BIW Mg Front End PNGV - Mg intensive front end structure - Multi-material vehicles - 45% weight reduction compared to steel - ~25% overall vehicle weight reduction - 56% reduction in part count 18 | Vehicle Technologies Program eere.energy.gov Characteristics of Production Vehicles Vehicle Material Content vs. Year Average Curb Weight vs. Year - EPA Midsize Car 18.0% 3900 16.0% 3800 14.0% HS and MS 3700 Steel 12.0% 3600 Aluminum lbs.) 10.0% 3500 8.0% Magnesium ( Weight 3400 6.0% 3300 Polymers 4.0% and 3200 Composites Percentage of Total Vehicle Mass (%) Mass Vehicle Total of Percentage 2.0% 3100 0.0% 3000 1980 1990 2000 2010 1980 1985 1990 1995 2000 2005 2010 Production Year Production Year Wards, American Metals Market EPA 19 | Vehicle Technologies Program eere.energy.gov Advanced Material Vehicles Vehicle Curb Weight vs. Footprint • Some advanced 5000 material use is 4500 “tactical”… 4000 Audi A8 …hoods, interior Ferrari F430 pieces, etc. 3500 lbs.) 3000 Corvette Z06 • A few vehicles use 2500 advanced materials at ( Weight Curb a full-vehicle level… 2000 Lotus Exige …but do not save 1500 considerable weight! 1000 20 40 60 80 100 120 140 Footprint (sq-ft) 20 | Vehicle Technologies Program eere.energy.gov The Weight Reduction Story • Lightweight materials have found increased application in production vehicles • Weight reduction doesn’t always result in weight reduction – Offset by the
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