WORKING PAPER 2018-16

Fuel-efficiency technology trend assessment for LDVs in China: Vehicle technology

Authors: Zifei Yang Date: 17 September 2018 Keywords: vehicle technology, fuel efficiency, passenger car

1 Background Fuel e ciency Fuel-consumption standards drive down technologies China’s use of fuel by the on-road sector and encourage the uptake of advanced vehicle-efficiency technologies. Under- Advanced Vehicle Thermal Hybrids and standing the need for a policy roadmap Transmissions engines technology management electrifction and long-term strategies to provide cer- tainty for long-term fuel consumption, Figure 1 Categorization of fuel efficiency technologies in the briefing technology advancement, and potential compliance costs for manufacturers, This series of technical work- and expected to be in production in China is looking ahead to advance post- ing papers aims to provide a the next 5-10 years. 2020 standards for light-duty vehicles. comprehensive understanding of This research relies on information In its “Made in China 2025” strategic the current availability, effective- from publicly available sources, third- initiative (MIIT, 2015), China set a 2025 ness, and future market penetration party databases, and information fleet efficiency target of 4 L/100 km of key fuel-efficiency technologies from the participating partners. Our for passenger cars, a 20% decrease that manufacturers are likely to use approach includes: from the 2020 target of 5 L/100 km. In in China by 2030. This information enables a more accurate, China-spe- the Technology Roadmap for Energy • A detailed literature survey, cific understanding of future technol- Saving and New Energy Vehicles pub- including both Chinese and global ogy pathways. lished by the Society of Automotive regulatory documents, official Engineers of China (SAE China, 2016), We group technologies into sev- announcements, and industry and a 2030 fleet efficiency target of 3.2 eral categories: advanced engine, academic reports. L/100 km was set. To evaluate whether transmission, vehicle technologies, • Analysis of databases from Polk and how these targets can be met, it is thermal management, and hybrids and and Segment Y. essential to understand what technolo- electrification (Figure 1). The specific gies will be available within the 2020- • Conversations with manufactur- technologies we considered include 2030 timeframe and what the costs ers, tier one suppliers, research those that are available today and of applying those technologies in the entities, and domestic and inter- others that are under development Chinese market will be. national experts.

Acknowledgments: The authors thank the Energy Foundation China for sponsoring this series of studies. We greatly appreciate the generous contributions of time by the following experts: Ligang Wang (SAE-China), Ernst Platten (Röchling), Hao Wang (CATARC).

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For each key technology, we discuss redesign including parts consolida- use on body-in-white (BIW), or the how it reduces passenger-car fuel tion, improved manufacturing pro- steel structure of the vehicle before consumption, its effectiveness in cesses, and holistic optimization could painting and addition of other parts, reducing fuel consumption, and its result in 5%­–10% improvement (ICCT, was less than 20% per vehicle (Fan, current level of application or poten- 2013). Over the past two decades, 2009). Nowadays, many new mod- tial application in the China market. Chinese manufacturers increasingly els claim BIW with 50%­–70% HSS. Wherever applicable, we compare shifted traditional materials toward Automotive steels can be classified technology trends in China with those high-strength steel, aluminum, in several ways. The definition of HSS in the United States and the European magnesium, and plastics and polymer in the United States is steel with yield Union to reflect potential technology composites to reduce vehicle mass. strength equal or higher than 480 pathways in the long term. megapascals (MPa). But the definition The application of lightweighting of HSS by Chinese OEMs includes a This working paper assesses technol- technology is especially important for range from 180 MPa to 780 MPa (Table ogy progress and new developments electric vehicles because lower curb 1). Baoshan Iron & Steel Co. Ltd., the in vehicle technologies, including weight reduces the energy needed largest steel company in China, has lightweighting, active aerodynamics, to propel the vehicle. This in turn developed a line of HSS among which and low rolling resistance tires. allows for use of a smaller battery those materials with yield strengths to maintain the same driving range. below 600 MPa are more broadly The cost savings from shrinking the 2 Introduction commercialized than those above. battery at least partially compensate Meanwhile, there is increased use of Among various technologies, light- for the increased cost of light-weight press hardening steel (PHS) on recent weighting has been considered critical materials. models in China. For example: for improving vehicle energy efficiency. Vehicle weight reduction decreases Active aerodynamics and low roll- • The application of HSS on the the load on the vehicle, thus lowering ing resistance tires also reduce fuel Chery Tiggo 7 is 60% of the the amount of fuel necessary to move consumption. Similar to lightweight- BIW, including 8% AHSS. PHS is it. Reducing weight directly lowers ing, these technologies are important applied on six key parts of the the power needed to accelerate the for both conventional and electric vehicle body, including the A and vehicle, decreases energy dissipated vehicles. B pillars, and delivers a bending by the brakes, and lowers tire rolling rigidity of as much as 21,000 Nm/ resistance. It also has a secondary Deg (Chery International, 2018a). effect on fuel consumption by 3 Current status • The 2015 BAIC Senova X55 allowing engine downsizing and brake applies 68% HSS in BIW, including and suspension lightweighting while 3.1 LIGHTWEIGHTING 8% AHSS. PHS is applied on 11 maintaining constant performance. In general, China’s lightweighting parts, with a tensile strength For every 1 kg of primary mass reduc- technology development is shift- of more than 1,500 MPa (China tion, the estimated secondary mass ing from focusing only on materials Daily, 2015). reduction ranges from 0.5 kg to 1.25 to also considering integrated mass- kg (Isenstadt et al., 2016). optimization design. • The average yield strength of HSS applied in Great Wall vehicles is Studies have indicated that a 10% Lightweighting materials include high more than 300 MPa. The Great weight reduction can decrease fuel strength steel (HSS), advanced high Wall H2 and H8 models feature consumption by 5% without downsiz- strength steel (AHSS), aluminum HSS on more than 60% of BIW. ing the engine and by 6%­–8% if the alloy, magnesium alloy, and plas- The A pillar of the H2 adopts PHS engine is downsized to maintain con- tic and polymer composites. Differ- of 1,500 MPa. The H7 applies HSS stant performance. ent lightweighting materials are at to 68% of BIW, 12% of which is different stages of development. PHS. The rear bumper uses alu- Light-weighting technologies minum alloy to further reduce include component substitution with weight (Havel, 2017). advanced materials and material pro- HSS/AHSS cessing, which could improve fuel Steel is still the main material in • The 2016 FAW Magotan applies efficiency 1%­–5%. Integrated vehicle Chinese cars. In 2009, average HSS more than 81% of HSS to BIW. The

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use of PHS accounts for 27% of Table 1 definition comparison of several categories of steel between China and the BIW, 11 percentage points than the Unites States. previous model (Autohome, 2016). Yield strength range (megapascals, MPa) China United States Aluminum Iron and mild steel 150-210 Less than 480 The development of aluminum began High-strength steel (HSS) 210-550 480 and above to accelerate with the ninth five-year- Advanced high-strength 550 and above 780 and above plan beginning in 1996, when China steel (AHSS) encouraged and financed research Press hardened steel (PHS) 1,100-1,300 on aluminum materials and casting technology. By now, the production of • The Fengshen E30L, a battery- magnesium aluminum alloy for as casting aluminum should satisfy the electric vehicle introduced by much as 93% of its body (Chery needs of the car industry. Plenty of Dongfeng in 2014, applied an International, 2018b). The Chery domestic manufacturers have applied all-aluminum BIW. The weight of eQ1 is 24% lighter than its prede- aluminum alloy in components such BIW was 145 kg, 75 kg less than cessor, the Chery eQ. As a result, as wheels and cylinder head covers the estimated weight if the BIW the battery capacity of the Chery on models since the 1990s, when were made of conventional steel eQ1 is 4 kWh smaller than that the average aluminum used per car (DFMC, 2015). of the Chery eQ while maintain- ranged from 40 kg to 80 kg. In 2015, ing a similar driving range (Chery the average usage of aluminum was • In 2016, the Chery Jaguar Land EV, 2018). Compared with a steel 105 kg per vehicle. As shown in Figure Rover Changshu Plant launched a structure, the aluminum BIW 2, die casting is the major manufac- purpose-built aluminum body shop increases cost by 50%, or 2,500­ turing process for aluminum parts on with Novelis, a U.S.-based global –3,000 RMB. But the cost saving vehicles, followed by casting and flat- company, as its local supplier. With from reduced battery capacity rolled (Du, 2016). the new plant, Chery Jaguar Land could be as high as 2,000­–3,000 Rover Automotive adopted an all- RMB per kWh (Fu, 2017). aluminum body for the domestically VEHICLE ALUMINUM PRODUCT IN 2015 manufactured Jaguar XFL, the first • NIO, a Chinese electric vehicle Forging 2% Jaguar model customized to the startup, launched an SUV model China market. The model, launched ES8 that adopts a 96.4% alu- in 2016, featured a BIW of 75% minum BIW and an aluminum Extrusion aluminum. The body adopted cus- chassis. The aluminum alloy is 9% tomized RC5752 high-strength alu- aerospace grade 7003 series, Flat rolled minum alloy, which is designed to enabling a torsional stiffness 10% contain up to 75% recycled mate- of 44,140 Nm/Deg. The BIW rial. The crumple zone adopted weight is 335 kg, 13.6% of the Die Casting AC300 T61 high-strength alumi- vehicle’s total curb weight (Song, 56% num alloy, which has the advan- 2017). Novelis is the supplier of Casting tages of high strength and high the ES8’s body-in-white (Labat, 23% energy absorption. In addition, 2017), while Magna is the supplier 72% of the aluminum body is con- of aluminum front sub-frame and nected by self-pierce riveting and rear cradle (Magna, 2017). adhesive joining technology, which • BYD is applying lightweight- make body connection strength ing technologies by system. The Figure 2 Chinese vehicle aluminum two to three times stronger than automaker adopted aluminum- product by manufacturing type in 2015 simple riveting (Chery Jaguar Land magnesium alloy for the multi- (Du, 2016) Rover, 2018). road rear suspension of the Tang There is emerging use of significant • The Chery eQ1, a mini-battery and Song models and for the aluminum application on BIW of electric vehicle introduced front and rear suspension of the domestically manufactured vehicles. in 2017, uses high-strength Qin100 (Sina, 2017).

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Magnesium alloy 2000 0.25

With support from the Ministry of Science Imported vehicles and Technology, 100 manufacturers 1800 0.2 are capable of die-casting magnesium alloy for transmission housings, pedal brackets, instrument panels, steering 1600 0.15 wheels, torque converters, and other parts, supplying domestic and foreign manufacturers. The application of cast Fleet average 1400 0.1 magnesium alloy for domestic models is limited to a couple of parts, mainly Domestic vehicles concentrated on dashboard frames or Average curb weight (kg) 1200 4.6% 0.05 steering wheel frames. There are few Annual weight applications of wrought magnesium increase rates: 1.7% 1.6% 1.2% 1.2% alloy, despite its great potential for 1000 0 door frames, trunk lids, and engine 2010 2011 2012 2013 2014 2015 covers. Today, the average magnesium use per vehicle is less than 1.5 kg (SAE Figure 3 Fleet average curb weight of passenger cars in China from 2010 to 2015 China, 2017). 110 Power to weight Power Plastics and polymer composites 105 103 103 102 In general, use of plastics on domestic 100 99 95 97 cars varies from 50 kg to 110 kg, which 93 Fleet average power (kW) is close to the world average. Plastics 90 85 are mostly seen in interior components Fleet average power/weight (W/kg) and increasingly replace exterior non- 80 75 73 74 structural components. 71 71 70 69 70 Chinese manufacturers have limited 65 60 capacity for supplying most polymer 2010 2011 2012 2013 2014 2015 composites. Nearly 90% of the long fiber-reinforced thermoplastic applied Figure 4 Fleet average power and power to weight ratio, 2010-2015 on domestic cars is imported. There are several possible reasons shift vehicles into weight classes A study showed that as the average for this: with higher fuel-consumption curb weight of passenger cars was targets, or hold off on the use of reduced by 2%­–6% through the use of • Lightweighting is not fully lightweighting technologies to lightweighting technologies from 2014 incentivized under the existing keep vehicle models on the pre- to 2020, the cost per vehicle increase stepped, weight-based fuel-con- ferred side of fuel-consumption sumption standards. Vehicles that by 1,000 RMB to 3,000 RMB (Hao, targets (Hao, Wang, Li, Liu, & reduce curb weight are subject to Wang, Li, Liu, & Zhao, 2017). In a recent Zhao, 2016). evaluation by the U.S. Environmental more-stringent targets, so manu- • Weight reductions from apply- Protection Agency, lightweighting facturers are not equally incen- ing lightweighting are most likely resulted in 5%–10% cost saving across tivized to adopt lightweighting offset by higher demand for all vehicle segments (EPA, 2016). technologies as a way to comply with fuel-consumption standards performance and upscale fea- Lightweighting by Chinese manufac- (He & Yang, 2014). In addition, the tures. From 2010 to 2015, the turers are not fully reflected in the stepped fuel-consumption targets average power of the vehicle fleet weight of the vehicle fleet. In fact, create several gaming opportuni- increased by 19% (Figure 4). The average curb weight rose 11% from ties that allow manufacturers to ratio of power to weight also rose. 2010 to 2015 (Figure 3). make minor modifications that Additional weight increases may

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come from interior technologies 100% for improving driver and passen- 90% SUV ger comfort. 80% 70% F • The market structure changed E 60% toward larger cars and SUVs. Demand for larger vehicles and 50% D SUVs rose in the past decade. 40% Figure 5 shows a significant 30% decline in the market share of mini 20% C

and small vehicles, or segments Market share of new sales 10% B A and B. Meanwhile, SUVs surged 0% A from less than 5% of sales in 2005 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 to 10% by 2010 and 40% in 2017 Calendar year (CAAM, 2018). Figure 5 Market penetration by segment from 2005 to 2015

might not be the same in China if a deformation of the tires under load, 3.2 ACTIVE AERODYNAMICS lot of driving occurs at lower speeds thereby improving fuel economy and AND LOW ROLLING than on the five U.S. test cycles. A reducing CO emissions. The EPA esti- RESISTANCE TIRES 2 more precise estimate of the benefit mated that tires with a 10% reduction In additional to design improvements of such technology in China requires in rolling resistance can lower fuel to reduce aerodynamic drag, an consideration of the China driving consumption by 1.9%, and tires that emerging technology is active grille condition and test cycles. Active grille offer a 20% reduction will lower fuel shutters (AGS). AGS is a mainstream shutters have a higher benefit to cost consumption by additional 2%, for a technology that improves aerody- ratio compared with other technolo- total of 3.9%. namics at high speeds by mechani- gies in ITB’s evaluation (ITB, 2017). cally actuating flaps that control This study did not collect detailed radiator airflow to reduce drag. In Active grille shutters have already information on application of low addition to reducing aerodynamic been implemented in China by some rolling resistance tires in China. The losses, AGS technology can be con- joint ventures with European and China Society of Automotive Engi- sidered an active thermal manage- American partners. Chang’an Ford ment technology. Because grille introduced AGS on its 2012 Focus and neers in its Technology Roadmap for shutters can control airflow based on later on its Kuga models. GAC-FCA Energy Saving and New-Energy Vehi- powertrain thermal needs, they can introduced a domestically produced cles lists developing low rolling resis- assist in rapid engine and transmis- 2016 Cherokee that included AGS tance tires among goals for 2020, sion warm-up and reduce friction on most versions. Other examples suggesting that this technology is still losses during cold engine start. The include the BMW 530i and the Buick at an early stage in China (SAE China, AGS technology of the Ford Focus Lacrosse eAssist. 2016). In the United States, the EPA reduces fuel consumption by 0.15– assumed that tires with 10% lower 0.2 L/100 km at 120 km/h. When the The main supplier of AGS in China is rolling resistance have been avail- AGS is totally closed, drag is low- Bodun Group, which accounted for able since 2007 and exceeded 90% ered by 7.8%, resulting in as much as 70% of the market in 2016. Roechling penetration by 2017. Tires with 20% a 2% reduction in CO emissions at Automotive, one of the biggest global 2 percent less rolling resistance have 120 km/h (Autohome, 2012). The EPA suppliers of AGS, opened a new plant been available since 2017. We would provides off-cycle credits for active in Shenyang in 2015 and is ramping assume a similar penetration growth aerodynamics technologies assum- up production. ing that a 3% reduction in drag coef- path and fuel consumption impact on ficient can reduce fuel consumption Lower rolling resistance tires reduce passenger vehicles in China but with by around 0.3%. Note that the ben- frictional losses associated with the a delayed timeline compared with the efit from aerodynamic technologies energy dissipated mainly in the United States.

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4 Further development Table 2 Lightweighting material application target set in the Energy Saving and New-Energy Vehicle Technology Roadmap (SAE China, 2016) pathways In its Energy Saving and New-Energy By 2020 By 2025 By 2030 50% AHSS>600 30% of BIW with Some application Vehicle Technology Roadmap, SAE HSS/AHSS/PHS MPa AHSS>900 MPa of PHS>2000 MPa China set a goal of reducing curb weight from 2015 levels by 10% by Aluminum 190 kg/vehicle 250 kg/vehicle 350 kg/vehicle 2020, 20% by 2025, and 35% by Magnesium 15 kg/vehicle 25 kg/vehicle 45 kg/vehicle 2030 (SAE China, 2016). This mass Carbon fiber reduction target would be achieved reinforced polymer Some application 2%/vehicle 5%/vehicle composites through increased application of lightweighting (Table 2) and mass- also indicated developing low rolling The percentages following each tech- optimization design. resistance tires by 2020, optimizing nology summarizes its potential for To achieve this goal, it is equally tire structure and size by 2025, and reducing fuel consumption. In most important to maintain a relatively improving rubber formulas by 2030. cases, the potential is compared with stable fleet structure. SAE China baseline vehicles without the speci- fied technologies. The number repre- (2016) also proposed a vision for 5 Summary increasing sales of compact vehicles sents an average impact or an impact or smaller cars in China from 2020 Figure 6 summarizes the key vehicle range considering the differences in to 2030. Without a policy slowdown technologies discussed in this work- baseline vehicle segment, specifica- or even reversal of the existing trend ing paper. The adoption status of each tions, and other factors. of increasing market share for larger technology in China is marked before Based on the application status of the name of each technology. The vehicles, achieving the proposed advanced technologies in China, we start sign in front of active grille shut- weight reduction will be unlikely. group the technologies into three ter indicates that it is a technology categories: There is a trend of increased adop- applied on only a couple of models tion of AGS in China as manufacturers in China. A blue question mark indi- Commercialized technologies. Tech- are already deploying the technology cates technologies without sufficient nologies that are already adopted on on coming new models. According to market penetration information. We at least several production models in suppliers, there is an increase in the have seen increasing application of China and could be applied widely in number of manufacturers that plan to lightweighting technologies in China, the fleet. apply AGS on production vehicles from but it is challenging to estimate the 2018 to 2021. The SAE China technol- level of lightweighting achievement Emerging technologies. Technolo- ogy roadmap set a target of improv- for the entire fleet. The application of gies that are available on passenger ing aerodynamics by 10% from 2015 to low rolling resistance tires on passen- cars sold in the Chinese market but 2030 (SAE China, 2017). The roadmap ger vehicles is still at an early stage. only on a couple of models, such as

Fuel efficiency / GHG reducing technologies

Percentages in () are fuel consumption/GHG emission reduction potential

Figure 6 Vehicle technology map for passenger cars in China

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variants of flagship models or luxury Table 2 Vehicle technologies at different development stages in China models that target high-end users. Commercialized Underdeveloped technologies Emerging technologies technologies Underdeveloped technologies. Technologies that have been adopted • Lightweighting — 10% • Lightweighting — 20% • Lightweighting — 30% weight reduction weight reduction weight reduction in other markets but are not yet available on cars produced in China, • Low rolling resistance • Low rolling resistance • Low rolling resistance tires (5%) tires (10%) tires (20%) or technologies that have been announced by manufacturers or sup- • Active aerodynamics pliers and are likely to be adopted on production passenger cars in the definition. For lightweighting tech- This information is used for estimat- near future. nology and low rolling resistance ing fuel-saving potential of all effi- tires, we use the level of weight reduc- ciency technologies in the summary Table 2 lists the vehicle technologies tion and rolling resistance reduction of this series of working papers. under each category based on our to differentiate development phases.

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