Draft Technical Assessment Report: Midterm Evaluation of Light-Duty Vehicle Greenhouse Gas Emission Standards and Corporate Average Fuel Economy Standards for Model Years 2022-2025 Appendix Office of Transportation and Air Quality U.S. Environmental Protection Agency National Highway Traffic Safety Administration U.S. Department of Transportation And California Air Resources Board EPA-420-D-16-900app July 2016 Appendix Table of Contents Appendix A CARB Analysis of Vehicle Load Reduction Potential for Advanced Clean Cars Appendix B Mass Reduction Technologies B.1 Design Optimization ................................................................................................... B-4 B.2 Material Advancements - Steel ................................................................................... B-6 B.3 Material Advancements - Aluminum ....................................................................... B-24 B.4 Material Advancements - Magnesium ...................................................................... B-40 B.5 Material Advancements - Plastics ............................................................................. B-46 B.6 Material Advancements - Composites ...................................................................... B-52 B.7 Material Advancements - Glass ................................................................................ B-76 B.8 Multi-Material Technology Examples ...................................................................... B-77 B.9 Additional Vehicle Level Cost Analysis .................................................................. B-81 B.10 Mass Reduction Technology Adoption Trends in the Marketplace ......................... B-84 Appendix C C.1 OMEGA Pre-Processors, Vehicle Types & Packages ................................................ C-1 C.1.1 Vehicle Types ......................................................................................................... C-2 C.1.2 Technology Packages, Package Building & Master-sets ....................................... C-3 C.1.3 Master-set Ranking & the Technology Input File ................................................ C-11 C.1.4 Applying Ranked-sets of Packages to the Projected Fleet ................................... C-14 C.1.5 New to OMEGA since the 2012 FRM ................................................................. C-15 C.2 OMEGA Overview ................................................................................................... C-15 C.3 OMEGA Model Structure ......................................................................................... C-17 Table of Figures Figure A.1 Potential Reduction in CO2 Emissions by Adoption of Best-In-Class MY2014 Technologies ............. A-2 Figure A.2 Sales-Weighted Vehicle Energy Intensity ............................................................................................. A-3 Figure B.1 Ashby Plot for Material Strength-Density .............................................................................................. B-3 Figure B.2 Mass Savings from Honda Civic 1.5L Engine Redesign Technologies10 ............................................... B-5 Figure B.3 Lightweighting with AHSS: Materials Profile (www.autosteel.org)12 ................................................... B-6 Figure B.4 Arcelor Mittal's Synergy Door Concept Design Highlights 15 ................................................................ B-8 Figure B.5 Front Lower Control Arm Stamped Clamshell Design Comparison21 ................................................. B-10 Figure B.6 Redesign of the Cadillac ATS/CTS to Achieve 74kg of Mass Reduction24 ......................................... B-11 Figure B.7 Material Type Application for the Acura TLX Presented at 2015 Great Designs in Steel ................... B-11 Figure B.8 Body Structure Material Grades for 2016 Honda Civic29 ..................................................................... B-13 Figure B.9 High Strength and Ultra High Strength Steel changes in the 2014 Silverado 1500 .............................. B-13 Figure B.10 London Metals Exchange Steel Billet Prices (in $USD/tonne)35 ........................................................ B-14 Figure B.11 London Metals Exchange Aluminum Prices (in $USD/tonne)36 ........................................................ B-15 Figure B.12 FSV Comparison to 1994 Reference Vehicle37 .................................................................................. B-17 Figure B.13 Honda Civic Rear Crash Construction Including Softzones While Reducing Mass29 ........................ B-18 Figure B.14 Nissan Murano Steel Grades used in IIHS Compliance - 3D View40 ................................................. B-19 Figure B.15 Nissan Murano Steel Grades for IIHS Compliance - Bottom View40 ................................................. B-19 Figure B.16 Honda Civic IIHS Small Overlap Test Construction Upgrades29 ....................................................... B-20 Figure B.17 Comparisons of Established Steel Grades and Potential Nanosteel Grades (in purple) ...................... B-21 Figure B.18 NanoSteel 3rd Generation AHSS: Structural Change During Cold Forming44 .................................. B-22 Figure B.19 Microlattice Material by HRL Laboratories ....................................................................................... B-23 Figure B.20 Ducker Worldwide on Aluminum Penetration for Closures and Complete Bodies ............................ B-25 Figure B.21 Ducker Worldwide Estimates of Rolled, Extruded and Vacuum Die Cast Aluminum Product Demand Increase ............................................................................................................................................. B-25 Figure B.22 Novelis Automotive Global Supply .................................................................................................... B-26 Appendix Figure B.23 Kaiser Aluminum Automotive Alloys/Tempers ................................................................................. B-28 Figure B.24 Kaiser Aluminum Light Vehicle Extrusion Applications in Pickup Trucks63 .................................... B-28 Figure B.25 Kaiser Aluminum Light Vehicle Extrusion Applications in Sedans63 ................................................ B-29 Figure B.26 Aluminum Hydroform Parts on the F-150 ........................................................................................... B-29 Figure B.27 2014 Ford F-150 versus 2015 Ford F-150 Weight in Pounds ............................................................. B-30 Figure B.28 Aluminum Makeup of the F150.......................................................................................................... B-31 Figure B.29 Aluminum Intensive Vehicles Include Land Rover, Ford F150 and Tesla S ...................................... B-32 Figure B.30 Micromill - Continuous Cast Aluminum Sheet .................................................................................. B-33 Figure B.31 Aluminum F150 Crew Cab Performances in IIHS Small Overlap Crash Test ................................... B-34 Figure B.32 Aluminum Door Inner Made with Friction Stir Welding Technique .................................................. B-36 Figure B.33 Schematic of the LIBS Apparatus ...................................................................................................... B-37 Figure B.34 Novelis Aluminum Production and Recycling Process ...................................................................... B-38 Figure B.35 Scrap Loop - 33% Manufacturing Scrap is Recycled into New Sheet Product and 5% Castings ....... B-39 Figure B.36 Coordinating Aluminum Material Recycling 5xxx and 6xxx Grades ................................................. B-39 Figure B.37 Maximizing Tractor Trailer Use for Recycled and New Al Product to F150 Production Facilities ... B-40 Figure B.38 Product Development Timeline for Magnesium Automotive Components, Meridian ....................... B-41 Figure B.39 GM Capability to Make Structural Panels out of Magnesium83 ......................................................... B-42 Figure B.40 Price of Magnesium over 25 Years (not adjusted for inflation) .......................................................... B-44 Figure B.41 Auto Part Targets for Lightweight Plastics and Rubber (3M Company) ............................................ B-48 Figure B.42 Photo of Polimotor 1 (left) and a Computer Rendering of Polimotor 2 (right) ................................... B-51 Figure B.43 Carbon Fiber Product Forms ............................................................................................................... B-53 Figure B.44 Glass Fiber Reinforced Polymer Springs (Right) Are A Drop In Replacement For Steel Suspension Springs (Left)98 ................................................................................................................................. B-55 Figure B.45 BIW Comparison of BMWi3 (left) and Prius (right) .......................................................................... B-57 Figure B.46 Part -By Part Weight Savings Realized By Improving the SMC Formulation Used In the C7 Corvette B- 59 Figure B.47 SABIC Potential Lightweight Crash Energy Management Solutions ................................................ B-60 Figure B.48 Commodity and Engineering Polymers are Playing an Increasing Role in Automotive Light Weighting Solutions99........................................................................................................................................