LIGHTWEIGHT VEHICLE TECHNOLOGY CASTLE BROMWICH, UK 02.05.2012 MARK WHITE CHIEF TECHNICAL SPECIALIST
LIGHTWEIGHT VEHICLE TECHNOLOGY AGENDA Light Weight Vehicle rationale XJ LWV Body Materials Aluminium Sheet Strategy Material Selection Increased Recycling (REALCAR - REcycled ALuminium Car research project) LWV Barriers - Aluminium Cost Considerations 3 LIGHTWEIGHT VEHICLE TECHNOLOGY LEADER IN AUTOMOTIVE INNOVATION World-First Automatic World-first Terrain Response full electric drive World-First Adaptive System (in development) premium F-segment Cruise Control technology World-first user- demonstrator selectable terrain World-first Limo-Green response system stop-start World-First mid-size SUV dual-view screen Low Carbon Propulsion/ Vehicle Capability KE recovery. Energy Efficiency/ What Parasitics Human/Vehicle Makes Us Interaction World-first Gen. 1 Different Light-weight Vehicles Gen. 2 capacitive sense Design Enabling interior switches Product Life-cycle World-first aluminium Monocoque World-first pyrotechnic bodyshell deployable bonnet protects World-first pedestrians whist closed-loop maintaining sleek design aluminium re-cycling 4
LIGHTWEIGHT VEHICLE TECHNOLOGY CO 2 CHALLENGE FOR CAR MAKERS We must make cars that comply with future CO 2 & FE requirements From 2012 - 2019 a mass based CO 2 limit will be applied to all new cars OEM’s must address the CO 2 challenge in a cost effective manner, whilst maintaining vehicle attributes to be a sustainable business & meet targets 5 LIGHTWEIGHT VEHICLE TECHNOLOGY CO 2 CHALLENGE FOR CAR MAKERS Options available: Weight Efficiency Hybrid Elec Vehicles Aerodynamics Propulsion: Vehicle Architecture Flywheel [Kinetic] Rolling resistance Plug in Hybrids BIW & Closures PT & Thermal Electric Vehicles Chassis parts Mild/micro hybrids Energy management Combustion Material application - Chassis systems Transmission Joining technology - Electrical Full hybridisation Driveline LCA Climate systems Powertrain Efficiency Weight v attributes Weight: Aimed at reducing BIW, PT & Chassis weight, but across whole vehicle Parasitics: Reduce heat, friction & pumping losses, increase combustion efficiency 6
LIGHTWEIGHT VEHICLE TECHNOLOGY EU CO 2 TECHNOLOGY ROADMAP EU CO 2 Technology Roadmap http://ec.europa.eu/environment/co2/co2_home.htm 7 LIGHTWEIGHT VEHICLE TECHNOLOGY WEIGHT REDUCTION POTENTIAL 100% -10-20% Relative cost -40% Optimum HS Steel -50% -60% Current Steel -70%? CFRP today Magnesium Will cost Aluminium dominate CFRP ? function ? 8
LIGHTWEIGHT VEHICLE TECHNOLOGY CO 2 EMISSIONS BY VEHICLE WEIGHT 300 250 Petrol Diesel Lexus LS600h CO 2 g/ km Jaguar S 2.7 200 Jaguar XF 2.7 Hybrid Lexus RX400h Lexus GS450h 150 Focus Modus Civic Citroen C1 Prius Citroen C2 100 Insight 50 500 1000 1500 2000 2500 9 Kerb weight (kg) LIGHTWEIGHT VEHICLE TECHNOLOGY WEIGHT & THE EU CERTIFIED CYCLE What’s the CO 2 benefit of 100 kg weight reduction? Certified CO 2 figures are calculated using categories which cover a range of vehicle weights (typically 115 kg) Due to the certified FE test being static, vehicle weight has no real effect. Resistance on rollers is used & is a constant value in each category 115kg drop per High Test We ight Therefore, we get steps in the certified CO 2 Class values for a range of weights within a category 2% CO 2 drop If we are at the top of a category & save per Te st CO 2 We igh t Class 100 kg we have the same CO 2 figure 1 lower category is worth circa 2% CO 2 Low Equating to 3.6 grams of CO 2 on an XJ Mass 10 High Low
LIGHTWEIGHT VEHICLE TECHNOLOGY WEIGHT & LIFE CYCLE CO 2 100 kg weight reduction effect per vehicle on LCA Production 650 kg FE Improvement (certified) 720 kg Fuel production 86 kg Total LCA save per vehicle 1,456 kg (using ISO 14040/44) Real world FE 110 kg Total Carbon Impact of 100 kg save 1,566 kg Therefore, every 1 kg reduction results in 16 kg CO 2 per vehicle But it ‘s on every car we make so it’s actually 2,56Kt of CO 2 per 1kg For every 100 kg that’s over a quarter of a million tonnes saved by JLR! 11 LIGHTWEIGHT VEHICLE TECHNOLOGY WEIGHT & LIFE CYCLE CO 2 100 kg weight reduction effect per vehicle on LCA Production 650 kg FE Improvement (certified) 720 kg Fuel production 86 kg Total LCA save per vehicle 1,456 kg (using ISO 14040/44) Real world FE 110 kg Total Carbon Impact of 100 kg save1,566 kg Therefore, every 1 kg reduction results in 16 kg CO 2 per vehicle But it ‘s on every car we make so it’s actually 2,56Kt of CO 2 per 1kg For every 100 kg that’s over a quarter of a million tonnes saved by JLR!
LIGHTWEIGHT VEHICLE TECHNOLOGY JAGUAR XJ MATERIALS – COMPLETE BODY Current XJ 2% 1% 1% 5% 1% 19% Previous 5% generation XJ Al sheet 6xxx 3% 2% 11% Al sheet 5xxx 6% 9% Al casting Al extrusion 9% Mg casting Mild steel Al Sheet 6xxx AHS steel Al Sheet 5xxx Al Casting HSS steel Al Extrusion PHS steel Mild Steel % by mass AHS 58% 13 66% LIGHTWEIGHT VEHICLE TECHNOLOGY XJ COMPLETE BODY OVERVIEW Al sheet 5xxx Component type Previous generation XJ Current XJ 58% by mass Stampings 91% 88% Castings 5% 6% Profiles 4% 5% % by part count Other - 1% 14
LIGHTWEIGHT VEHICLE TECHNOLOGY XJ DIE CAST PARTS Castings used in key areas for : – Complex geometry – Local stiffness in high load input areas – Part integration – Reduce multiple sheet stack-up issues – Self pierce rivet joining to other parts 15 LIGHTWEIGHT VEHICLE TECHNOLOGY XJ EXTRUDED PROFILE PARTS Bolt-on – Use of high strength extruded alloys to minimise weight & meet package requirements – Bolt-on parts to support vehicle repair strategy Bolt-on – Support manufacturing Bill Of Process (BOP) 16
LIGHTWEIGHT VEHICLE TECHNOLOGY XJ BODY STRUCTURE MATERIALS Al sheet 6xxx Al sheet 5xxx Al casting Al profile Mg casting Mild steel AHS steel HSS steel PHS steel 17 LIGHTWEIGHT VEHICLE TECHNOLOGY BODY STRUCTURE SHEET MATERIALS Requirements - BIW Alloy Types AA6xxx – Good formability MEDIUM STRENGTH OR – Corrosion resistance BAKE-HARDENING AA5xxx ALLOYS – Good crash performance – Long term stability of properties Requirements – Outer skins Alloy Types – Good formability BAKE-HARDENING AA6xxx ALLOYS – High strength after paint bake – Corrosion resistance 18
LIGHTWEIGHT VEHICLE TECHNOLOGY EXTERIOR SHEET MATERIALS 6111-T4 meets the following requirements: – Suitable for all Class A exterior panels – Sufficient formability to achieve style – Compatibility with deep draw lubricants – Dent resistance via strain & bake hardening New XJ bodyside material selected AA6111 T4PD – Bake hardening without body shop oven Panel thickness = 1.2mm – Minimum gauge provides max weight save Previous generation XJ used NG5754 Panel thickness = 1.5mm – Weight save 20%+ over previous generation XJ – 20% Material cost savings 19 LIGHTWEIGHT VEHICLE TECHNOLOGY STRUCTURAL CRASH ALLOY - Ac300 T61 – Typical in-service strength circa 225 MPa versus 140MPa for NG5754 – Ac300 in the T61 condition offers higher specific energy absorption than strain hardening 5xxx series alloys – Gauge for gauge the alloy absorbs 30% more energy per unit length – Weight for weight more effective than DP600 steel – Opportunity to down gauge NG5754 components by 20% of the original gauge in crash crush applications - saving both weight and piece cost – Ac300 T61 is resistant to stress corrosion cracking and can be used in environments with elevated temperatures 20
LIGHTWEIGHT VEHICLE TECHNOLOGY XJ JOINING TECHNOLOGY – Self-Piercing Rivets (SPRs) are the main joining technology – Adhesive bonding used for NVH & durability – 1K adhesive used for sheet joints – Blind rivets for single sided joint access – Low speed & high speed ‘bolt-on’ structures – No welding in the body shop – Elimination of previous generation XJ roof joints - zero MIG welding in house Adhesive bonding (body & closures) = 154m 21 LIGHTWEIGHT VEHICLE TECHNOLOGY XJ JOINING TECHNOLOGY 3000 ~11% reduction Number of SPR’s Previous New XJ XJ – New XJ body is larger & meets increased functional requirements – 11% reduction in SPR count in body structure over previous generation Standard wheelbase XJ (BSLD) has 2840 SPRs compared to over 5000+ spot welds for an equivalent – Savings in both direct & investment costs steel body. SWB Body Complete has 3118 SPR’s 22
LIGHTWEIGHT VEHICLE TECHNOLOGY XJ BODY COMPLETE WEIGHT 1843 [1] [2] eight [Kg] [1] W 324 4 11 Unladen Vehicle Weight 17 Mass [Kg] 20 A B New XJ D 26 Fenders 246 Tailgate ( body + closures) Body Structure Bonnet Rear Doors Body Complete Front Doors Competitor data based upon LWB derivative data [1] - A2mac1 data Steel body complete equivalent ~ 454Kg [2] - JLR Teardown data Data based upon mounting parts included in module, SWB 3.0L V6 Diesel 23 LIGHTWEIGHT VEHICLE TECHNOLOGY PRODUCT LIFE CYCLE ANALYSIS Production, 14% Use, 85% Disposal, 1% Energy Energy Energy Raw material 600 600 500 500 (MJ/kg) (MJ/kg) 400 400 Production Production Use Use Disposal Disposal 300 300 200 200 100 100 0 0 Waste Emissions to Waste Waste Steel Steel Aluminum Aluminum Magnesium Magnesium CDRC CDRC Emissions to Emissions to Production Production End of Life End of Life 24 air and water air and water air and water
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