Abstract
Weight reduction is commonly adopted in vehicle design as a means for energy and emissions savings. However, selection of lightweight materials is often focused on performance characteristics, which may lead to sub optimizations of life cycle environmental impact. Therefore systematic material selection processes are needed that integrate weight optimization and environmental life cycle assessment. This paper presents such an approach and its application to design of an automotive component. Materials from the metal, hybrid and polymer families were assessed, along with a novel self-reinforced composite material that is a potential lightweight alternative to non-recyclable composites. It was shown that materials offering the highest weight saving potential offer limited life cycle environmental benefit due to energy demanding manufacturing. Selection of the preferable alternative is not a straightforward process since results may be sensitive to critical but uncertain aspects of the life cycle. Such aspects need to be evaluated to determine the actual benefits of lightweight design and to base material selection on more informed choices.
Highlights
The transport sector accounts for about one third of total energy demand in Europe and is among the major contributors of greenhouse gas emissions [1]
2.5 Results analysis and material selection In order to fulfil the functional requirement of low life cycle environmental impact, a comprehensive analysis of the results is needed, which may consider the following aspects: (i) total life cycle impact of each material alternative separately and in comparison to the others, (ii) environmental performance of each alternative in different life cycle stages, (iii) trade‐offs between life cycle stages or environmental impact indicators and (iv) variations in the design target or properties of the product and its life cycle that may influence the life cycle impact of the material
This paper presents an integrated material selection approach for vehicle design that combines weight minimization and environmental life cycle assessment and its application to a hypothetical material selection case study for a truck roof
Summary
The transport sector accounts for about one third of total energy demand in Europe and is among the major contributors of greenhouse gas emissions [1]. To assess whether there are any significant unexpected environmental trade‐offs over the life cycle, these novel materials need to be assessed using a life cycle perspective Such an assessment should consider physical, mechanical, and environmental characteristics in an integrated manner [11] and be adopted in standard material selection and vehicle design processes. A few complete frameworks for material selection in a design context based on structural optimization and life cycle environmental assessment techniques have been published [16, 18, 20] Some of these are prescriptive, for instance concerning the use of preselected environmental indicators or decision making functions. While this may simplify application, there is a risk that it prevents integration in a company’s established material selection process
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