Analyzing the impact of geographic variability on emissions reduction and cost efficiency in automotive lightweighting strategies

Abstract

Lightweight design is crucial in automotive design, especially for battery electric vehicles (BEVs), as it can extend driving range or minimize battery size for a set distance. However, the choice of materials like high-strength steels, while beneficial for vehicle weight, often carries greater environmental costs during production. A comprehensive analysis considering the entire lifecycle and electricity sources is essential to identify truly eco-friendly materials. The market introduction of innovative materials like green steel and recycled products further complicates the selection process due to increased competition. Current assessments of lightweight strategies are complex and challenging to compare, highlighting a research gap in easy-to-understand and actionable evaluations. This study aims to investigate automotive lightweighting across various propulsion systems and regions using prospective Life Cycle Assessment (LCA). It introduces a novel approach by examining how the mix of electricity generation affects the environmental benefits of lightweight materials. A new Key Performance Indicator (KPI) is proposed to help those with limited LCA expertise evaluate the environmental impact of different structural materials. The research also provides visual tools and analyzes cost savings from lower lifecycle greenhouse gas emissions, presenting a rounded view of the economic and environmental advantages of diverse lightweight strategies.