Abstract
The paper presents an innovative lightweight design solution for the rear crash management system of a C-class car, developed within the AffordabLe LIghtweight Automobiles AlliaNCE (ALLIANCE) EU research project. The innovation provides that the reference version of the module, based on conventional steel components, is revolutionized through the introduction of extruded 6000/7000 series aluminum alloys. The two competing alternatives are described and compared in relation to design and technological solutions, including also a sustainability analysis which assesses the entire Life Cycle (LC) of the system on the basis of a wide range of environmental indicators. The lightweight solution allows achieving a large mass reduction (almost 40%), while providing improvements in terms of strength, production efficiency and design freedom. On the other hand, the introduction of new materials and manufacturing technologies entails contrasting sustainability effects depending on impact category, thus not allowing to affirm that the novel alternative is unequivocally preferable under the environmental point of view. However, the comprehensive evaluation of all sustainability aspects through a multi-criteria decision analysis (TOPSIS method) reveals that the environmental profile of the innovative design is slightly preferable with respect to the conventional one.
Highlights
One of the main objectives of the European community policies is the mitigation of Greenhouse Gas (GHG) emissions by 60% compared to the 1990 levels by 2050 [1]
The difference lies in the fact that the drawback in production is usually not so high for advanced metals, so that Fuel Consumption (FC) saving during use is able to offset the negative effects at relatively low life cycle distances [37,38]; on the contrary, the relevant impact increase in raw material provision for composites and hybrid materials makes that the environmental benefits during operation are not enough to achieve a break-even point within the assumed Life Cycle (LC) mileage [39]
This paper presents a re-engineering activity performed on the rear Crash Management System (CMS) module of a C-class car and it is a follow-up of [44]
Summary
One of the main objectives of the European community policies is the mitigation of Greenhouse Gas (GHG) emissions by 60% compared to the 1990 levels by 2050 [1]. The difference lies in the fact that the drawback in production is usually not so high for advanced metals, so that FC saving during use is able to offset the negative effects at relatively low life cycle distances (less than 100,000 km) [37,38]; on the contrary, the relevant impact increase in raw material provision for composites and hybrid materials makes that the environmental benefits during operation are not enough to achieve a break-even point within the assumed LC mileage [39] In this regard, a crucial point is represented by the share of secondary sources used for material provision, on the basis of which the system-level payback times can shorten or extend significantly [40]. The design and research activity has been carried out within the AffordabLe LIghtweight Automobiles AlliaNCE (ALLIANCE) European research and innovation project [45], whose objective is developing innovative advanced materials and manufacturing technologies to reach 25% full-vehicle weight reduction while decreasing the global warming impact by 6%
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