Abstract
Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional cast iron (CI) with lighter metals. Currently, aluminum alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review was performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminum alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, were collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” was implemented to take into account the energy input of each stage of the component life cycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that, although aluminum components contribute toward reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.
Highlights
Over the years, the material selection for modern car components changed a lot
Aluminum components contribute toward reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high
Who investigated one made of cast iron (CI). Their results showed that the CI engine block presents some significant the effects ofwith substituting aluminum with a newly developed one made of cast iron (CI)
Summary
The material selection for modern car components changed a lot. As a reference, in the 1970s, a design engineer would have to select from four to five sheet forming grades, whereas today there are more than 50 options [1]. Ashby et al [3] presented the embodied energy of producing components for the automotive industry investigation, the energy involved during the use phase of a vehicle is much larger than that during and discussed the contribution of each life-cycle phase. According to their investigation, the energy the material extraction and manufacturing phase. The is methodology on whether Alfor alloys a better impact assessment of substitution of materials in the automotive sector so as to improve the current option than cast iron (CI), when the total energy burden is considered The case study selected was the engine block, as it is the single heaviest component in most passenger cars
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