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Environmental Evaluation of Lightweight Exterior Body Panels in New Generation Vehicles
ISSN: 0148-7191, e-ISSN: 2688-3627
Published June 03, 2002 by SAE International in United States
Annotation ability available
Event: Future Car Congress
The Center for Clean Products has conducted a life-cycle assessment involving a comparison of exterior body closure panels made of different lightweight materials (aluminum, carbon fiber-reinforced polymer [CFRP] and glass fiber-reinforced polymer [GFRP]), to steel closure panels weighing 220 lbs as the baseline. In an additional, more forward-looking assessment, a monocoque body made of a carbon fiber-based composite was assumed to replace a conventional steel body, resulting in a substantial weight reduction (more than 60%).
The primary results reveal that CFRP appears to be the least environmentally burdensome material in 9 of the 14 impact categories evaluated. This is mainly due to the fact that CFRP has the maximum weight reduction potential of all the materials evaluated (about 60% over steel), resulting in a much smaller quantity of material needed. Of the remaining 5 categories, aluminum has the lowest score in three categories while GFRP has the lowest score in two categories. Steel does not have the lowest impact scores in any of the categories examined.
In the monocoque analysis, CFRP's position is further strengthened (compared to the original assessment). However, its impact scores in three categories turn around from being lower than those of steel to being higher than steel. The major contributors in each case are various releases associated with using larger amounts of carbon fiber.
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- Jonathan G. Overly - The Center for Clean Products and Clean Technologies at the University of Tennessee, Knoxville
- Rajive Dhingra - The Center for Clean Products and Clean Technologies at the University of Tennessee, Knoxville
- Gary A. Davis - The Center for Clean Products and Clean Technologies at the University of Tennessee, Knoxville
- Sujit Das - Energy Division, Oak Ridge National Laboratory
CitationOverly, J., Dhingra, R., Davis, G., and Das, S., "Environmental Evaluation of Lightweight Exterior Body Panels in New Generation Vehicles," SAE Technical Paper 2002-01-1965, 2002, https://doi.org/10.4271/2002-01-1965.
SAE 2002 Transactions Journal of Materials & Manufacturing
Number: V111-5; Published: 2003-09-15
Number: V111-5; Published: 2003-09-15
- Review of the Partnership for a New Generation of Vehicles National Research Council. National Academy Press Washington, D.C. 2000 47
- Ibid. 50
- Ibid. 47
- Sullivan, John Hu Jenny Life Cycle Energy Analysis for Automobiles Proceedings of the 1995 Total Life Cycle Conference Society of Automotive Engineers
- Review of the Partnership for a New Generation of Vehicles 50
- Ford Motor Co. Personal communication with John Sullivan August 2000
- Das, Sujit The Life-Cycle Impacts of Aluminum Body-in-White Automotive Material 41 44 August 2000
- The Aluminum Association Life Cycle Inventory Report for the North American Aluminum Industry August 1998
- Dearlove, Thomas [Advanced Composites Consortium of USCAR]; Tom Gibson and Ron Williams [General Motors]; John Sullivan, Carl Johnson, and Jim DeVries [Ford Motor Co.] Personal Communication May-November 2000
- Automotive Engineering International Society of Automotive Engineers (SAE) International 71 May 2000
- Life-Cycle Environmental Evaluation of Aluminum and Composite Intensive Vehicles 3
- Mascarin, Anthony E. et al. Costing the Ultralite in Volume Production: Can Advanced Composite Bodies-in-White Be Affordable? The Hypercar Center, Rocky Mountain Institute Paper written for the 1995 International Body Engineering Conference & Exposition (Detroit, MI) 31 October 2 November 1995 31 August 1995
- Review of the Partnership for a New Generation of Vehicles 47
- American Iron and Steel Institute ULSAC Overview Report http://www.autosteel.org/ulsac_overview_report/
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- AEI March 2001 75
- Automotive Engineering International Society of Automotive Engineers (SAE) International 13 October 2000
- AEI May 2000 71
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- Ibid. 20