Page 102 - Technology Roadmap Transportation

TECHNOLOGY VISION 2035

6.0

MATERIALS AND

RECYCLING ISSUES

6.1 INTRODUCTION: by both prompt recycling of scrap materials
The quest to reduce the weight of vehicles is during manufacture, as well as recycling of the
not new. It is safe to say that weight reduction end-of-life vehicles incorporating such materials.
of vehicles is an evolving field of materials and Statutory mandates in a global economy and
manufacturing, which offers a robust vehicle environmental considerations also dictate a
design. Reducing the overall vehicle size is the need to recover or make usable many non-
easiest way to reduce its weight. However, in metallic materials, which are currently not
reality, the average vehicle weight has increased recycled. The development of viable strategies
steadily since the early 1980’s due to the for control of materials of concern is also critical
growing appetite for larger vehicles. These to enhancing recyclability.
trends are expected to continue making it
unlikely that light weighting can be achieved by 6.2 CURRENT AND FUTURE MATERIALS
a simple reduction in fleet vehicle size. TRENDS IN GLOBAL ROAD TRANSPORT
The automotive industry uses a large number
Another method used to reduce vehicle of materials to manufacture vehicles, which
mass is through a complete vehicle redesign. include iron, aluminum, plastics, steel, glass,
Examples of redesign may be a switch from rubber, copper, and others. These parts are
body-on-frame to uni-body construction used to create everything from dashboard
or reducing non-structural elements of the needles and wirings, to the engine block and
vehicles. However, in many instances, this is transmission gears.
not possible. For example, changing the body
construction affects the overall volume of These materials have evolved greatly over last
the vehicles produced and may increase cost few decades, becoming more sophisticated,
due to complex assembly procedures. Unlike and safer. New automotive manufacturing
vehicle size and content reductions, advanced technologies have emerged over the years
light-weight materials may be introduced in the and are used in increasingly innovative ways.
vehicle with little or no impact on the consumer. Urban vehicles are becoming lighter and fuel
In fact, light weighting while maintaining vehicle efficient, primarily due to use of new materials
size may actually increase the performance of such as carbon fiber, steel, aluminum, titanium,
the vehicle. A combination of high-strength, magnesium and plastics. Currently, however
low cost and capability to be produced in cost is a major criterion limiting the use of
high volumes has made mild steel a very these materials. Figure 6.1 shows scenario in the
attractive material in automotive applications. automotive sector.
Therefore, mild steel has been a dominant
material for automotive components. However, EU and Japan are at the forefront of using new
as technology changes and fuel economy materials in automotive sector. The potential
acquires more importance, other materials for new materials is immense. As they allow
would gain acceptance in automotive industry. new types of designs and improve aesthetics of
As these new materials become prominent in the vehicles. Materials have been the backbone
the automotive industry, engineers and scientists of the automotive industry, which is being
would have an opportunity to explore new impacted by CO emission legislations. Engine
2
applications for them, further increasing their downsizing, turbo-charging and light-weighting
utilization. are the global trends in the automotive industry,
which are affecting the choice of materials. A
Economic use of advanced lightweight materials 10% reduction in vehicle weight results in a
for automotive construction will be enhanced 5-7% fuel savings provided the power-train is

100 ROADWAYS