Life Cycle Energy and Environmental Assessment of Aluminum-Intensive Vehicle Design

Advanced lightweight materials are increasingly being incorporated into new vehicle designs by automakers to enhance performance and assist in complying with increasing requirements of corporate average fuel economy standards. To assess the primary energy and carbon dioxide equivalent (CO(2)e) implications of vehicle designs utilizing these materials, this study examines the potential life cycle impacts of two lightweight material alternative vehicle designs, i.e., steel and aluminum of a typical passenger vehicle operated today in North America. LCA for three common alternative lightweight vehicle designs are evaluated: current production (Baseline), an advanced high strength steel and aluminum design (LWSV), and an aluminum-intensive design (AIV). This study focuses on body-in-white and closures since these are the largest automotive systems by weight accounting for approximately 40% of total curb weight of a typical passenger vehicle. Secondary mass savings resulting from body lightweighting are considered for the vehicles' engine, driveline and suspension. A cradle-to-cradle life cycle assessment (LCA) was conducted for these three vehicle material alternatives. LCA methodology for this study included material production, mill semi-fabrication, vehicle use phase operation, and end-of-life recycling. This study followed international standards ISO 14040: 2006 [1] and ISO 14044: 2006 [2], consistent with the automotive LCA guidance document currently being developed [3]. Vehicle use phase mass reduction was found to account for over 90% of total vehicle life cycle energy and CO(2)e emissions. The AIV design achieved mass reduction of 25% (versus baseline) resulting in reductions in total life cycle primary energy consumption by 20% and CO(2)e emissions by 17%. Overall, the AIV design showed the best breakeven vehicle mileage from both primary energy consumption and climate change perspectives.