Green Principles for Vehicle Lightweighting.

A large portion of life cycle transportation impacts occur during vehicle operation, and key improvement strategies include increasing powertrain efficiency, vehicle electrification, and lightweighting vehicles by reducing their mass. The potential energy benefits of vehicle lightweighting are large, given that 29.5 EJ was used in all modes of U.S. transportation in 2016, and roughly half of the energy spent in wheeled transportation and the majority of energy spent in aircraft is used to move vehicle mass. We collect and review previous work on lightweighting, identify key parameters affecting vehicle environmental performance (e.g., vehicle mode, fuel type, material type, and recyclability), and propose a set of 10 principles, with examples, to guide environmental improvement of vehicle systems through lightweighting. These principles, based on a life cycle perspective and taken as a set, allow a wide range of stakeholders (designers, policy-makers, and vehicle manufacturers and their material and component suppliers) to evaluate the trade-offs inherent in these complex systems. This set of principles can be used to evaluate trade-offs between impact categories and to help avoid shifting of burdens to other life cycle phases in the process of improving use-phase environmental performance.

Impacts of Vehicle Weight Reduction via Material Substitution on Life-Cycle Greenhouse Gas Emissions.

This study examines the vehicle-cycle and vehicle total life-cycle impacts of substituting lightweight materials into vehicles. We determine part-based greenhouse gas (GHG) emission ratios by collecting material substitution data and evaluating that alongside known mass-based GHG ratios (using and updating Argonne National Laboratory's GREET model) associated with material pair substitutions. Several vehicle parts are lightweighted via material substitution, using substitution ratios from a U.S. Department of Energy report, to determine GHG emissions. We then examine fuel-cycle GHG reductions from lightweighting. The fuel reduction value methodology is applied using FRV estimates of 0.15-0.25, and 0.25-0.5 L/(100km·100 kg), with and without powertrain adjustments, respectively. GHG breakeven values are derived for both driving distance and material substitution ratio. While material substitution can reduce vehicle weight, it often increases vehicle-cycle GHGs. It is likely that replacing steel (the dominant vehicle material) with wrought aluminum, carbon fiber reinforced plastic (CRFP), or magnesium will increase vehicle-cycle GHGs. However, lifetime fuel economy benefits often outweigh the vehicle-cycle, resulting in a net total life-cycle GHG benefit. This is the case for steel replaced by wrought aluminum in all assumed cases, and for CFRP and magnesium except for high substitution ratio and low FRV.

Vehicle-cycle and life-cycle analysis of medium-duty and heavy-duty trucks in the United States.

Medium- and heavy-duty vehicles account for a substantial portion (25 %) of transport-related greenhouse gas (GHG) emissions in the United States. Efforts to reduce these emissions focus primarily on diesel hybrids, hydrogen fuel cells, and battery electric vehicles. However, these efforts ignore the high energy intensity of producing lithium (Li)-ion batteries and the carbon fiber used in fuel-cell vehicles. Here, we conduct a life-cycle analysis to compare the impacts of the vehicle manufacturing cycle for Class 6 (pickup-and-delivery, PnD) and Class 8 (day- and sleeper-cab) trucks with diesel, electric, fuel-cell, and hybrid powertrains. We assume that all trucks were manufactured in the US in 2020 and operated over 2021-2035, and we developed a comprehensive materials inventory for all trucks. Our analysis reveals that common systems (trailer/van/box, truck body, chassis, and lift-gates) dominate the vehicle-cycle GHG emissions (64-83 % share) of diesel, hybrid, and fuel-cell powertrains. Conversely, propulsion systems (lithium-ion batteries and fuel-cell systems) contribute substantially to these emissions for electric (43-77 %) and fuel-cell powertrains (16-27 %). These vehicle-cycle contributions arise from the extensive use of steel and aluminum, the high energy/GHG intensity of producing lithium-ion batteries and carbon fiber, and the assumed battery replacement schedule for Class 8 electric trucks. A switch from the conventional diesel powertrain to alternative electric and fuel-cell powertrains causes an increase in vehicle-cycle GHG emissions (by 60-287 % and 13-29 %, respectively) but leads to substantial GHG reductions when considering the combined vehicle- and fuel-cycles (Class 6: 33-61 %, Class 8: 2-32 %), highlighting the benefits of this shift in powertrains and energy supply chain. Finally, payload variation significantly influences the relative life-cycle performance of different powertrains, while LIB cathode chemistry has a negligible effect on BET life-cycle GHGs.