Lighter Vehicles for Fuel Efficiency and Emission Reduction

July 7, 2008 – 5:04 am

Car manufacturers are embarking on lightweight materials for producing lightweight and ecofriendly cars to meet the emission norms resulting from global environmental concerns. For instance, European Commissions emission reduction norms require automotive manufacturers to cut car emissions from the current level of 160 g/km of CO2 to 130 g/km by 2012. The new regulation, which is awaiting approval by member states of the European Union, requires CO2 emissions to be in proportion to the car weight. Violation of the regulation will attract a penalty of up to €95 per excess gram of CO2 emitted by the automobile.

This has sparked the demand for lightweight materials such as polypropylene that can be used for producing cars without compromising on cost, performance, safety and recyclability. A number of lightweight high strength materials including aluminum, magnesium, titanium, advanced high-strength steels, fiber-reinforced composites and metal matrix composites can be used for producing lightweight cars, but high production cost of these materials makes them unviable. According to the US Department of Energy mild steel can form a suitable substitute for these materials.

The US Department of Energy is conducting research on developing novel technologies that can reduce material cost and enhance their manufacturability. For every 10% of weight reduced in a car, the fuel economy increases by 7%. Researchers in the automotive industry are striving to develop materials that meet the emission norms. Research efforts are being focused on:
• Cost reduction
• Developing enhanced manufacturing, processing, and forming technologies
• Design data, predictive modeling, and test methodologies
• Joining, recycling, repair, and non-destructive evaluation

Worldwide auto manufacturers are also implementing efforts to make their vehicles fuel efficient, lightweight and ecofriendly. Mazda Motor Corporation has expressed plans to enhance the fuel efficiency of its vehicles by 30% through 2015. The process also includes weight reduction of new vehicles produced by 100 kilograms. Mazda has been implementing efforts to produce ecofriendly vehicles for quiet some time. From 2001 to 2008, Mazda has increased the average fuel economy of its vehicles sold in the Japanese market by 30%. Volkswagen has taken up the mission of reducing the weight of all its models ranging from Bentley to Skoda.

Engineers in General Motors and Ford are using new adhesive technologies and thin steel to reduce automotive weight and they have gained significant success by doing so. Shawn Morgans, Ford’s body structure technical leader notes that the company has reduced the weight of the 2008 Ford Focus by 3.7 pounds through increased use of crash-durable structural adhesives in the upper body. He further commented that “We have reduced spot welds; the focus from here on will be to reduce the gauge of the steel.” (Source: www.designnews.com)

In view of the rising fuel prices and environmental concerns, consumers are showing preference towards fuel-efficient and lightweight vehicles. People worldwide are replacing SUVs and pickups with smaller crossovers and fuel-efficient cars. In the US, used car dealers are refusing to buy SUVs as they are unable to find any takers. As reported in April 2008, small cars are emerging as the largest segment in the US auto market and accounted for 18% of the new car sales.

Responding to the changing market demands and rising cost of raw material, automobile manufacturers are concentrating more on producing lighter vehicles. Thus, in the future lightweight, fuel efficient and environmentally friendly vehicles are expected to rule the market.