LIGHTWEIGHT VEHICLE TECHNOLOGYCASTLE BROMWICH, UK

02.05.2012

MARK WHITE CHIEF TECHNICAL SPECIALIST

3

Light Weight Vehicle rationale

XJ LWV Body Materials

Aluminium Sheet Strategy

Material Selection

Increased Recycling (REALCAR - REcycled ALuminium Car research project)

LWV Barriers - Aluminium Cost Considerations

LIGHTWEIGHT VEHICLE TECHNOLOGYAGENDA

4

LIGHTWEIGHT VEHICLE TECHNOLOGYLEADER IN AUTOMOTIVE INNOVATION

World-Firstdual-view screen

Design Enabling

Human/VehicleInteraction

Vehicle CapabilityLow Carbon Propulsion/KE recovery.

Light-weight Vehicles

Energy Efficiency/Parasitics

Product Life-cycle

What Makes Us Different

World-First Automatic Terrain ResponseSystem (in development)

World-first user-selectable terrain response system

World-first pyrotechnicdeployable bonnet protectspedestrians whistmaintaining sleek design

World-first aluminiumMonocoquebodyshell

World-firststop-startmid-size SUV

World-firstcapacitive senseinterior switches

World-First Adaptive Cruise Control

Limo-Green

World-firstfull electric drivepremium F-segmenttechnology demonstrator

Gen. 1Gen. 2

World-firstclosed-loop aluminium re-cycling

5

We must make cars that comply with future CO2 & FE requirements

From 2012 - 2019 a mass based CO2 limit will be applied to all new cars

OEM’s must address the CO2 challenge in a cost effective manner, whilst maintaining vehicle attributes to be a sustainable business & meet targets

LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 CHALLENGE FOR CAR MAKERS

6

Options available:

Propulsion:

Mild/micro hybrids

Full hybridisation

Weight:

Aimed at reducing BIW, PT & Chassis weight, but across whole vehicle

Parasitics:

Reduce heat, friction & pumping losses, increase combustion efficiency

Hybrid Elec VehiclesFlywheel [Kinetic]Plug in Hybrids

Electric VehiclesCombustionTransmissionDrivelinePowertrain Efficiency

Weight EfficiencyVehicle Architecture

BIW & ClosuresChassis partsMaterial applicationJoining technologyLCAWeight v attributes

Aerodynamics Rolling resistancePT & ThermalEnergy management- Chassis systems- ElectricalClimate systems

LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 CHALLENGE FOR CAR MAKERS

7http://ec.europa.eu/environment/co2/co2_home.htmEU CO2 Technology Roadmap

LIGHTWEIGHT VEHICLE TECHNOLOGYEU CO2 TECHNOLOGY ROADMAP

8

Cur

rent

Ste

el

Opt

imum

HS

Ste

el

Alu

min

ium

Mag

nesi

um

CF

RP

toda

y

CF

RP

?

100%-10-20%

-40%-50%

-60%-70%?

Relative cost

Will cost dominate function ?

LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT REDUCTION POTENTIAL

9Kerb weight (kg)

LIGHTWEIGHT VEHICLE TECHNOLOGYCO2 EMISSIONS BY VEHICLE WEIGHT

PetrolDiesel

Hybrid

Modus

Citroen C2

Focus

Jaguar S 2.7

Jaguar XF 2.7

Insight

PriusCivic

Lexus GS450h

Lexus RX400h

Lexus LS600h

Citroen C1

50

100

150

200

250

300

500 1000 1500 2000 2500

CO

2g

/ k

m

10

What’s the CO2 benefit of 100 kg weight reduction?Certified CO2 figures are calculated using categories which cover a range of vehicle weights (typically 115 kg)

Due to the certified FE test being static, vehicle weight has no real effect. Resistance on rollers is used & is a constant value in each category

Therefore, we get steps in the certified CO2

values for a range of weights within a category

If we are at the top of a category & save100 kg we have the same CO2 figure

1 lower category is worth circa 2% CO2

Equating to 3.6 grams of CO2 on an XJ

LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & THE EU CERTIFIED CYCLE

CO 2

M as sHigh Lo w

High

Low

115kg d r o p p er T es t W e ig ht

Clas s

2% CO 2 d r op p er Te s t

W e igh t Clas s

11

100 kg weight reduction effect per vehicle on LCA

Production 650 kg

FE Improvement (certified) 720 kg

Fuel production 86 kg

Total LCA save per vehicle 1,456 kg (using ISO 14040/44)

Real world FE 110 kg

Total Carbon Impact of 100 kg save 1,566 kg

Therefore, every 1 kg reduction results in 16 kg CO2 per vehicle

But it ‘s on every car we make so it’s actually 2,56Kt of CO2 per 1kg

For every 100 kg that’s over a quarter of a million tonnes saved by JLR!

LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & LIFE CYCLE CO2

100 kg weight reduction effect per vehicle on LCA

Production 650 kg

FE Improvement (certified) 720 kg

Fuel production 86 kg

Total LCA save per vehicle 1,456 kg (using ISO 14040/44)

Real world FE 110 kg

Total Carbon Impact of 100 kg save1,566 kg

Therefore, every 1 kg reduction results in 16 kg CO2 per vehicle

But it ‘s on every car we make so it’s actually 2,56Kt of CO2 per 1kg

For every 100 kg that’s over a quarter of a million tonnes saved by JLR!

LIGHTWEIGHT VEHICLE TECHNOLOGYWEIGHT & LIFE CYCLE CO2

13

LIGHTWEIGHT VEHICLE TECHNOLOGYJAGUAR XJ MATERIALS – COMPLETE BODY

6%

1%

1% 1%2%

5%

5%

58%

19%

% by mass

Al sheet 6xxx

Al sheet 5xxxAl casting

Al extrusion

Mg casting

Mild steel

AHS steelHSS steelPHS steel

11%

66%

9%

9%

2% 3%

Al Sheet 6xxx

Al Sheet 5xxx

Al Casting

Al Extrusion

Mild Steel

AHS

Previous generation XJ

Current XJ

14

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ COMPLETE BODY OVERVIEW

% by part count

Al sheet 5xxx58% by mass

1%-Other

5%4%Profiles

6%5%Castings

88%91%Stampings

Current XJPrevious generation XJComponent type

15

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ DIE CAST PARTS

Castings used in key areas for:

– Complex geometry

– Local stiffness in high load input areas

– Part integration

– Reduce multiple sheet stack-up issues

– Self pierce rivet joining to other parts

16

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ EXTRUDED PROFILE PARTS

Bolt-on

Bolt-on– Use of high strength extruded alloys

to minimise weight & meet package requirements

– Bolt-on parts to support vehicle repair strategy

– Support manufacturing Bill Of Process (BOP)

17

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ BODY STRUCTURE MATERIALS

Al sheet 6xxx

Al sheet 5xxx

Al casting

Al profile

Mg casting

Mild steel

AHS steel

HSS steel

PHS steel

18

LIGHTWEIGHT VEHICLE TECHNOLOGYBODY STRUCTURE SHEET MATERIALS

Alloy Types

AA6xxxBAKE-HARDENINGALLOYS

MEDIUM STRENGTH OR

BAKE-HARDENINGALLOYS

Alloy Types

AA6xxx

AA5xxx

Requirements - BIW

– Good formability

– Corrosion resistance

– Good crash performance

– Long term stability of properties

Requirements – Outer skins

– Good formability

– High strength after paint bake

– Corrosion resistance

19

LIGHTWEIGHT VEHICLE TECHNOLOGYEXTERIOR SHEET MATERIALS

6111-T4 meets the following requirements:

– Suitable for all Class A exterior panels

– Sufficient formability to achieve style

– Compatibility with deep draw lubricants

– Dent resistance via strain & bake hardening

– Bake hardening without body shop oven

– Minimum gauge provides max weight save

– Weight save 20%+ over previous generation XJ

– 20% Material cost savings

New XJ bodyside material selected AA6111 T4PD Panel thickness = 1.2mm

Previous generation XJ used NG5754Panel thickness = 1.5mm

20

LIGHTWEIGHT VEHICLE TECHNOLOGYSTRUCTURAL CRASH ALLOY - Ac300 T61 – Typical in-service strength circa 225 MPa versus 140MPa for NG5754

– Ac300 in the T61 condition offers higher specific energy absorption

than strain hardening 5xxx series alloys

– Gauge for gauge the alloy absorbs 30% more energy per unit length

– Weight for weight more effective than DP600 steel

– Opportunity to down gauge NG5754 components by 20% of the original gauge

in crash crush applications - saving both weight and piece cost

– Ac300 T61 is resistant to stress corrosion cracking and can be used in environments

with elevated temperatures

21

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ JOINING TECHNOLOGY

– Self-Piercing Rivets (SPRs) are the main joining technology

– Adhesive bonding used for NVH & durability

– 1K adhesive used for sheet joints

– Blind rivets for single sided joint access

– Low speed & high speed ‘bolt-on’ structures

– No welding in the body shop

– Elimination of previous generation XJ roof joints

- zero MIG welding in house

Adhesive bonding (body & closures) = 154m

22

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ JOINING TECHNOLOGY

Nu

mbe

r of

SP

R’s

PreviousXJ

NewXJ

3000~11% reduction

– New XJ body is larger & meets increased functional requirements

– 11% reduction in SPR count in body structureover previous generation

– Savings in both direct & investment costsStandard wheelbase XJ (BSLD) has 2840 SPRscompared to over 5000+ spot welds for an equivalent steel body. SWB Body Complete has 3118 SPR’s

23

LIGHTWEIGHT VEHICLE TECHNOLOGYXJ BODY COMPLETE WEIGHT

Fro

nt D

oors

Rea

r D

oors

Bon

net

Tai

lgat

e

Fen

ders26

2017

11 4 324

246

Bod

y S

truc

tureM

ass

[Kg]

Unl

aden

Veh

icle

Wei

ght

Bo

dy

Com

ple

te(

bod

y +

clo

sure

s)

1843

A B New XJ D

Wei

ght [K

g]

Competitor data based upon LWB derivative data[1] - A2mac1 data[2] - JLR Teardown data

[1]

[1]

[2]

Steel body complete equivalent ~ 454KgData based upon mounting parts included in module, SWB 3.0L V6 Diesel

24Waste

Production Use Disposal

Raw material

Waste WasteEmissions to air and water

Production Use Disposal

Energy Energy Energy

Disposal, 1%

Production, 14%

Use, 85%

LIGHTWEIGHT VEHICLE TECHNOLOGYPRODUCT LIFE CYCLE ANALYSIS

Emissions to air and water

Emissions to air and water

0

100

200

300

400

500

600

Steel Aluminum Magnesium CDRC

Production End of Life

(MJ/kg)

0

100

200

300

400

500

600

Steel Aluminum Magnesium CDRC

Production End of Life

(MJ/kg)

25

LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR - RECYCLED SOURCESAluminium Recycling Opportunities

26

LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – ALUMINIUM SOURCES

End-of-life (ELV) vehicles

– Application of aluminium in vehicles

increasing

– Assess current industry material

separation

– Need to assess aluminium quality

– Avoid downcycling

Post-consumer waste

– Mechanical Biological Treatment plants

– Waste to energy plants

– Material quality impacts

– Cost opportunities

Recycled Aluminium Opportunities

AluminiumRemelter

Mechanical Biological

Treatment (MBT)

Energy from Waste (EfW)

Industrial Shredder

Separated Aluminium Shred

Scrapped Vehicles

End-of-Life vehicle processing

Post consumer aluminium waste

Note: 2009 = 40,500 tonnes land-filled in UK (Source: Alupro)

27

LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – ALUMINIUM SOURCES

Opportunity identified….assessment of aluminium in general wastePost-Consumer Waste Studies

Aluminium extracted from domestic household waste

Aluminium (3101)Aluminium (UBC) Aluminium (Foil)Aluminium (Areosol)

56.5% 23.7% 6% 6%

Actual MBT aluminium study conducted….further study in progress– Trial to separate and melt aluminium content

– Assess chemistry and suitability for 5XXX sheet

– Assess potential to reduce cost vs. primary aluminium

– Reduce aluminium lost to landfill Typical consumer aluminium waste

28

LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – IMPROVED RECYCLING

– Whitley and Gaydon Engineering Sites

– Heritage Motor Centre

– Purchase of Ecopacteur bins

– Actively investigating roll-out across business

– Increase awareness of recycling/reduce landfill

– JLR video can be viewed at www.everycancounts.co.uk

‘Every Can Counts’ Initiative – Adoption at Jaguar Land Rover

Can Crushing Bin

Every Can Counts – Video of introduction at Jaguar Land Rover JLR Case Study

29

LIGHTWEIGHT VEHICLE TECHNOLOGYREALCAR – NEXT STEPS

Alloy development

– Rigorous testing and validation

– Design rules

Recyled aluminium sources

– Vehicle ELV + post consumer

– Improved segregation

– Improvements in infrastructure

Recycling promotion

– Avoid materials going to landfill

– Responsible approach in the workplace

– Help educate/social responsibility

TSB application to develop a further recycled tolerant alloy ‘REALCAR 2’

30Market Rates - Al LME vs. HR Steel

0

500

1000

1500

2000

2500

3000

Jan-75 Jan-80 Jan-85 Jan-90 Jan-95 Jan-00 Jan-05 Jan-10

$/M

T Al LMEHR Steel

LIGHTWEIGHT VEHICLE TECHNOLOGYCOST CONSIDERATIONS

Raw Material Volatility

– Need to address the LME volatility cycle

31

1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 20081980 1990 2000

PriceUSD

2,200

2,400

2,600

2,800

1,200

1,400

1,600

1,800

2,000

Strategic weight save only – Luxury/ Sports

Premium sector Sports/ Saloons/ SUVs

Executive sector – all Models

D & C/D Segment High Volume & Mixed Metal Cars

10 - 20KT per year maximum

50 - 100KT per year maximum

100 - 250KT per year maximum in Eu

250KT - 500Kt per year plus in Eu

LIGHTWEIGHT VEHICLE TECHNOLOGYVOLATILITY EFFECT ON LWV MIGRATION

10 - 20KT per year maximum

32

G W P p e r B IW ( k g C O 2 e )

0

1 0

2 0

3 0

4 0

5 0

6 0

7 0

8 0

9 0

1 0 0

R S W S P R

C o n s u m a b le p ro d u c t io n

E x tra c t io n h e a t lo s s e s

E le c t r ic ity

LWV Body saves 40% relative to steel, enabling secondary weight saves (power train down sizing)

Joining technology gives significant energy save v welding & reduces waste (water & air extraction)

Significant improvement in Fuel Economy & CO2

reduction when combined with Power Train down sizing

Up to 50% recycled aluminium in LWV body, World-First Closed-Loop Aluminium Re-Cycling

Steel Diesel V8 SUV

Steel Petrol V8 SUV

LWV Diesel V6 SUV

LWV Diesel V8 SUV

LWV Diesel V6 HEV

Steel Diesel V8 SUV

Steel Petrol V8 SUV

LWV Diesel V6 SUV

LWV Diesel V8 SUV

LWV Diesel V6 HEV

LIGHTWEIGHT VEHICLE TECHNOLOGYLWV TECHNOLOGY SUMMARY

Thank you Vielen Dank

MerciGrazie