These guidelines are intended for those engineers and scientists who evaluate the corrosion performance of painted automotive parts in laboratory cyclic tests. The guidelines are intended to help ensure that the results of the tests can be used to reach conclusions concerning the variables under study without being confounded by the test procedure itself. The guidelines also serve as a means to assist users of this type of test in obtaining good inter-laboratory agreement of results.

Materials, Processes and Parts Council

A Conceptual Framework for Value Chain Analysis of End of Life Aircraft Treatment in the Context of Sustainable Development

2014-01-22329/16/2014

The End of Life phase of Aircraft is a relatively complex phase in life cycle of this product. The retired Aircrafts need to be parked in certain conditions. Some valuable parts are disassembled and the rest of them are dismantled. Materials are separated and upgraded, waste is burned or deserted and toxic materials restrained or incinerated. All of these activities should be performed in an ecologically right manner; however, collectively produced added values for all stakeholders need to be considered. This paper aims to provide a conceptual framework for value chain analysis of Aircraft recycling process in the context of sustainable development. The value chain related to recycling aircraft at the end of life was chosen to generate an in-depth analysis of the value chain, considering environmental and socio-economic concerns. The value chain framework for recycling of fleets is identified. The key processes with environmental and social impacts are determined. The decision making process along the value chain and the policy framework including codes, regulations and standards are addressed. Finally, the proposed approach with providing a basis for evaluation of effectiveness, efficiency and stability across the value chain aids decision makers to design a sustainable framework for End of Life aircrafts treatment.

Keivanpour, Samira, Mascle, Christian, Ait Kadi, Daoud

Impacts of Non-Traditional Uses of Polyurethane Foam in Automotive Applications at End of Life

2014-01-90995/5/2014

Polyurethane (PU) foam is used for many automotive applications with the benefits of being lightweight, durable, and resistant to heat and noise. Applications of PU foams are increasing to include non-traditional purposes targeting consumer comfort. An example of this is the use of PU foam between the engine and engine cover of a vehicle for the purpose of noise abatement. This addition will provide a quieter ride for the consumer, however will have associated environmental impacts. The additional weight will cause an increase in fuel consumption and related emissions. More significant impacts may be realized at the end-of-life stage. Recycling PU foams presents several challenges; a lack of market for the recyclate, contamination of the foams, and lack of accessibility for removal of the material. PU foam pieces are likely to end up being landfilled after the vehicle is shredded, negating the benefit of choosing this material for its recyclability over another non-recyclable material. PU foams have been credited with contributing to the light weighting of vehicles, however it is important to distinguish between cases where PU foams replace heavier materials and where they are added for comfort. It is also necessary to make manufacturers aware of the gap between what is technically feasible in terms of recycling and what can be practically accomplished with present day technology and markets. As the use of PU foams increase it is imperative to address the obstacles surrounding recycling so that the benefits of these foams can be realized without negative end-of-life impacts.

Miller, Lindsay J., Sawyer-Beaulieu, Susan, Tam, Edwin

New technologies for 2014

13AEID1203_0112/3/2013

OEM and supplier engineers are all about technical innovation. In this special feature, Automotive Engineering International highlights (in no particular order) some notable ones debuting on 2014 models. Mercedes-Benz, using networked electronic systems (sensor fusion), introduced on its MY2014 S-Class a suspension system that can “see” the road surface ahead and make ultra-high-speed decisions on how to deal with it. Called Magic Body Control (MBC), the anticipatory system comes with “a world first” Road Surface Scan stereo camera and Mercedes' established Active Body Control. The windshield-mounted camera monitors the road to a distance of 15 m (49 ft) in front of the car. Analyzing the resultant images and information about the car's driving status, a control unit then calculates its optimum strategy. This means softening or stiffening damper reaction ahead of the event and increasing or reducing the load to each wheel via an active hydraulic system. MBC reacts in “fractions of a second” and operates up to speeds of 130 km/h (81 mph). See related article at http://articles.sae.org/12330.

Glossary of Terms in Use in Green Innovation and Sustainable Practices in the Automotive Industry

J2965_201306 (Current)6/17/2013

Develop terminology and definitions specifically for the automotive industry that defines greener and more sustainable materials and practices. The document will provide information and context for how and where the terms are used in the auto sector. In some cases, there may be more than one definition provided as some terms have different meanings in different countries.

Green Technology Steering Committee

Opportunities and Control Measures for Sustainable Transport Growth in Emerging Economy Regions-India

2013-01-10374/8/2013

Sustainable development is a very complex concept involving several inter-related issues and concerns. Globalization has given a new dimension to social, economic and environmental development associated with the perceived responsibilities and growth indicators. Both developing and developed countries have the opportunities to exploit comparative advantages in the changing economic, social and environmental scenario while targeting sustainable growth together with expansion of the business prospects. Every region perceives these opportunities with different notion. There is a plethora of indicators for assessing sustainability. However, assessment criteria, prioritization and trade off for a given sustainability parameter against the other could be very complex while evolving transport growth model in emerging economies. The paper intends to deliberate the various yard sticks to evolve sustainable development of transport sector, highlighting issues and concerns in the developing countries. The attributes that contributed in the past, for transportation growth and the future challenges viz. automotive growth in India, energy demand, fuel efficiency norms, technology options, alternate fuels and alternate energy (electric mobility) will be dealt with the case studies. The control measures and the way forward in achieving the targeted sustainable growth for the developing countries will be recommended.

Banerjee, Prashant Kumar, Chaudhari, Manohar, Salunkhe, Uday, Ravishankar, S

Uncertainties in the Life Cycle Assessment of Passenger Vehicles

2013-01-12794/8/2013

Reducing the environmental impact of transport on Climate Change is an important policy target and the European Union has been spearheading legislation in this area. However, the EU has chosen, until now, to focus on tailpipe emissions, which only represent the impact of the use phase of the vehicle and leave aside the impacts of material production and car manufacturing as well as the end of life. Anyway, the corresponding regulations have given the direction for car manufacturer to focus on lightweighting, which is an important part of the solution. It is incomplete, however, as a more holistic approach encompassing all the phases of the Life of a vehicle ought to be taken on board, which is exactly what a Life Cycle Analysis (LCA) is meant to do. The purpose of this paper is to analyze the advantages and the limitations of LCA in the transport sector. Some very different categories of vehicles, in terms of powertrain, power and weight are examined as well as a degree of uncertainty in various LCA variables. The Greenhouse Gas Automotive Materials Comparison Model developed by the University of California Santa Barbara has been used to model these various vehicles. LCA demonstrates clear differences between many scenarios: the influence of the type of powertrain and of lightweighting - when carried out properly - are obvious. On the other hand, comparing lightweighting materials in terms of GHG emissions often exhibits differences which are less than the uncertainty of the data and thus are inconclusive. Lightweighting with Advanced HSS, however, is clearly a positive solution.

Carvallo, Adriana, Birat, Jean-Pierre L., Gauriat, Antoine, Thomas, Jean-Sébastien

Titanium Alloy Welding Wire 6Al – 4V, Extra Low Interstitial Environment Controlled Packaging

AMS4956F (Historical)4/2/2013

AMS G Titanium and Refractory Metals Committee

Treatment of End of Life Vehicles in Brazil: Challenges and Opportunities

2012-36-021710/2/2012

Style changes and technological advances have led to reduced service life of current products as automobiles. These are among the goods that are constantly re-designed to meet our growing needs for improved products. However, these demands for new products and more modern has meant a great cost to our natural resources, such as excessive use of raw materials, water and energy during production, use and end of life cycle of these assets. The increasing scarcity of land available for the proper disposal of waste in landfills, in addition to the high cost of implementing these areas and the increasing distances to urban centers imply the need to reduce solid waste generation, including here the automotive. The growth of the automotive market has created a serious problem due to the disposal of urban waste volumes generated, the great diversity of materials involved and their toxicity. The objective of this study is to analyze the various constituent materials of the vehicle and its impact on the environment (APPENDIX 1). We will deal with some aspects of the project, construction, use and final disposal of automotive vehicles. We will understand how the decisions within the project to meet the performance requirements and vehicle safety may have an impact on the recyclability of motor vehicles. We are also going to discuss implications of the taxes and how they can encourage or obstruct sustainable practices. We will look at how the legislation must be improved to develop the automotive recycling industry. In the end, we will examine the current conditions present in the country for treatment of vehicles at the end of the cycle of life and identify the challenges, barriers and opportunities for the treatment of End of Life Vehicles (ELV) in Brazil. We will discuss the current disposal ELV in Brazil and how this impacts on the environment and natural resources.

Filho, Jose Joaquim

Experimental Investigation of Light Metal Scrap on Out-of-Plane Tea Ring and Shredding Test

2012-01-20629/24/2012

The objective of “Experimental Investigation of Light Metal on Out-of-Plane Tearing and Shredding Test (wall thickness less than or equal to 10mm)” is to find solutions to shredding and recovery processing of end-of-life vehicles and household appliances. By way of tensile test, the mechanical characteristics of the light metal scrap material were obtained. On the basis of strengthening effect, the constitutive relations of materials were reduced to bilinear model. Through the trousers test, Light Metal Scrap produced equal and opposite elastic-plastic bending deformation twice in the tearing process was observed. So in process of trousers tearing test, the total work external force did was mainly composed of specific tearing work and elastic-plastic bending work of trousers legs. The features of light metal scrap materials in tearing and shredding process are investigated, and the specific tearing work per unit area of new crack surface was regarded as a tearing property of light metal. The specific tearing work under different loading rate was compared and that the specific tearing work is not insensitive to loading rate in a certain range was found. The investigation showed that: The tensile specific work of rupture of light metal scrap is one order bigger than specific tearing work, meaning that tearing mode will be better on shredding recovery treatment of end-of-life vehicles and household appliances.

Liu, Jianxiong

Sensitivity/Uncertainty Analysis of Material Thermal Degradation Models

2012-01-09554/16/2012

Time-temperature analysis methods are usually applied to predict the useful life of automotive components. Components life is affected by exposure to heat during vehicle service life. The extent of reduction in component life, which may be caused by material thermal degradation, depends on the component temperature and the time duration at that temperature. The rate of material thermal degradation of automotive components varies widely depending on material thermal stability, vehicle duty cycle, and the thermal environment that the component is exposed to. Thermodynamic properties such as the activation energy of each material are used to determine the rate of thermal degradation [1,2]. In this approach, material thermal degradation models are used to predict component life during the service life of a vehicle. As the rate of thermal degradation increases with increasing material temperature, the useful life of a component will be reduced as the material temperature increases. Therefore, it is desired to keep the rate of thermal degradation low enough so that a certain level of component performance can be maintained at the end of the vehicle life. The acceptable performance level may be component dependent and vehicle dependent. For example, a passenger car will require different performance than a heavy duty truck even if same material is used on both vehicles. To maintain the required component performance, the definitions of “long term temperature goal” and “short term temperature goal” are introduced. Therefore, the factors affecting the predicted component life can be summarized as follows: measured component temperatures, material long and short term temperature limits (goals), material activation energy, and vehicle duty cycle. All of these factors typically have an inherent uncertainty. These uncertainties will affect the overall confidence level in the predicted time-temperature calculations. Therefore, it is the main purpose of this paper to estimate the uncertainty in component life predictions and their sensitivity to each of the input factors. Given these uncertainties, it is statistically possible to determine the most influential parameters and the overall uncertainty in the predicted component life. Several examples are given where the sensitivity/uncertainty analysis for different vehicle components are presented.

El-Sharkawy, Alaa, Kamrad, Joshua

Extracting the “Mines on Wheels,” An Important Contribution to Sustainability

2012-01-03504/16/2012

Since the industrial application of the internal combustion engine, the number of vehicles and their technologies has continuously grown world-wide to over 50 million vehicles yearly since 2000 and are forecast to grow to 180 million yearly by 2050. Over time societal and consumer needs with regard to vehicles have changed and environmental considerations have become much more important such as increasing fuel efficiency and reducing vehicle emissions. The precious metals group (PGM) plays an important role in meeting these needs. The continuously increasing use of metals combined with the fact that natural resources are finite make that business as usual is not sustainable. The automotive industry is the single largest user of PGM's and those contained in end of life catalytic converters are richer than any known primary source of PGM. The vehicle is a “mine on wheels” not only for the PGM contained in the converters but also for other metals used in the advanced technology vehicles. Umicore is a major supplier of catalytic converters and is active in spent automotive catalyst recycling. Umicore is also a major supplier to and potential recycler of future technologies such as electrical and fuel cell vehicles. Valuation of material from end-of-life vehicles is an essential part of any recycling process but can be tainted by varying practices or malpractices. Umicore promotes the use of a scientific method based on the real metal content of the spent product where all commercial transactions are assay-based. Accurate analysis is essential, but even more so is the accurate weighing and sampling of incoming material. Umicore provides state-of-the-art material weighing and sampling combined with a unique European based smelting & refining process which guarantees optimum metal yields. Providing a reliable and transparent recycling process allows Umicore to transform the “mines on wheels” into an important contributor to sustainability.

Caffarey, Mark, Meskers, Christina, Van Kerckhoven, Thierry

Reverse Logistic Planning and Product Take Back Analysis for Sustainable Product & Process Design

2011-01-08524/12/2011

Diverse factors of sustainability drive the life cycle analysis of the product which already exists and need to go through Eco-redesign strategy. Sustainability in all sphere of the design approach requires compliance with regulations and standards. The concept of the reverse logistics and take back is getting very important in the wake of product recalls for exclusive compliance of safety requirements to satisfy the regulations. That is why it is very important that the reverse logistic supply chain net work for the product return lead time and life cycle impact of product planning should begins long before disposal and at the new product design time. This is why it is now believed to be best the way to measure the impact through a Life cycle analysis and reverse logistic planning which necessarily to be decided at the conceptual stage as to how the steps and stage of reverse logistic will be followed. The EU End of life vehicle directive and its effect are very important in this direction. A conceptual model is presented in this regard which shows the role of reverse logistic and life cycle assessment of the product like packaging of plastic for which there is dearth of significant reverse logistic aspect that can influences the manufacturer's choice for the potential consumer. The dynamics in the lead time affect performance if this can be maximized stochastically in the wake of product take back and recalls for establishing global green economy. However, the model describes the function from the retailer path with which is the vital connection for other products like fridge, deep freezers, air conditions, juicers, mixers, cooking range heaters etc can be done by using the reverse logistic for re-manufacturing. Reverse Logistic and Life cycle analysis planning determines the big picture of the entire life cycle of the product in a holistic fashion for making policy decision and recommendations for all stake holders of the global market economy. Besides after the unloaded products to the specified consumer market station the return path of the same delivery service can be utilized logically for the reverse logistic and product take back. In the next generation of logistics, proactive companies must be innovative enough to integrate all strategic and operational factors in their reverse-logistics systems studies for their product take back as a part of a Comprehensive design for the new product & process system life cycle analysis.

Ali Qureshi, Zulfiqar

Vehicle Recycling, Reuse, and Recovery: Material Disposition from Current End-of-Life Vehicles

2011-01-11514/12/2011

The goal of this research was to determine and quantify today's actual end-of-life vehicle disposition rates based on their age and material content. The current facts and status of today's automotive recycling industry were sought. Disposition rates and material trends were projected using adjusted ELV age data from Duranceau and Linden's 1999 research and average materials content data from open-sources. End-of-life vehicle age and population data adjustments were used to estimate representative material compositions for the US and Canadian ELV fleet. The disposition rates were broken down by percentages of (1) part weight reused, (2) part weight remanufactured, (3) part weight recycled pre-shredder, (4) weight of recovered fluids, and (5) weight of metals recycled post shredder. The 86.3% percent material recovery established in this study was compared to the 84% reported in Paul's 2001.

Duranceau, Claudia M., Sawyer-Beaulieu, Susan

Intake System Design Approach for Turbocharged MPFI SI Engine

2011-26-00011/19/2011

The automotive industry is currently facing the challenge of significantly stringent requirements regarding CO₂ emission and fuel economy coming from both legislations and customer demand. Advanced engine technologies play a vital role for downsizing of gasoline engine. The development of key design technologies for high efficiency gasoline engines is required for the improvement of competitive power in the global automobile industry. This paper focused on effect of geometry of intake manifold of gas exchange process and consequently the performance of the engine. Specially, the optimal design technologies for the intake manifold and intake port shape must be established for high performance, increasingly stringent fuel economy and emission regulations. Space in vehicle or packaging constraints and cost are also important factors while consideration of the design. Two models of intake manifolds discussed in this paper, such as short runner intake manifold and long runner intake manifold with different plenum chambers. Parameters like manifold plenum volume, runner length affecting dynamically on gasoline turbocharged engine performance are studied and evaluated. By employing these parameters, performance prediction of 2.2-liter MPFI Turbocharged Gasoline Engine is done by using mathematical models made from AVL Boost 5.1 software. CFD simulations are conducted on the both proposal to examine the distribution of the air flow from plenum to individual runners. Actual test bed engine performance is predicted and compared with boost performance. Injector position is defined on last section of primary pipe or runner in order to maximize fuel vaporization. The fact, fuel should not be injected on port walls and accordingly angle has been confirmed by injector target test.

Jagtap, Harishchandra, Vinayak, Chavan, Koli, Ravindra

The compromise between alternative materials usage and the reduction in weight and fuel consumption in passenger vehicles, a life cycle approach

2010-36-022910/6/2010

All over the world, the combat actions to reduce the vehicles' environmental impacts are focused on reducing emissions during the vehicle use; guiding many companies to work on lighter technologies development without considering its whole life cycle's impacts. It was demonstrated that the knowledge of the whole life cycle of the product under study is fundamental to fully evaluate its benefits and burdens. In this context, life cycle assessment (LCA) is an important tool for the systems improvement; his entire life cycle approach allows the identification and assessment of critical aspects and may be useful for helping decision makers to develop his products so as to cause the least environmental impact. During this study, applying the LCA methodology, it became evident that the use of lighter materials is environmentally advantageous to certain impacts, such as reducing the greenhouse gases emission, but may be disadvantageous to others, while the use of composite materials with fibers from renewable sources presents smaller gains in all impacts assessed. A key finding is that each phase of the vehicle's life cycle can represent a significant percentage of its total impact, and a LCA study must be conducted to point which phase is the main responsible for the total impact assessed, and finally, to show that the application of an alternative technology may really produce good results over the vehicle's whole life.

de Souza, Julio Cesar, Timponi, Nilson Sardinha

The Recycling Potential of Brazilian Vehicles

2010-36-043410/6/2010

Brazil has a fleet with more than 30 million vehicles of combustion engine, lights and rides, riding for all territory, with a rate of 2 million sold per year. With this increased of fleet, specially from the end of 1990s, promoted principally by automobile factories that had come to Brazil and by circumstantial changes on the internal economy, some problems happened. The main problems are mobility difficulties on large cities (as traffic jams) and the environmental impacts (resources depletion, climate changes, issues of greenhouse effect gases, air pollution, acidification, waste generation, among others). Beyond that, in function of an inexistent national program and an undefined and unclear policy, there are uncountable (and potential) number of vehicles that could be sent to recycling processes, contributing to closed looping as raw material of new vehicles. In according to this perception, this paper aims to provide information related to the main vehicles parts and components in end-of-life that can be inserted in a closed loop model from reverse manufacturing practices. This information can contribute to the traceability and recycling components, for generation of new qualifications and for the ecodesign of new vehicles, beyond that contribute to the more eco-effective sustainable development of the Brazilian automotive industry.

Lazzari, Marcio

Secondary Cooling Circuit for Turbocharged Engines: Estimation of the Fuel Consumption Reduction in Real use According to the LCCP Method

2009-01-306610/1/2009

This paper deals with the application of a secondary cooling circuit to a turbocharged engine for a segment C car. The secondary coolant loop, working at low temperature, has been used to cool down the charge air by means of a coolant-to-air exchanger and as hot source of the HVAC circuit by means of a coolant-to-refrigerant condenser. The system is able to ensure both a constant air temperature at engine inlet, with smaller variations for different vehicle working conditions if compared to the normal production equipment, and a lower pressure at the condenser of the HVAC system, thus leading to a reduction in the fuel consumption of the vehicle. Starting from experimental measurements on MVEG cycle, an estimation of the fuel consumption reduction of the system in real use has been done using an LCCP tool FGA did develop and it is here presented. A further estimation of the impact of the this innovative cooling system on the fuel consumption of segment A car equipped with a turbocharged engine has been done still by means of the LCCP method.

Vestrelli, Francesco, Monforte, Roberto, Fausto, Di Sciullo

Life Cycle Analysis to Estimate the CO2-Equivalent Emissions from MAC Operation

J2766_200902 (Historical)

2/16/2009

This recommended best practice outlines a method for estimating CO2-Equivalent emissions using the GREEN-MAC-LCCP© (Global Refrigerants Energy and ENvironmental – Mobile Air Conditioning – Life Cycle Climate Performance) model (also referred to as “the model” in this standard).

Interior Climate Control Vehicle OEM Committee