Non-metallic Materials: Supporting the Decarbonization of the Automotive Sector

The growing challenges of carbon footprint reduction in the automotive market is driving efforts not just to reduce the fuel economy and recyclability of materials, but to radically reduce the vehicle life-cycle emissions. Efforts towards carbon neutrality during manufacturing and assembly (including the supply chain) and zero tailpipe emissions by accelerated development of electric powertrains are enabling the introduction of new solutions in the automotive industry. Several trends can be identified when developing new parts/systems/materials for the automotive sector: (i) supporting the electrification of the power train, either for BEV, HBEV (Hybrid Battery Electric Vehicles) or HEV; (ii) recyclability (design for recycling), circularity and overall reduction of materials carbon footprint; (iii) enhanced safety of the vehicle occupants and pedestrians; (iv) light weighing as a means to reduce specific fuel consumption and to decrease emissions, increase range or alleviate additional weight added by the batteries (specific for BEV); (v) higher functional integration to reduce the part count and simplify assembly; (vi) aerodynamics as a means to enhance range and reduce specific energy consumption; and (viii) de-centralization of the supply chain, thereby de-risking geopolitical dependency of highly localized components/materials. This very challenging context is bringing the perfect ecosystem to push the boundaries on the R&D space of the automotive sector by the increased adoption of non-metallic materials in novel structural and semi structural applications. Advances made in polymers especially thermoplastics development, and improved design and simulations tools have led to a clear trend where boundaries of what traditionally “must be” metal (more astringent requirements) are being push, cannibalizing some of the traditional “metallic” applications by plastic-intensive multi-material design approaches including the use of hybrid composites (long glass fiber reinforced thermoplastic products together with strategically placed continuous glass fiber composite inserts). The offered broad choice of physical and mechanical properties normally linked to lower density than metallic counterparts, higher level of parts integration, achievability of complex shapes, recyclability/circularity or appropriate manufacturing rates are making them the materials of choice for applications such as tailgates, battery boxes, front-ends or cross-car beams among others.

Speakers

Francisco D. Nieves Bogonez

KAUST

KAUST Research Centers

KCC Research Groups