Road transport de-carbonisation. challenges and technologies. Carloandrea Malvicino

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1 Road transport de-carbonisation challenges and technologies Carloandrea Malvicino Fuel Economy and Vehicle Systems efficiency - Project line Director 20 Novembre, 2010

2 Conclusions Sustainability is the key factor The automotive sector asks for sustainable solutions to improve the fuel economy of vehicles Nanotechnology can contribute to the forthcoming clean and efficient mobility as enabling technology for effective: weight reduction on-board energy generation, recovery re-use and storage smart components and multifunctional materials Systems integration is a key element and a very important aspect to consider for an useful product development. A collaborative approach is crucial to exploit the nanomaterial potential in the automotive domain 2

3 Summary CO 2 emission reduction is one is the main evolution driver worldwide The mobility is a challenging business domain The passengers car market is even more challenging Sustainable innovation are required to achieve the target keeping the product affordable and sustainable Focus will be on Motion resistance reduction (aero and rolling) Weight reduction Engine downsizing Thermal management Waste energy recovery Electrification

4 Very different scenarios but a global market

5 always in evolution Road fatalities in the EU since 2001 Increased complexity Higher energy consumption Increasead weight Higher failure rates Higher costs Reduced fatalities (-30%) Improved fuel economy (+30%) Reduced noxious emissions (- 95%) Increased comfort Better driveability

6 Grams CO 2 per kilometer, normalized to NEDC Grams CO 2 per kilometer, normalized to NEDC with even more severe regulations Worldwide 270 asks to a CO 2 emission Regulations US-LDV California-LDV Canada-LDV EU Japan China S. Korea Australia US-LDV California-LD Canada-LDV EU Japan China S. Korea Australia US 2025: Solid dots and lines: historical performance 107 China 2020: Solid Solid dots dots and dashed and lines: historical enacted targets performance Solid dots and dotted lines: proposed targets Japan 2020: China : Solid dots and dashed lines: enacted targets Hollow dots and dotted lines: unannounced proposal Solid dots and dotted lines: proposed targets EU 2020: Japan 2020: 1 Hollow dots and dotted lines: unannounced proposal EU 2020: [1] China's target reflects gasoline fleet scenario. If including other fuel types, the target will be lower. [2] US and Canada light-duty vehicles include light-commercial vehicles. [1] China's target reflects gasoline fleet scenario. If including other fuel types, the target will be lower.

7 and rules EU regulations road map on emissions Designing the Future with "Clean Power" - Analysis and Strategic Solution Concepts on a Powertrain System Level - Dr.-Ing. Detlev Schöppe, Dr.-Ing. Hong Zhang, Dipl.-Ing. Friedrich Kapphan, Dipl.-Ing. Christof Schmidt - Continental, Regensburg, Germany - 21st Aachen Colloquium Automobile and Engine Technology 2012

8 asking for new technologies sustainable able to reduce the losses and improve the combustion efficiency

9 Development Guidelines The key elements to achieve the CO 2 emissions target can be summarized as follows: thermal engine improvement: combustion, frictions, vehicle motion resistance reduction: aerodynamics and rolling weight reduction effective on board management and high efficiency subsystems energy recovery: kinetic and heat increase of the travelled distance without emitting fossil CO 2 ((i.e. decarbonized mobility): progressive electrification, alternative fuel Approximately 2/3 of the energy contained in the fuel is converted into heat, which is wasted The economic affordability is crucial requiring an holistic approach and a deeper functional integration 9

10 The challenge in Europe should be faced with an approach AVERAGE EU FLEET 2006 AVERAGE EU FLEET LOW SEGMENT 2012 HIGH SEGMENT M= fleet average mass

11 not any more restricted to improving product s ability to accomplish its mission in the best possible way but also covering a broader sustainability concept aimed at improving ecological and social conditions

12 Why the passenger car market is challenging? Named «Hi-TECH» «Fast Food»

13 Why the passenger car market is challenging? fast, safe, trendy, high tech, comfortable, design Battery Electric Vehicle nice, safe, compact,trendy, high tech, affordable, sustainable,

14 Today For the fourth year, Fiat S.p.A. confirmed in Dow Jones Sustainability World and Europe Indexes Member 2012/13 In 2011 Fiat Group: 123,3 gco 2 /km (JATO Statistics) FOR THE FIFTH YEAR RUNNING LEADER FOR THE LOWEST CO2 EMISSIONS AMONG THE MAIN EUROPEAN BRANDS

15 a comprehensive approach to sustainable mobility is in place Customer Responsibility Downsizing Turbo Charged Mini hybrid Start & Stop Alternative Fuels & Non-conventional propulsion Twin air Transmissions MTA - DDCT Conventional Powertrain

16 The Fiat approach to de-carbonization Short term Reduce the energy needed by the vehicle during operation Increase the efficiency of the internal combustion engine Start&Stop, S&S extended to mini-hybrid Medium term Adapt the engine to fuels with low fossil carbon content Full hybrid, full hybrid plug-in Long term Shift to new powertrains fed by new energy vectors that enable the use of non fossil energy sources Full electric

17 The supply chain is a key factor The 2020 challenge demands the development of a new generation of components and a deeper systemic approach to the vehicle development This is an opportunity for suppliers to increase their competitively The suppliers can support the OEM thanks to their specific know how on components and subsystems and their evolution scenario Together, Suppliers and OEM, have all the information to focus the areas of main interest 17

18 New paradigms are possible Until now, the road mobility has evolved almost independently from the infrastructure context From fuel on board At least once in our history the combined evolution of vehicle and infrastructure led to great change to fuel on line can a similar approach be applied to personal mobility? Charge while driving 18

19 NANOTECH POTENTIAL APPLICATIONS

20 Polymer nanocomposite MATERIALS MODELLING METROLOGY COMPONENTS FINAL PRODUCT CNT on glass Natural fibers TEM of CNT in PP Extrusion PP with CNT, POSS, nanoclay New lightweight low cost fabrics Injection moulding Natural fiber reinforced PP PP nanocomposite (insitu) trim Thermoplastics with low level loadigs (1-5%) Improved mechanical properties Reduction of thermal expansion Reduction in flammability Low environmental impact Easy adaptation of standard processing technologies Life-cycle cost reduction Recycled polymers based components Interiors, Body, Chassis, Engine compartment

21 Multifunctional smart polymers MATERIALS MODELLING METROLOGY COMPONENTS FINAL PRODUCT Integrated cabling, sensors and switches CNT-based polymers for parts and components with integrated sensing and switches capabilities for comfort, safety and energy saving EXPECTED ADVANTAGES Compactness Cabling complexity reduction No external discrete components Lightweight Mechanical and thermal properties

22 Lightweight components based on nanostructured coatings MATERIALS MODELLING METROLOGY COMPONENTS FINAL PRODUCT PVD (sputtering) Wet processes (InkJet) Interiors parts Nanostructured PVD film AFM of Ni alloy nanocoating Plating Plasma, PVD, CVD for a plurality of functional properties surfaces One order of magnitude improvements of the mechanical properties respect to traditional not nano-phased films Replacement of metal components (motion linkages, gears ) Reduction of the volume occupied by the electronics components Reduction of copper cabling Switches of all shapes and sizes PWT gear plastic components Interiors trims, door panels PWT components

23 Printed functionalities Active plastic components with integrated wirings, energy harvesting, storage and switches to realize autonomous systems integrated in interiors and exteriors parts Concept systems New portable lighting and displays functionalities Autonomous lighting systems Rear-view mirror Delocalized heating/cooling Volume reduction of electronics Cabling reduction and simplification Weight and volume reduction Novel functionalities

24 Thermoelectric materials MATERIALS MODELLING METROLOGY COMPONENTS Thermal simulation FINAL PRODUCT Heat recovery from exhaust Nanocomposites Components CAD design Cooling/Heating on-board Heat recovery from exhaust 30-40% of fuel energy in the exhaust gases ( C) TE generators with conversion efficiency of 10%: fuel consumption reduction (300 l/yr) CO 2 emission reduction (5-8%) alternator size reduction Cooling/Heating on-board Delocalized cooling/heating No need for pipelines, just electric wires Absence of moving parts and noise Absence of cooling fluids (solid state devices) Optimized thermal management

25 Fluids based on nanoparticles for fuel economy MATERIALS MODELLING METROLOGY COMPONENTS FINAL PRODUCT Inorganic fullerenes (spherical MoS2 or WS2) Engine fluids Graphene (AFM) expanded, Graphite NanoPlatelets Cooling systems Functionalized CNT Exhaust gases Cooling fluid Elimination of hazardous additives Reduction of frictions (fuel economy) Wear reduction (oil and engine durability) Improved thermal exchange (component size and weight reduction) Introduction of novel fuel economy systems Engine and transmission lubricants Engine and cooling systems refrigerants

26 Photovoltaic Panels Glass and Plastic glazing Car roof 100 Wp with trasparency and 200 Wp full PV Energy produced by crystalline silicon cells [kwh/m2/day]

27 Photovoltaic panels Conformable On-board Solar Panels Si spherical technology Dye-Sensitized PV CIS/CIGS PV Electrodes QDs Nanostructured n-type conductor Solid-state p-type conductor Improvements in scale-up manufacturing (deposition rates, yield, throughput) to reduce the efficiency gaps from laboratory and commercial products.i mprovements in stability and reliability of cells and modules especially in outdoor applications (packaging technologies and materials). The major challenge will be in the manufacture of integrated solutions.

28 Conclusions Sustainability is the key factor The automotive sector asks for sustainable solutions to improve the fuel economy of vehicles Nanotechnology can contribute to the forthcoming clean and efficient mobility as enabling technology for effective: weight reduction on-board energy generation, recovery re-use and storage smart components and multifunctional materials Systems integration is a key element and a very important aspect to consider for an useful product development. A collaborative approach is crucial to exploit the nanomaterial potential in the automotive domain 28

29 THANK YOU! Carloandrea Malvicino Fuel Economy & Vehicle Systems Efficiency Project Line Director Centro Ricerche Fiat S.C.p.A. Strada Torino, Orbassano (TO), Italia Tel Fax carloandrea.malvicino@crf.it