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Environmental performance of self-reinforced composites in automotive applications - Case study on a heavy truck component
KTH, School of Architecture and the Built Environment (ABE), Sustainable development, Environmental science and Engineering.ORCID iD: 0000-0002-2664-8783
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0001-9909-7620
KTH, School of Architecture and the Built Environment (ABE), Sustainable development, Environmental science and Engineering.ORCID iD: 0000-0002-5535-6368
KTH, School of Engineering Sciences (SCI), Aeronautical and Vehicle Engineering.ORCID iD: 0000-0002-6616-2964
2016 (English)In: Materials & design, ISSN 0264-1275, E-ISSN 1873-4197, Vol. 103, p. 321-329Article in journal (Refereed) Published
Resource type
Text
Abstract [en]

A screening environmental life cycle analysis (LCA) of the novel self-reinforced poly(ethylene therephthalate) (SrPET) is presented in this paper. A truck exterior panel is used as case study where a concept design made by SrPET is assessed and compared to a glass fibre reinforced composite and a thermoplastic blend that are currently used for the selected component. The results showed that the SrPET panel has 25% lower environmental impact compared to the current design, with no significant life cycle trade-offs. SrPET offers possibilities for weight reduction while maintaining good mechanical properties. As the impact during use phase is expected to decrease in the future the relative importance of manufacturing and end-of-life (EOL) will increase. Thus SrPET can be considered a competitive material for replacing existing energy intense non-recyclable composites.

Place, publisher, year, edition, pages
Elsevier, 2016. Vol. 103, p. 321-329
Keyword [en]
Self-reinforced composites, Environmental impact, Automotive component, Life cycle assessment
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-189067DOI: 10.1016/j.matdes.2016.04.090ISI: 000376892300037Scopus ID: 2-s2.0-84966335400OAI: oai:DiVA.org:kth-189067DiVA: diva2:943781
Note

QC 20160628

Available from: 2016-06-28 Created: 2016-06-27 Last updated: 2017-12-14Bibliographically approved
In thesis
1. Assessing design strategies for improved life cycle environmental performance of vehicles
Open this publication in new window or tab >>Assessing design strategies for improved life cycle environmental performance of vehicles
2016 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Vehicle manufactures have adopted different strategies for improving the environmental performance of their fleet including lightweight design and alternative drivetrains such as EVs. Both strategies reduce energy during use but may result in a relative increase of the impact during other stages. To address this, a lifecycle approach is needed when vehicle design strategies are developed. The thesis explores the extent that such a lifecycle approach is adopted today and assesses the potential of these strategies to reduce the lifecycle impact of vehicles. Moreover it aims to contribute to method development for lifecycle considerations during product development and material selection.

Current practices were explored in an empirical study with four vehicle manufacturers. The availability of tools for identifying, monitoring and assessing design strategies was explored in a literature review. The results of the empirical study showed that environmental considerations during product development often lack a lifecycle perspective. Regarding the use of tools a limited number of such tools were utilized systematically by the studied companies despite the numerous tools available in literature.

The influence of new design strategies on the lifecycle environmental performance of vehicles was assessed in three case studies; two looking into lightweight design and one at EVs. Both strategies resulted in energy and GHG emissions savings though the impact during manufacturing increases due to the advanced materials used. Assumptions relating to the operating conditions of the vehicle e.g. lifetime distance or for EVs the carbon intensity of the energy mix, influence the level of this tradeoff. Despite its low share in terms of environmental impact EOL is important in the overall performance of vehicles.

The thesis contributed to method development by suggesting a systematic approach for material selection. The approach combines material and environmental analysis tools thus increases the possibilities for lifecycle improvements while minimizing risk for sub-optimizations.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2016. p. 60
Series
TRITA-INFRA-FMS-PHD ; 2016:04
Keyword
Vehicle design, Design strategies, Lightweight design, Electric vehicles, Design for Environment (DfE), DfE tools, Life cycle assessment (LCA), Simplified LCA, Composite materials
National Category
Environmental Sciences Environmental Management
Research subject
Planning and Decision Analysis
Identifiers
urn:nbn:se:kth:diva-192536 (URN)978-91-7729-108-4 (ISBN)
Public defence
2016-10-17, F3, Lindstedtsvägen 26, Stockholm, 13:00 (English)
Opponent
Supervisors
Note

QC 20160920

Available from: 2016-09-20 Created: 2016-09-14 Last updated: 2016-09-20Bibliographically approved
2. Processing of self-reinforced poly(ethylene terephthalate) composites for automotive applications
Open this publication in new window or tab >>Processing of self-reinforced poly(ethylene terephthalate) composites for automotive applications
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The vehicles of the future must have less negative environmental impact during their use phase than the vehicles of today in order to avoid major climate change on earth. Consequently electric vehicles are currently under development with the purpose of reducing CO2 emissions when the vehicle is

driven. There are also efforts put in to reducing the weight of vehicles in order to reduce the demand for energy to drive them. One important aspect of weight reduction is that new materials and technologies are developed. Plastic materials have low a density and can therefore be used to reduce the weight of vehicle components and with composite materials there is further potential for weight reduction. Self-reinforced thermoplastic composite materials are materials in which both reinforcement and matrix are thermoplastic materials and thanks to their low density and relatively good mechanical properties, these materials may be used for weight reduction of vehicle components.

 

The aim of this thesis is to study selected process parameters for component manufacturing with self-reinforced poly(ethylene terephthalate) (SrPET) in order to increase knowledge and thereby advance the field of self-reinforced PET composites. This thesis shows that stretching the material in the manufacturing process increases the mechanical performance of the material due to increased orientation of the amorphous phase in the PET reinforcement. However, stretching introduces stresses in the material that give rise to negative shape distortions in the formed component. The degree of stretching during forming must therefore be controlled in order to achieve a robust serial production. The concept of a SrPET component over-moulded for integration of stiffeners and attachments has been evaluated in a life-cycle-assessment. This evaluation shows that the component weight can be reduced compared to technology currently in use and thereby contribute to increased sustainability of transport.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2017
Series
TRITA-AVE, ISSN 1651-7660 ; 2017:94
National Category
Composite Science and Engineering
Research subject
Vehicle and Maritime Engineering
Identifiers
urn:nbn:se:kth:diva-219926 (URN)978-91-7729-651-5 (ISBN)
Public defence
2018-01-26, Kollegiesalen, Brinellvägen 8, Stockholm, 09:00 (English)
Opponent
Supervisors
Note

QC 20171215

Available from: 2017-12-15 Created: 2017-12-14 Last updated: 2017-12-15Bibliographically approved

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