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Manufacturing components
2.801 kgCO2eq
Basic weight-saving scenario by
light-materials Consistent with data
from William Joost
presentation
How much Mg is required for saving up to 100kg(1)
onboard? for saving up to 100kg(1) onboard?
5.333 kgCO2eq
The LCA assessment scheme in
automotive sector fossil-fuel fueled
Weight-saving of 100kg
made of Mg
Average grain
Average grain
size (nm) for
size (nm) for
Material square (20x4)
round SSB
SSB
BAS 1 437 ± 24 525 ± 38
BAS 2 377 ± 39 502 ± 25
Raw Material PMT
Kq [Mpa
Material Test condition YS (MPa) UTS (MPa) E% m0.5]
Mg-RSP
EIGA
Electrode Induction
Melting Gas
Atomisation
PMT
Extrusion Unit Green compaction
UNIT
SSB
Direct extrusion
UNIT
Metallurgy”
Mg chips
EIGA
Eco-Mg
SSB
Direct extrusion UNIT
Note 1: Average value for BAS1 and BAS2 type with the main
differences due to the Mg-Y-Zn alloy composition
Note 2: Average value for SO2 and R-134a
(*) Ref: F.D’Errico, G.Garces Plaza, F. Giger and Shae K. Kim, “Final
Assessment of Preindustrial Solid-State Route for High-Performance
Mg-System Alloys Production: Concluding the EU Green Metallurgy
Project”, JOM, October 2013, Volume 65, Issue 10, 1293-1302
The LCA results for Green Metallurgy “cradle-to exit gate”
stage: the Eco-Magnesium alloys route
• The Eco-Mg AM30
accounts for 100.5
kgCO2eq/ kg
(courtesy of KITECH).
The downstream path: LCA results for the
“entry gate-to-exit gate” Eco-Mg route*
• The downstream process route spans :
– from cold compaction of input material
Mg billets Cast-billets of
feedstock, Eco-Mg type alloy in the Eco-Mg
(BAS system)
form of chips,
– to the hot-extrusion stage to produce
semi-finished bars (SSB) Mg-RSP
Mg chips
EIGA
• The total GWP of the downstream Eco-Mg
process accounts for total 6.2
kgCO2eq/kgSSB
PMT
3.4 kgCO2eq/kgSSB Green compaction UNIT
+
SSB
2.8 kgCO2eq/kgSSB Direct extrusion UNIT
(*) Ref: F.D’Errico, et all. , JOM, October 2013, Volume 65, Issue 10, 1293-1302
Note 1: The highest value has been considered, with SF6 use Usage
Note 2: The lowest value when low-impacting cover gases are used
76.54 kgCO2eq/kg
(46.5 kgCO2eq/kg)
LCA results for the “entry gate-to-exit gate” route
Cast-billets of
Scenario B Eco-Mg
30% in-situ recycled chips mixed with 100%
of recycled material
Mg chips 70%
Assumption
Eco-Mg
GWP of feedstock material is counted as 0
kgCO2eq. per kg of feedstock materials.
It represents the zero-emission “cradle-to-entry
PMT 30%
gate” carbon footprint in terms of GWP. Green compaction UNIT
Usage
6.2 kgCO2eq/kgSSB
Basic weigth-saving scenario by
light-materials
How much Mg is required for saving up to 100kg(1)
onboard?
886 kgCO2eq
Net GWP for 100kg saved onboard on ICE vehicle
Influence of substitution ratio and Cradle-to-Exit gate GWP
Lesson we learned…
Recycling and reducing substitution ratio (i.e. developing high-
performance Mg alloys) appear unique consistent strategies to positively
impact on net GWP
Overall drawback, recycle industry does not exist in reality, since the
Project has employed only fresh (clean) machined chips
The e-ligthweigth solution
“Light-weighting plugged-in Now CFRP is entering
in mass-production
fully electric will surely be a vehicle
key-factor to extend travel CFRP is (still) hard to
distance, reduce technology be fully recycled
cost per kWh and reduce the BMW claims it is
operation costs, i.e. kWh per produced by non-batch
mile” (JOM, November 2008) process
Temperatures in an e-
vehicle do not surpass
70°C
What can Mg-fan figure
out?
Thank you so much for
your kind attention!
My contacts:
Fabrizio D’Errico
Politecnico di Milano
Dept. of Mech. Engineering
Via La Masa 34,
20156 Milan (Italy)
E-mail: fabrizio.derrico@polimi.it
Tel: +39 02 2399 8215