Comparative LCA study of lightweight auto parts of MMLV Mach-I vehicle as per ISO 14040/44 LCA standards and CSA Group 2014 LCA guidance document for auto parts

Abstract

Weight reduction in automotive design and manufacture is a priority across the industry, as strict new regulations push for greater vehicle efficiency and CO2 reduction in the US, Europe and Asia. In response to the global automotive market changes, the US Department of Energy (DOE) cofunded Magna International and Ford Motor Company to engineer, prototype and test a new lightweight aluminum-intensive passenger vehicle, facilitating extensive use of advanced lightweight and high-strength materials, resulting in significant environmental and fuel economy benefits. The Multi Material Lightweight Vehicle (MMLV) Mach-I design achieved an overall 364 kg (23%) full vehicle mass reduction, enabling engine downsizing. The life cycle assessment (LCA) calculations estimate the magnitude of mass-induced fuel savings due to the lightweight auto parts and the down-sized engine to be 962 gallons over the useful vehicle life of 250,000 km (155,343 miles), which implies the potential of achieving a combined fuel economy of 34 mpg (6.9 l/100 km) associated with the Mach-I design compared to 28 mpg (8.4 l/100 km) for the 2013 Ford Fusion. Additionally, the LCA calculations estimate a 16% reduction in Global Warming Potential (GWP) from 68,446 kg CO2-eq for the Fusion to 57,629 kg CO2-eq for the MMLV Mach-I. A similar 16% reduction in Total Primary Energy (TPE) from 986,090 MJ for the Fusion to 829,893 MJ for the MMVL Mach-I is estimated over the useful life of the vehicles. This paper is aimed at communicating the results of a comparative life cycle assessment (LCA) study of the MMLV Mach-I auto parts [1] under contract of Magna International, in accordance with International Organization for Standardization (ISO) standards 14040/44 and CSA Group 2014 LCA Guidance document for auto parts [2, 3, 4]. ISO 14040/44 provide general over sectorial rules and requirements for conducting LCA study, which cover but are not specifically tailored for the auto sector. To complement ISO 14040/44 rules, the CSA Group LCA Guidance establishes auto sector specific technical parameters and LCA rules and requirements to calculate the life cycle environmental impact of auto parts/vehicles in North America. A variety of LCA tools, softwares, databases and protocols can be used to assess the life cycle environmental impact of auto parts/vehicles. The Mach-I LCA model was created using SimaPro v.8.03 2014, the world’s leading LCA software chosen by industry, research institutes, and consultants in more than 80 countries. Input data associated with the LCA calculation was provided by Ford Motor Company and Magna International, as part of work supported by the Department of Energy National Energy Technology Laboratory under Award Number No. DE-EE0005574.