Multi-parametric study of the effect of materials substitution on life cycle energy use and waste generation of passenger car structures

Aluminium and fibre reinforced plastics have been put forward as alternatives for steel to reduce passenger car weight and save energy during use. Often-reported drawbacks are increased energy for production and reduced recyclability, and hence, increased waste generation. This study considers the merits of the alternatives by making a multi-parametric comparison of the life cycle energy use and waste generation of three lightweight alternatives to today’s all-steel car structure. The ‘development level’, captured as the percentage of high strength steel in today’s car structure, is identified as an important new variable in the analysis of automotive life cycle energy use.

► This study compares various lightweight car body structures against the current steel ’benchmark’. ► The benchmark’s development level strongly affects the energy savings over the life cycle. ► Too often, this variable is ignored in similar, earlier studies. ► Waste generation over the life cycle is largely determined by end-of-life choices (e.g. incineration versus land filling).