Periodic Reporting for period 2 - ALMA (Advanced Light MAterials and processes for the eco-design of electric vehicles)
Reporting period: 2022-08-01 to 2024-01-31
The automotive industry is at the cusp of critical transformations prefaced by a changing climate: transition from fossil fuels-based internal combustion engine vehicles (ICEVs) to sustainable electric alternatives. This transition involves technological advancements and therethink and redesign of vehicles. ALMA plugs into the gap, addressing the urgent need for lightweight, sustainable, and efficient EVs, and envisioning a circular model that explores efficient and cost-effective end-of-life (EoL) solutions, prioritizing reusability, repairability, and recyclability.
The main goal of ALMA is the development of a novel EV structure for a passenger car with reduced weight and environmental impact, thanks to the adoption of an integrated eco-design and circular approach across the entire life cycle supported by LCA and LCC tools as core activities at the forefront of the project. Through an eco-design approach leveraging advanced lightweight materials, ALMA seeks to redefine industry standards for EV construction. Moreover, ALMA pioneers an eco-design and circular approach in battery electric vehicles (BEVs) for passenger cars, which includes choosing strategies such as the “right material for right application”, efficient assembly/disassembly solutions using debondable adhesives, recycling options and model-based characaterisation of materials at multi-scale level. It also adopts a circular approach across entire vehicle life cycle to enable further uses for the structure at the end-of-life (EoL). An integrated health monitoring and inspection system (HMS) detects and determines damages during operation preventing critical failure and enables future repair and reuse. In essence, ALMA's mission is to provide an impetus to the automotive sector, marked by responsible design, reduced environmental footprint, and a commitment to a circular economy.
In the face of climate change, addressing questions about EV range becomes an important consideration influencing the widespread adoption of electric mobility. ALMA’s holistic eco-design approach in vehicle construction using lightweight multi-materials combined with EoL material recovery and recycling solutions, addresses this societal and environmental need, setting the stage for a more sustainable automotive sector.
Following the implementation of these innovations, the ALMA project achieved its expected outcomes: the body-in-white (BiW) of ALMA’s concept car is 160 kg lighter, representing approximately 22% weight reduction compared to the baseline BEV BiW. Over the car’s entire service life, the use of other materials and weight reduction contributes to a total reduction of 1,850 kg CO2-eq, a 24% decrease in emissions. In contrast, the emissions for the entire car saw a 9% decrease.
The main goal of ALMA is the development of a novel EV structure for a passenger car with reduced weight and environmental impact, thanks to the adoption of an integrated eco-design and circular approach across the entire life cycle supported by LCA and LCC tools as core activities at the forefront of the project. Through an eco-design approach leveraging advanced lightweight materials, ALMA seeks to redefine industry standards for EV construction. Moreover, ALMA pioneers an eco-design and circular approach in battery electric vehicles (BEVs) for passenger cars, which includes choosing strategies such as the “right material for right application”, efficient assembly/disassembly solutions using debondable adhesives, recycling options and model-based characaterisation of materials at multi-scale level. It also adopts a circular approach across entire vehicle life cycle to enable further uses for the structure at the end-of-life (EoL). An integrated health monitoring and inspection system (HMS) detects and determines damages during operation preventing critical failure and enables future repair and reuse. In essence, ALMA's mission is to provide an impetus to the automotive sector, marked by responsible design, reduced environmental footprint, and a commitment to a circular economy.
In the face of climate change, addressing questions about EV range becomes an important consideration influencing the widespread adoption of electric mobility. ALMA’s holistic eco-design approach in vehicle construction using lightweight multi-materials combined with EoL material recovery and recycling solutions, addresses this societal and environmental need, setting the stage for a more sustainable automotive sector.
Following the implementation of these innovations, the ALMA project achieved its expected outcomes: the body-in-white (BiW) of ALMA’s concept car is 160 kg lighter, representing approximately 22% weight reduction compared to the baseline BEV BiW. Over the car’s entire service life, the use of other materials and weight reduction contributes to a total reduction of 1,850 kg CO2-eq, a 24% decrease in emissions. In contrast, the emissions for the entire car saw a 9% decrease.
In 2021, ALMA introduced a novel lightweight EV designed with advanced materials to minimize environmental impact. The project successfully achieved its goal of conserving materials, reducing energy consumption, and decreasing carbon emissions across the vehicle's life cycle. Notably, ALMA's BEVs showcases a 160kg lighter BiW, marking an impressive 22% reduction compared to the baseline BEV BiW. Furthermore, throughout the ALMA BEV's service life, the incorporation of alternative materials and weight reduction measures resulted in a substantial total reduction of 1850 kg carbon dioxide equivalent (CO2-eq), equivalent to a remarkable 24% decrease in emissions.
To achieve these accomplishments, the ALMA project embraced an eco-design approach, utilizing BEVSIM's Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) tool for informed material selection at each development stage. ArcelorMittal's innovation with Advanced High Strength Steels (AHSS) and steel laminates significantly contributed to lightweighting the vehicle's structure, complemented by efficient manufacturing processes and Multi-Part Integration concepts. Multi-scaled simulation methods streamlined material experimentation, while optimized vehicle structure using SMC composites for lightweighting. In the pursuit of circularity, a reversible assembly method, featuring debondable adhesives on the battery tray, showcased a commitment to efficient separation of materials at the end-of-life. Innerspec's structural monitoring system, employing acoustic signature analysis, demonstrated its capability to assess wear and detect potential damages in composites helping in early repairability of parts before critical damage. Regarding recyclability and material recovery of steel, ArcelorMittal demonstrated, at industrial scale, that the novel steel sheets proposed in the project can be recycled using the current technology applied. TNO, on the other hand, explored recycling and recovery of composite materials through solvolysis and pyrolysis processes, indicating promising potential for reuse.
To make best use of project results, the communication and dissemination strategy maximized influence through enhanced digital presence, showcasing achievements globally. Consortium partners actively presented scientific and technical advancements at international events, fostering collaboration with cluster projects. Achievements were documented in a comprehensive brochure and demonstrated through physical prototypes.
To achieve these accomplishments, the ALMA project embraced an eco-design approach, utilizing BEVSIM's Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) tool for informed material selection at each development stage. ArcelorMittal's innovation with Advanced High Strength Steels (AHSS) and steel laminates significantly contributed to lightweighting the vehicle's structure, complemented by efficient manufacturing processes and Multi-Part Integration concepts. Multi-scaled simulation methods streamlined material experimentation, while optimized vehicle structure using SMC composites for lightweighting. In the pursuit of circularity, a reversible assembly method, featuring debondable adhesives on the battery tray, showcased a commitment to efficient separation of materials at the end-of-life. Innerspec's structural monitoring system, employing acoustic signature analysis, demonstrated its capability to assess wear and detect potential damages in composites helping in early repairability of parts before critical damage. Regarding recyclability and material recovery of steel, ArcelorMittal demonstrated, at industrial scale, that the novel steel sheets proposed in the project can be recycled using the current technology applied. TNO, on the other hand, explored recycling and recovery of composite materials through solvolysis and pyrolysis processes, indicating promising potential for reuse.
To make best use of project results, the communication and dissemination strategy maximized influence through enhanced digital presence, showcasing achievements globally. Consortium partners actively presented scientific and technical advancements at international events, fostering collaboration with cluster projects. Achievements were documented in a comprehensive brochure and demonstrated through physical prototypes.
The ALMA project achieved its expected outcomes: the BiW of ALMA’s concept car is 160 kg lighter, representing approximately 22% weight reduction compared to the baseline BEV BiW. Over the car’s entire service life, the use of other materials and weight reduction contributes to a total reduction of 1,850 kg CO2-eq, a 24% decrease in emissions. With its emphasis on lightweight, sustainable, and efficient battery electric vehicles (BEVs) for passenger cars, the ALMA project presents multiple benefits for both the EU and the international community. In the EU context, the project aligns with the region's commitment to sustainable mobility and contributes to the ambitious goals of the European Green Deal and Circular Economy Action Plan, an essential component in achieving EU’s net-zero ambition by 2050. The transition from fossil fuels to electric mobility, with novel contributions made by projects such as ALMA, fosters innovation and job creation in the clean energy sector, enhancing the EU's global competitiveness. The project's focus on lightweight multi-material structure and eco-design approach not only reduces carbon emissions throughout the vehicle life cycle but also promotes energy efficiency in the use phase, aligning with the EU's decarbonisation targets. Furthermore, by advancing hybrid material solutions, efficient manufacturing processes and innovative technologies, such as our unique eco-design approach informed by LCA and LCC tool BEVSIM in the electric vehicle industry, ALMA supports the EU's position as a leader in sustainable transportation. In addition, the ALMA project’s innovative solutions can potentially be applied, albeit with modifications, to other road vehicles, especially buses and heavy-duty vehicles. ALMA's success in implementing an eco-design approach, adopting a circular economy mindset, and interdisciplinary collaboration across different partners demonstrates the effectiveness of EU funding in promoting cutting-edge R&D. Beyond the EU, the project sets a precedent for global sustainable mobility practices informed by a circular approach, influencing the broader transition to cleaner energy solutions.