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Design of a Lightweight Rear Crash Management System in a Sustainable Perspective

Author

Listed:
  • Francesco Del Pero

    (Department of Industrial Engineering, University of Florence, Via di S. Marta 3, 50139 Florence, Italy)

  • Massimo Delogu

    (Department of Industrial Engineering, University of Florence, Via di S. Marta 3, 50139 Florence, Italy)

  • Martin Kerschbaum

    (Toyota Motor Europe, Hoge Wei 33—Technical Centre, B-1930 Zaventem, Belgium)

Abstract

The paper presents an innovative lightweight design solution for the rear crash management system of a C-class car, developed within the AffordabLe LIghtweight Automobiles AlliaNCE (ALLIANCE) EU research project. The innovation provides that the reference version of the module, based on conventional steel components, is revolutionized through the introduction of extruded 6000/7000 series aluminum alloys. The two competing alternatives are described and compared in relation to design and technological solutions, including also a sustainability analysis which assesses the entire Life Cycle (LC) of the system on the basis of a wide range of environmental indicators. The lightweight solution allows achieving a large mass reduction (almost 40%), while providing improvements in terms of strength, production efficiency and design freedom. On the other hand, the introduction of new materials and manufacturing technologies entails contrasting sustainability effects depending on impact category, thus not allowing to affirm that the novel alternative is unequivocally preferable under the environmental point of view. However, the comprehensive evaluation of all sustainability aspects through a multi-criteria decision analysis (TOPSIS method) reveals that the environmental profile of the innovative design is slightly preferable with respect to the conventional one.

Suggested Citation

  • Francesco Del Pero & Massimo Delogu & Martin Kerschbaum, 2020. "Design of a Lightweight Rear Crash Management System in a Sustainable Perspective," Sustainability, MDPI, vol. 12(13), pages 1-20, June.
    • Handle: RePEc:gam:jsusta:v:12:y:2020:i:13:p:5243-:d:377400
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    References listed on IDEAS

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    1. Karel Kellens & Martin Baumers & Timothy G. Gutowski & William Flanagan & Reid Lifset & Joost R. Duflou, 2017. "Environmental Dimensions of Additive Manufacturing: Mapping Application Domains and Their Environmental Implications," Journal of Industrial Ecology, Yale University, vol. 21(S1), pages 49-68, November.
    2. Hyung‐Ju Kim & Colin McMillan & Gregory A. Keoleian & Steven J. Skerlos, 2010. "Greenhouse Gas Emissions Payback for Lightweighted Vehicles Using Aluminum and High‐Strength Steel," Journal of Industrial Ecology, Yale University, vol. 14(6), pages 929-946, December.
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    Cited by:

    1. Julian Grenz & Moritz Ostermann & Karoline Käsewieter & Felipe Cerdas & Thorsten Marten & Christoph Herrmann & Thomas Tröster, 2023. "Integrating Prospective LCA in the Development of Automotive Components," Sustainability, MDPI, vol. 15(13), pages 1-26, June.
    2. Kai Rüdele & Matthias Wolf, 2023. "Identification and Reduction of Product Carbon Footprints: Case Studies from the Austrian Automotive Supplier Industry," Sustainability, MDPI, vol. 15(20), pages 1-24, October.
    3. Moritz Ostermann & Julian Grenz & Marcel Triebus & Felipe Cerdas & Thorsten Marten & Thomas Tröster & Christoph Herrmann, 2023. "Integrating Prospective Scenarios in Life Cycle Engineering: Case Study of Lightweight Structures," Energies, MDPI, vol. 16(8), pages 1-24, April.

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