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Uday Shetty, Operations Director, Envalior India in an interaction with Asia Manufacturing Review shared his views on how high-performance materials are reshaping the future of sustainable mobility, particularly in electric and hybrid vehicles, key material innovations that are enabling automotive manufacturers to meet stringent environmental regulations and fuel efficiency targets and more.
How are high-performance materials reshaping the future of sustainable mobility, particularly in electric and hybrid vehicles?
High-performance materials are transforming sustainable mobility by addressing the underlying concerns for electric and hybrid vehicles: weight, energy efficiency and safety. Lightweight materials, such as carbon fiber composites and aluminum alloys, help reduce vehicle weight. This acts as an effective way for extending the electric vehicle (EV) range; for every 10% reduction in weight, a vehicle's efficiency can potentially improve by 6-8 percent. This not only increases the range, but also reduces battery stress. For thermal management and safety, advanced materials like phase change materials (PCMs) and fire-retardant composites are integrated into battery packs to prevent overheating and thermal runaway, a major safety concern. Internal combustion engines as a single power source are becoming obsolete, and the future of transportation is changing quickly. Advanced materials that make EVs safer, lighter, and more sustainable are necessary for this shift.
What key material innovations are enabling automotive manufacturers to meet stringent environmental regulations and fuel efficiency targets?
The automotive sector is moving to advanced multi-material solutions. The use of high-performance engineering materials and thermoplastic composites is helping in the automotive parts that have high rigidity, tensile strength and are lighter than metals. This is critical for lightweighting, which directly addresses fuel consumption in internal combustion engine vehicles and offsets the considerable weight of batteries in EVs. These materials are crucial in improving a vehicle’s sustainability.
Which industries beyond automotive, such as aerospace or rail, are driving demand for high-performance, sustainable materials?
Beyond automotive, several key industries are driving the demand for high-performance, sustainable materials, primarily for weight reduction and increased efficiency. The use of lightweight materials in aircraft structures has led to the development of more fuel-efficient and environmentally friendly airplanes. By reducing the weight of the aircraft, airlines can significantly lower fuel consumption and carbon emissions, contributing to a greener aviation industry. High-performance materials, like ceramic matrix composites and titanium alloys, have revolutionized jet engine design. These materials allow engines to operate at higher temperatures and pressures, resulting in improved thrust and fuel efficiency. The wind energy sector is another sector witnessing an increased demand of high-performance materials. Manufacturers of wind turbine blades are increasingly using advanced, lightweight composites to create longer, more efficient blades that capture more wind power. Over 85-90 percent of a wind turbine is already recyclable, but the blades, made from complex composites, are the most difficult part to recycle. Hence, the focus is also on end-of-life solutions; research is accelerating in recyclable resins and sustainable composites to make turbine blades easier to dismantle and recycle.
Can high-performance materials significantly reduce the carbon footprint of mobility solutions over their lifecycle?
When we talk about a product’s carbon footprint, we must consider its life cycle assessment (LCA). LCA takes into account all of the emissions produced throughout a product's life, from the manufacture of raw materials to recycling or disposal. LCAs create well-informed judgments on the sustainability of materials, manufacturing processes, and product design by taking a comprehensive approach to a product's environmental impact. Understanding the use of high-performance materials during LCA is crucial when discussing ways to reduce the carbon footprint. The carbon footprint of mobility solutions can be considerably decreased by using materials like sophisticated alloys and lightweight composites. When compared to vehicles with internal combustion engines, hybrid and electric vehicles have up to 89% lower total life-cycle emissions. It results in significant fuel or energy savings when the vehicle is being used. The heavy battery weight in electric vehicles is mitigated by lightweighting, which extends the driving range and enables a smaller, less resource-intensive battery.
What role does digital simulation and AI play in the development of next-generation lightweight materials?
Answer: Combining advanced manufacturing processes and information technology, industry 5.0 encompasses a new wave of transformation in the manufacturing landscape. By embracing a data-driven approach, the manufacturing industry is shifting to an entirely proactive and product-driven approach to develop new materials and structural designs. Digital simulation allows the creation of accurate “digital twins” of materials and components. These online models can then be tested virtually under various weights and temperature values, allowing us to predict product performance without ever having to physically manufacture a prototype.
This accelerates the design cycle, significantly reducing the cost and time it takes for R&D. AI and ML supplement this process. These technologies can analyze large data sets produced by the simulation process and search for new material compositions or structural designs in terms of performance and lightweighting. An AI system can predict how a new polymer blend would perform in terms of a crash event or how a composite would behave under extreme thermal conditions. With predictive analysis, we can open up limitless opportunities to merge multiple materials to find solutions that were hard to discover with physical testing.
How can the growing need for flame-retardant, thermally stable materials in EV battery systems and power electronics be addressed?
A multifaceted strategy incorporating advanced materials and system design is critical in addressing the growing safety challenge of flame-retardant and thermally stable materials in EV battery systems. Materials that can stop or limit thermal runaway are becoming more and more popular due to the demand. This includes both passive and active solutions. Thermal insulation between battery cells is accomplished with passive materials like mica, aerogels, and ceramic blankets. Heat transfer is slowed by the low thermal conductivity of these lightweight materials. New flame-retardant polymer composites are being created for structural elements, such as cell holders and battery casings in addition to passive insulation. These materials are designed to withstand fire and be lightweight.
How do material needs differ between developed and emerging markets in the context of sustainable mobility?
Developed and emerging markets have different material requirements for sustainable mobility. These differences are primarily driven by economic constraints, infrastructure, and different priorities. Developed economies put immense focus on lightweight high-performance materials to enhance EV efficiency and extend range. This includes using carbon fiber composites and advanced alloys to reduce vehicle weight, and specialty polymers for thermal management and battery safety. There is also a strong emphasis on the circular economy, with regulations pushing for increased use of recycled and bio-based materials. However, the material demands in developing markets stem from affordability, durability, and a strong supply chain. The material needs are often predicated upon more economical deliverables. While advanced materials are utilized, there is an extensive demand for locally sourced materials.
What role do partnerships with OEMs, startups, or research institutions play in accelerating innovation in this space?
Partnerships with OEMs, startups, and research institutions are critical for scaling innovation towards sustainable mobility. This collaborative approach dissolves traditional silos and brings together distinct strengths to tackle complex challenges, particularly in materials science. OEMs provide the scale, manufacturing capability and market access to put the new material in production vehicles. Startups, being agile and unencumbered by legacy systems, can rapidly develop and pilot new technologies. A startup can make a new flame-retardant composite for a battery enclosure, which an OEM can scale. Research institutions and universities provide the foundational science, as well as access to cutting-edge research, from new battery chemical compositions to advanced lightweighting materials. This ecosystem approach guarantees that fundamental research and practical, commercially viable solutions are developed hand-in-hand to facilitate the amplification of innovation rates necessary to achieve ambitious sustainability goals.