ADVANCED ADVANCED AUTOMOTIVE AUTOMOTIVE MATERIALS: MATERIALS: THE NEW DNA THE NEW DNA
OF OF PERSONAL MOBILITYPERSONAL MOBILITY
Mark Mark VerbruggeVerbruggeDirector, Chemical Sciences and Materials Systems LaboratoryDirector, Chemical Sciences and Materials Systems Laboratory
¶ GM, GM R&D
¶ Automotive challenges and potential paths forward– Looking for a new automotive DNA
¶ Topics awaiting materials innovation– Electrified vehicles (focus on energy storage and
conversion)
– Lightweight materials
¶ Collaborative Research Laboratories– Case study: GM-Brown CRL
OutlineOutline
¶Traces its roots to 1908
¶Worldwide Employment: 207,000
¶2011 Worldwide Vehicle Sales: 9 million
¶2011 Global Vehicle Market: 11.9%
¶2011 Global Revenue: $150.3 billion
¶2011 Net Income: $7.6 billion
GENERAL MOTORS COMPANYGENERAL MOTORS COMPANY
¶ Central R&D organization for General Motors
¶ Organized in 1920 under Charles (“Boss”) Kettering
¶ World’s first automotive research organization
¶ Now employs an extended Global Network
GM R&D HISTORYGM R&D HISTORY
GM’S GLOBAL R&D NETWORKGM’S GLOBAL R&D NETWORK
Alliance PartnerAlliance Partner
USCARUSCAREUCAREUCAR
OEMsOEMs
CollaborativeCollaborativeResearchResearch
LabsLabs
ScienceScienceand Techand Tech
OfficesOffices
UniversitiesUniversitiesSuzukiSuzuki
U. of MichiganU. of MichiganBrownBrownCarnegie MellonCarnegie MellonIIScIISc--BangaloreBangaloreM.I.T.M.I.T.UU. of Wisconsin. of WisconsinIITIIT--KharagpurKharagpurSJTUSJTU--ShanghaiShanghai
AustraliaAustraliaCanadaCanadaChinaChinaIndiaIndiaIsraelIsraelJapanJapanKoreaKoreaRussiaRussia
Individual ContractsIndividual ContractsStartStart--upsups
HRLHRL
SandiaSandiaGovernment Government LabLab
GlobalGlobalSitesSites
StrategicStrategicPartnersPartners
……………… SuppliersSuppliers
Affiliated LabAffiliated Lab
Warren Warren BangaloreBangaloreHoneoye FallsHoneoye FallsMainzMainz--KastelKastel
Palo Alto Palo Alto HerzliyaHerzliyaShanghaiShanghai
THE FIRST 125 YEARS OF THE AUTO INDUSTRY: THE FIRST 125 YEARS OF THE AUTO INDUSTRY: EVOLUTION TO MODERN DESIGNEVOLUTION TO MODERN DESIGN
18861886 19081908 19271927 19501950Karl Benz’ Karl Benz’
MotorwagenMotorwagen ––First AutomobileFirst Automobile
Henry Ford’sHenry Ford’sModel T Model T ––
First Affordable First Affordable AutomobileAutomobile
General Motors’General Motors’LaSalle Began LaSalle Began
Modern Era Modern Era of Americanof American
Automotive StylingAutomotive Styling
THE FIRST 125 YEARS OF THE AUTO INDUSTRY: THE FIRST 125 YEARS OF THE AUTO INDUSTRY: KEY DRIVERS AND TECHNOLOGY ENABLERSKEY DRIVERS AND TECHNOLOGY ENABLERS
19501950 19601960 19701970 19801980 19901990 20002000
Annual Model ChangeDesign Is King
~300,000Units/Models
PRODUCT
THE FIRST 125 YEARS OF THE AUTO INDUSTRY: THE FIRST 125 YEARS OF THE AUTO INDUSTRY: KEY DRIVERS AND TECHNOLOGY ENABLERSKEY DRIVERS AND TECHNOLOGY ENABLERS
19501950 19601960 19701970 19801980 19901990 20002000
Annual Model ChangeDesign Is King
~300,000Units/Models
“Safety”Focus
“OilShock”
TECHNOLOGY ENABLERS
EXTERNALITIES
PRODUCT
Reduced Emissions by 99%Reduced Emissions by 99%Improved FE by Improved FE by 180%/93%180%/93%Reduced Fatal Crashes by Reduced Fatal Crashes by 75%75%Improved Affordability by Improved Affordability by 30%30%
AUTO INDUSTRY PROGRESSAUTO INDUSTRY PROGRESS
THE FIRST 125 YEARS OF THE AUTO INDUSTRY: THE FIRST 125 YEARS OF THE AUTO INDUSTRY: KEY DRIVERS AND TECHNOLOGY ENABLERSKEY DRIVERS AND TECHNOLOGY ENABLERS
19501950 19601960 19701970 19801980 19901990 20002000
Annual Model ChangeDesign Is King
~300,000Units/Models
“Safety”Focus
“OilShock”
50,000-100,000
Units/Models
TECHNOLOGY ENABLERS
EXTERNALITIES
PRODUCT“Gotta have”
Design returns
The The SUSTAINABILITYSUSTAINABILITYCHALLENGE CHALLENGE
of 21of 21stst Century Century Personal MobilityPersonal Mobility
The The SUSTAINABILITYSUSTAINABILITYCHALLENGE CHALLENGE
of 21of 21stst Century Century Personal MobilityPersonal Mobility
EMERGING VS. MATURE MARKETS EMERGING VS. MATURE MARKETS ––GLOBAL COMPARISON: 2010GLOBAL COMPARISON: 2010
Source: GM Economics & Trade; IMF; U.S. Census Bureau/Source: GM Economics & Trade; IMF; U.S. Census Bureau/HaverHaver AnalysticsAnalystics
00
55
1010
1515
2020
ChinaChina EUEU U.S.U.S. JapanJapan BrazilBrazil IndiaIndia RussiaRussia CanadaCanada S. KoreaS. Korea AustraliaAustralia
Vehi
cle
Sale
s (M
)Ve
hicl
e Sa
les
(M)
20002000 20052005 20092009 20102010 20112011
TOP 10 MARKETS BY TOP 10 MARKETS BY NEW VEHICLE SALES IN 2011NEW VEHICLE SALES IN 2011
China Growth (%)China Growth (%)vs. 2010vs. 2010 vs. vs. 20052005 vs. 2000vs. 2000
2%2% 325%325% 854%854%
2011 Sales (M)2011 Sales (M)Emerging MarketsEmerging Markets 39.539.5
Mature MarketsMature Markets 36.536.5
World TotalWorld Total 76.076.0
0.00.0
0.20.2
0.40.4
0.60.6
0.80.8
1.01.0
1.21.2
1.41.4
00
11
22
33
44
55
66
77
88
99
19801980 19901990 20002000 20102010 20202020 20302030
Vehi
cle
Parc
(Bill
ion)
Vehi
cle
Parc
(Bill
ion)
Wor
ld P
opul
atio
n (B
illio
n)W
orld
Pop
ulat
ion
(Bill
ion)
World PopulationWorld Population Vehicle ParcVehicle Parc
PERSONAL MOBILITY MUST BE PERSONAL MOBILITY MUST BE REINVENTED FOR THE 21REINVENTED FOR THE 21stst CENTURYCENTURY
Data from U.S. Census Bureau and GM Global Market & Industry AnalysisData from U.S. Census Bureau and GM Global Market & Industry Analysis
Powered Mechanically by Powered Mechanically by Internal Combustion EngineInternal Combustion Engine
ControlledControlledMechanicallyMechanically
Energized by Energized by PetroleumPetroleum
StandStand--alone alone
Powered Electrically by Powered Electrically by Electric MotorsElectric Motors
ControlledControlledElectronicallyElectronically
Energized by Energized by BiofuelsBiofuels,,Electricity, and HydrogenElectricity, and Hydrogen
“Connected”“Connected”
Totally Dependence Totally Dependence on the Driver on the Driver
Semi/Full Autonomous Semi/Full Autonomous DrivingDriving
Vehicle Sized for Max Vehicle Sized for Max Use Use –– People and CargoPeople and Cargo
Vehicle Tailored to Vehicle Tailored to Specific UseSpecific Use
TECHNOLOGY DRIVERS FOR THE TECHNOLOGY DRIVERS FOR THE 22NDND CENTURY OF PERSONAL MOBILITYCENTURY OF PERSONAL MOBILITY
¶¶ EnergyEnergy HighHigh--efficiency vehicles efficiency vehicles using lowusing low--cost renewable energycost renewable energy
¶¶ EmissionsEmissions No tailpipe environmental impactNo tailpipe environmental impact
¶¶ SafetySafety Vehicles that don’t crashVehicles that don’t crashAutonomous drivingAutonomous driving
¶¶ CongestionCongestion CongestionCongestion--free routingfree routingMegacity parkingMegacity parking
¶¶ AffordabilityAffordability Personal mobility “for every purse Personal mobility “for every purse and purpose”and purpose”
ChallengesChallengesChallengesChallenges Stretch GoalsStretch GoalsStretch GoalsStretch Goals
ImproveImproveVehicleVehicle
Fuel EconomyFuel Economyand and
EmissionsEmissions
DisplaceDisplacePetroleumPetroleum
EnergyEnergyDiversityDiversity
Hydrogen Fuel Cell-Electric
Vehicles
Battery-ElectricVehicles (including
E-REV)Hybrid-ElectricVehicles (including
Plug-in HEV)IC Engine
and TransmissionImprovements
Petroleum (Conventional and Alternative Sources)Alternative Fuels (Ethanol, Biodiesel, CNG, LPG)
Electricity (Conv. and Alternative Sources)Hydrogen
TimeTime
ADVANCED PROPULSION TECHNOLOGY STRATEGYADVANCED PROPULSION TECHNOLOGY STRATEGY
PROJECT DRIVEWAYPROJECT DRIVEWAY
3535--50 MILES50 MILESGASGAS--FREEFREE
2,400,0002,400,000MILES LOGGEDMILES LOGGED
2011 CAR 2011 CAR OF THE OF THE YEAR AWARDS YEAR AWARDS AND AND TOP HONORSTOP HONORS
VOLTEC PROPULSION SYSTEMVOLTEC PROPULSION SYSTEM
EXTENDEDEXTENDED--RANGE RANGE DrivingDriving344 344 MILESMILES
BATTERYBATTERY Electric Electric DrivingDrivingMILESMILES3535
2013 CHEVROLET SPARK BEV2013 CHEVROLET SPARK BEV
NanophosphateLithium-ion Battery
Cathode (+) Oxides Layered LiCoO2, LiNiO2
Composite Li2MnO3-LiNxMnyCozO2
Spinel LiMn2O4
High Voltage Spinel – LiMn1.5Ni0.5O4
Silicates, Olivines – Li2MSiO4, LiFePO4
Requirements– Cost, safety, stability, conductivity
Anode (-)Carbon – LiC6
Silicon Composites and Alloys
ElectrolyteLiPF6 in Organic Carbonate SolventNeed: Higher Voltage StabilityProtective layers? New salts/solvents?
SeparatorCeramic-Coated PolymerChemically Functionalized Polymer?
GLOBAL LITHIUM BATTERY MATERIALS TECHNOLOGYGLOBAL LITHIUM BATTERY MATERIALS TECHNOLOGY
Li15Si4
• Significant majority of the battery cost/volume/mass is in the cell materials• Developments are needed in all four of the lithium-ion cell subcomponents
EVERYDAY DRIVERSEVERYDAY DRIVERS>6,000>6,000
EVERYDAY DRIVERS>6,000
MILES LOGGEDMILES LOGGED2,400,0002,400,000
MILES LOGGED2,400,000
PRODUCTION-INTENTFUEL CELL SYSTEM
PRODUCTION-INTENTFUEL CELL SYSTEM
FUEL CELL PROJECT DRIVEWAYFUEL CELL PROJECT DRIVEWAY
Cost reductionCost reductionInfrastructure deployment Infrastructure deployment
Zero Zero emissionsemissions350350--mile rangemile range33--minute H2 refuelingminute H2 refueling
Stack Manufacturability/Cost System Simplification/Cost
Seal processing time (stack,Seal processing time (stack, then seal)then seal)RequiresRequires injection moldable sealinjection moldable seal
Seal processing time (stack,Seal processing time (stack, then seal)then seal)RequiresRequires injection moldable sealinjection moldable seal
Novel plate designs/materialsNovel plate designs/materialsPhotopolymerPhotopolymer designs as frameworkdesigns as frameworkRequiresRequires electronically conductive coatingselectronically conductive coatings
Novel plate designs/materialsNovel plate designs/materialsPhotopolymerPhotopolymer designs as frameworkdesigns as frameworkRequiresRequires electronically conductive coatingselectronically conductive coatings
Fuel Cell SystemFuel Cell SystemReduction of sensors, actuatorsReduction of sensors, actuatorsState of health/life modelsState of health/life models
Fuel Cell SystemFuel Cell SystemReduction of sensors, actuatorsReduction of sensors, actuatorsState of health/life modelsState of health/life models
HH22 Storage Storage SystemSystemMaterials cost (C fiber, Materials cost (C fiber, SSSS AlAl))Reduction of valves, fittingsReduction of valves, fittings
HH22 Storage Storage SystemSystemMaterials cost (C fiber, Materials cost (C fiber, SSSS AlAl))Reduction of valves, fittingsReduction of valves, fittings
REMAINING FUEL CELL VEHICLE CHALLENGESREMAINING FUEL CELL VEHICLE CHALLENGESManufacturability/SimplificationManufacturability/Simplification
VEHICLE WEIGHT AND FUEL ECONOMYVEHICLE WEIGHT AND FUEL ECONOMY
¶6% improvement in fuel economy for 10% mass reduction
– 0.4 mpg improvement per 100 lbs., for 3,500-lb. vehicle
– 0.5 km/L improvement per 100kg weight reduction, for 1500kg vehicle
ADVANCED MATERIALS ADVANCED MATERIALS FOR LIGHTWEIGHT VEHICLESFOR LIGHTWEIGHT VEHICLES
Material Weight Reduction vs. Low-Carbon Steel
High-strength steel 15-25%
Glass-fiber composite 25-35%
Aluminum 40-50%
Magnesium 55-60%
Carbon-fiber composite 55-60%
MATERIALS IN A TYPICAL VEHICLEMATERIALS IN A TYPICAL VEHICLE
Lightweight materials can provide 35-60% weight
reduction compared to steel
Lightweight materials can provide 35-60% weight
reduction compared to steel
Polymer/CompositePolymer/Composite5%5%
Other18%
Low-CarbonFerrous
71%
AluminumAluminum3%3%
Hi/MedHi/Med--StrengthStrength
SteelSteel3%3%
19771977
TodayTodayPolymer/CompositePolymer/Composite
8%8%
Other20%
AluminumAluminum8%8%
MagnesiumMagnesium1%1%
Hi/MedHi/Med--Strength SteelStrength Steel
11%11%
Low-CarbonFerrous
52%
HydroformedHydroformedAl Frame RailsAl Frame Rails
Carbon FiberCarbon FiberFloor PanFloor Pan
Mg Engine CradleMg Engine Cradle
Ti Valves andTi Valves andConnecting RodsConnecting Rods
Mg Roof FrameMg Roof FrameHydroformedHydroformedAl Roof BowAl Roof Bow
CHEVROLET CORVETTE Z06CHEVROLET CORVETTE Z06
MgMg--Intensive Intensive FrontFront--endend
AHSS Passenger CompartmentAHSS Passenger Compartment
Steel: 79 Steel: 79 PartsParts; 84 kg; 84 kgMg: 35 Mg: 35 PartsParts; 46 kg; 46 kg
(Eliminate (Eliminate 44 Parts 44 Parts and and Save Save 38 kg 38 kg -- 4545%)%)
Castings (15): Castings (15): 31 31 kgkgExtrusions (3): 9 kgExtrusions (3): 9 kgSheet Sheet Parts Parts (17): 6 kg(17): 6 kg
MULTIMULTI--MATERIAL BODY MATERIAL BODY –– THE FUTURETHE FUTURE
Composite Floor PanComposite Floor Pan
GREEN AND RECYCLED VEHICLE MATERIALSGREEN AND RECYCLED VEHICLE MATERIALS
GM’S GLOBAL R&D NETWORKGM’S GLOBAL R&D NETWORK
Alliance PartnerAlliance Partner
USCARUSCAREUCAREUCAR
OEMsOEMs
CollaborativeCollaborativeResearchResearch
LabsLabs
ScienceScienceand Techand Tech
OfficesOffices
UniversitiesUniversitiesSuzukiSuzuki
U. of MichiganU. of MichiganBrownBrownCarnegie MellonCarnegie MellonIIScIISc--BangaloreBangaloreM.I.T.M.I.T.UU. of Wisconsin. of WisconsinIITIIT--KharagpurKharagpurSJTUSJTU--ShanghaiShanghai
AustraliaAustraliaCanadaCanadaChinaChinaIndiaIndiaIsraelIsraelJapanJapanKoreaKoreaRussiaRussia
Individual ContractsIndividual ContractsStartStart--upsups
HRLHRL
SandiaSandiaGovernment Government LabLab
GlobalGlobalSitesSites
StrategicStrategicPartnersPartners
……………… SuppliersSuppliers
Affiliated LabAffiliated Lab
Warren Warren BangaloreBangaloreHoneoye FallsHoneoye FallsMainzMainz--KastelKastel
Palo Alto Palo Alto HerzliyaHerzliyaShanghaiShanghai
¶ Strategic partnership in a key technology area for GM
¶ 5-year commitment
¶ Incorporates a group of professors in a large program vs. individual projects
¶ Encourages people exchange, sabbaticals, student interns, visits
¶ GM fully funds
¶ CRL co-directed
¶ Tasks and goals are defined together
COLLABORATIVE RESEARCH LABORATORIESCOLLABORATIVE RESEARCH LABORATORIES
GM/UNIVERSITY CRL STRUCTUREGM/UNIVERSITY CRL STRUCTURE
University GM R&DGM/University Collaborative Research Lab
Lab Co-Directors
Focus on CRL Mission and Goals
Administrative Support
Thrust Area 1
Co-Leaders
Thrust Area...
Co-Leaders
Thrust Area 2
Co-Leaders
Thrust Area 3
Co-Leaders
GENERAL MOTORS – BROWN UNIVERSITYCOLLABORATIVE RESEARCH LABORATORY FOR COMPUTATIONAL MATERIALS RESEARCH
Allan F. Bower,* William Curtin, Huajian Gao, K.-S Kim, Sharvan Kumar, Brian Sheldon, VivekShenoy, School of Engineering, Brown University, Providence RI
Josh Campbell, Louis Hector, Jr., Raj Mishra, Yue Qi, Anil Sachdev, Mark W. Verbrugge,* X. Xiao, Chemical Sciences and Material Systems Laboratory, General Motors R&D Center, Warren MI
*Co-Director
2005 to 2010• Microstructure Based Computational Plasticity Modeling• Elevated Temperature Deformation of Al and Mg Alloys• Engineered Surfaces and Interfaces
CRL Structure for our next 5CRL Structure for our next 5--yr phaseyr phase
Brown Univ. GM R&D GM/Brown
Collaborative Research Laboratory
Lab Co-Directors
Multi-Scale Computational Design of Al and Mg Alloys
and Steels
Characterization of Irreversible Deformation
and Fracture in Li-Insertion Electrode Materials
The importance of solid mechanics to the clarification of degradation processes that take place within lithium ion batteries prompted us to expand into this topic area for the CRL
Technology Matrix for Strategic Planning
Adapted from R. C. Harris, R. C. Insinga, J. Morone, and M. J. Werle, “The Virtual R&D Laboratory,” Research Technology Management, pp. 32—37, March-April (1996).In general, one should migrate to the diagonal.
AcquireCapability
Collaborateor
Monitor Field
Outsource
Abandon
Build Strength
Spread/Share Risk,Find Partners, Collaborate, etc.
Leverage External Resources,Borrow, Barter, etc.
Exit Sell
Cash cow
Do In-House
Share Risk
Weak Strong
Technical Capability Relative to Achieving Proprietary Advantage
Do In-HouseN
eed/
Pote
ntia
l for
Pro
prie
tary
Adv
anta
ge
Not likely
Absolutely
Probably
Not sure
Commodity
Basic
Emerging
Key
TechnologyCategory
Candidates for a Virtual Business
Moderate
From a firm perspective in growth mode
It’s critical to move out of the R&D box as quickly as possible.The same is actually true for all states noted• Stay in high-
volume, resource intensive production only when profitable
• Advanced Engr& Mfg have high burn rates
AcquireCapability
Collaborateor
Monitor Field
Outsource
Abandon
Build Strength
Spread/Share Risk,Find Partners, Collaborate, etc.
Leverage External Resources,Borrow, Barter, etc.
Exit Sell
Cash cow
Do In-House
Share Risk
Technical Capability Relative to Achieving Proprietary Advantage
Do In-HouseN
eed/
Pot
entia
l for
Pro
prie
tary
Adv
anta
ge
Candidates for a Virtual Business
R&D AdvancedEngineering andManufacturing
ProductEngr, Mfg.
Strategic Partner,e.g., a CRL
Lesson Learned &Move On
Profit
Time
R&D phase: Buying theoption
Weak Strong
Technical Capability Relative to Achieving Proprietary AdvantageModerate
¶¶CollaborationCollaboration
–– Trust…cultivate a professional Trust…cultivate a professional but lowbut low--risk environment to risk environment to encourage ideation, encourage ideation, roadmappingroadmapping, project plans, project plans
–– Problem selection…industrially Problem selection…industrially relevant but in need of a relevant but in need of a research solutionresearch solution
–– A A champion on both sides champion on both sides (university and industry(university and industry))
–– Hard work by great Hard work by great peoplepeople
What really makes a CRL successful?What really makes a CRL successful?
¶¶RecognizeRecognize the value of the value of accomplishmentsaccomplishments
GM-Brown CRL Accomplishments…2005 to 2010Publications in Refereed Journal Articles…62GM Internal Reports• Development of lightweight Aluminum and
Magnesium alloys with enhanced room temperature formability…6
• Optimizing the microstructure and composition of Al and Mg alloys for elevated temperature forming…9
• Developing engineered surfaces for wear-resistant linerless engines and coatings for dry drilling…12
• Failure mechanisms understating of battery negative electrode materials…3
Presentations…41Other key metrics…students graduated, awards, external collaborations and linkages
¶ GM, GM R&D
¶ Automotive challenges and potential paths forward– Looking for a new automotive DNA
¶ Topics awaiting materials innovation– Electrified vehicles (focus on energy storage and
conversion)
– Lightweight materials
¶ Collaborative Research Laboratories– Case study: GM-Brown CRL
SummarySummary