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