Alcoa Project Presentation

1. Alcoa Project Presentation Team 7 Engineering Design 100 Section 024 Prof. Bilen Colin Kaye, Alberto Vargas, Mike Karpowicz, Alex DeCoste

2. Table of Contents • Abstract • Mission Statement • Customer Needs • External Research • Concept Generation • Concept Screening • Concept Selection • Conclusion • References

3. Abstract • We want to compare the differences between steel and aluminum in order to create a newly redesigned bus that is safe, environmentally friendly, and is a cost effective vehicle.

4. Mission Statement • We chose to redesign the CATA Bus at State College to improve environmental sustainability and also the efficiency of the transportation system. By utilizing aluminum to redesign the buses, we are able to create a more efficient bus that will succeed in the long run compared to steel buses.

5. Customer Needs • For customer needs, our group polled the people who ride the buses. We studied the riders who take the colored loops around the campus as well as riders that live farther away. The riders who take the bus as commuters are obligated to pay a fare to ride, so their input was much more significant than the others. • The basic question we asked was what the rider liked about the bus, disliked, and what should be improved.

6. Customer Needs • Interpreted Need • Need less crowded buses • Need green buses • Need more buses per route • Need more timely buses • Need longer stops • Need bigger buses • Need cheaper buses • Need accurate bus stop information • Need quicker buses • Need comfortable seats • Need friendly bus drivers • Need safe buses Recorded Need • The buses are too crowded • The buses aren’t environmentally friendly • There aren’t enough buses per route • The buses aren’t on time • The bus doesn’t stop long enough • Buses are too small • The bus fare is too expensive • The bus stop information is bad • The buses are too slow • The buses aren’t comfortable • The bus drivers are unfriendly • The bus isn’t safe

7. Customer Needs

8. Customer Needs • The weight of each need was based on how frequently the customers referenced a particular need. • Based on the overall importance, we will focus on the 4 needs: • The environmental impact of building and operating a bus • The safety of the buses • The cost to build a bus* • The cost to operate a bus* *We assumed that adding more buses and having less crowded buses were dependent on the cost of buses. CATA can only afford to produce a certain number of buses due to limited funds.

9. External Research • What materials are used to make buses today? • Why use steel? … Why use aluminum? • What are the costs to implement each metal in a bus design? • What are the costs to operate a bus out of aluminum/steel? • What is the environmental repercussions of steel/aluminum?

10. External Research • Attributes of Steel: • Sturdy Material – steel is an extremely strong material used in cars, buildings, and many other things. It is invaluable in todays world. • Somewhat recyclable – Steel is made of iron ore than can be reused. Two out of three pounds of steel today is made from old steel. Steel is prone to corrosion however. • Moderately heavy metal – It has great strength for how much it weighs. • Relatively cheap to produce in large quantities. • Stainless Steel is primarily used in automobiles.

11. External Research • Attributes of Aluminum • Somewhat sturdy – can withstand a fair amount of weight and pressure • Extremely recyclable – aluminum cans that are used for soda and be melted down and then used to build airplanes. The power of recycling aluminum is great. Also corrosion resistant. • Very light metal – can help reduce the weight of automobiles but sacrifices integrity of the hull to do so. • Expensive to produce due to strenuous process of extracting it from ore. • The most widely utilized extricable aluminum alloy is 6063.

12. External Research - Comparisons • By comparison… • Steel definitely provides a safer bus than aluminum. In a crash, steel could take more of an impact before yielding than aluminum. • Aluminum is more environmentally friendlier than steel, as it is much more recyclable and lasts longer than steel in terms of corrosion. • Aluminum is lighter than steel, which means the more aluminum a bus has the lighter and more fuel efficient it is. Using aluminum instead of steel can improve fuel efficient from 7-20%. • Steel is cheaper to produce in large quantities compared to aluminum, so implementing a large amount of aluminum in bus would be very costly. Aluminum is .40$/lb. more expensive than steel today.

13. 100% Aluminum Concept Generation 50% Aluminum/ 50% Steel Bus 100% Steel We want to find the correct balance between steel and aluminum to satisfy the customer needs to the best of our abilities.

14. Aluminum Chassis Aluminum Frame Aluminum Shell Concept Generation Bus Frame Bus Shell Chassis Steel Frame Steel Chassis Steel Shell

15. Concept Generation • The concept generation maps that were created helped in the creation of the CATA bus redesigns by focusing on which parts of the bus can be replaced with aluminum to help make a highly sustainable and more efficient bus. After creating a model of the bus in SolidWorks, sustainability tests were run to see which models were the most sustainable to the environment. As a baseline, the bus was made with cast stainless steel and the data was taken in terms of energy consumption and pollution in the environment. For each of the redesigns, aluminum alloy 6063 was incorporated and then new measurements were taken. • The first redesign was a bus made completely out of aluminum. • The second redesign is a bus made all from steel, but with the frame made from aluminum. • The third redesign is a steel bus with an aluminum chassis. • The fourth redesign is an aluminum bus with the frame made out of steel. • The final redesign is an aluminum bus with a chassis made of steel.

17. Concept Screening • For the bus, we want to implement the correct amounts of aluminum and steel. • There are many parts that go into the bus design the bus. • We focused on the three main parts…

18. Concept Screening – Bus Components Bus Frame

19. Concept Screening – Bus Components Bus Chassis

20. Concept Screening – Bus Components Bus Shell

21. Concept Generation - Baseline Carbon Footprint 8.4E+7 kg CO2e Total Energy Consumed 8.6E+8 MJ Air Acidification 2.4E+5 kg SO2e Water Eutrophication 2.1E+5 kg PO4e

22. Concept Screening

23. Concept Selection

24. Conclusions • Steel Bus shell with an aluminum frame and chassis offers the best all-around qualities. • The most difficult aspect to change is the cost to build the bus, which increases as more aluminum goes into the bus. Aluminum is naturally more expensive per pound compared to steel. • The cost to operate however, provides a way to save money on fuel compared to an all steel bus. The bus is a long term investment, and overtime money will be saved. • Environmentally, the impact of building and operating the bus is less than baseline. It also will last more years than the baseline as aluminum doesn’t corrode as easily, and a large portion of the bus is recyclable! • As for safety, there is still a good deal of steel within the shell of the bus, protecting it in a crash.

25. Conclusions • With more money being saved in the long run with these buses, CATA could…. • Add more buses to the routes • Reduce the fare • Make bigger buses All of which satisfy the customer!

26. References 1. “Center Area Transportation Association Budget” Catabus.com, Nov. 11, 2013 <http://www.catabus.com/AboutCATA/Budget/Budgets/FY20132014FinalBud get.pdf> 2. “Let’s Go Design – Steel Vs. Aluminum” The Solidworks Blog, November 18th, 2013 <http://blogs.solidworks.com/solidworksblog/2010/08/lets-go-design- steel-vs-aluminum.html> 3. Hatch, John. Aluminum: Properties and Physical Metallurgy.ASM International. 1984. 4. “Aluminum Tests Its Mettle Against Steel in Drive for Lighter Cars” The Wall Street Journal. Nov. 18, 2013. <http://online.wsj.com/news/articles/SB100014240527487037269045761926 33836369392>