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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2003

Early Flight Fission Test Facilities (EFF-TF) and Concepts That Support Near-Term Space Fission Missions

Fission technology can enable rapid, affordable access to any point in the solar system. If fusion propulsion systems are to be developed to their full potential; however, near-term customers must be identified and initial fission systems successfully developed, launched, and utilized. Successful utilization will most likely occur if frequent, significant hardware-based milestones can be achieved throughout the program. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system pe$ormance and lifetime can be attained through non-nuclear testing. Through demonstration of systems concepts (designed by DOE National Laboratories) in relevant environments, this philosophy has been demonstrated through hardware testing in the Early Flight Fission Test Facilities (EFF-TF) at the Marshall Space Flight Center. The EFF-TF is designed to enable very realistic non-nuclear testing of space fission systems. Ongoing research at the EFF-TF is geared towards facilitating research, development, system integration, and system utilization via cooperative efforts with DOE labs, industry, universities, and other NASA centers.

VanDyke, Melissa↗
NASA NTRS2021

ExEP: Initial super-Nyquist wavefront control experiments in the Decadal Survey Testbed

In order to characterize exoplanets around nearby stars, upcoming and proposed space telescopes are being designed with high contrast coronagraph instruments. Coronagraphs are generally designed to suppress only a single, on-axis star, but there are numerous binary star systems within our observational range. Multi-star wavefront correction (MSWC) is a technique that uses deformable mirror(s) to simultaneously suppress light from more than one star to create a high contrast dark zone in the image. MSWC has already been well demonstrated in simulation and in air-based testbeds. In this paper, we describe our prepatory vacuum experiments in the Decadal Survey Testbed (DST) at the Jet Propulsion Laboratory. First we implemented super-Nyquist wavefront control (SNWC, a critical component of MSWC), and then we proceeded to simultaneous sub- and super-Nyquist control. With our existing calibration methods, SNWC reached a contrast of $8.6{\times}10^{-9}$ in a 10\% bandpass around a first-order diffraction spot; calibration improvements are needed to improve model agreement for higher-order spots. We have also implemented changes to our software (the open-source package FALCO) required for MSWC, and identified the necessary changes in hardware. Here we report our best SNWC lab results and our plans for implementing MSWC during a future set of experiments.

Bendek, Eduardo↗
NASA NTRS2004

Erosion Coatings Developed to Increase the Life and Durability of Composites

Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Sutter, James K.↗
DOE OSTI2022

VTO 2022 Annual Progress Report: Vertical GaN Device Development

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than $\$$6/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of $\$$2.7/kW. New materials such as wide bandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective co optimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

EVs@Scale High-Power Charging (HPC) Pillar Deep-Dive Technical Meeting

EVs@Scale Lab Consortium is addressing challenges, developing solutions, and enabling technologies for transportation electrification ecosystem. The consortium has five research pillars one of which focuses on high power charging (HPC). HPC pillar brings together hardware and software expertise, capabilities, and facilities related to high power EV charging, charge management, and grid integration. Deep-dive technical meetings are organized twice a year and provides an opportunity for more industry engagement and technical feedback for the national labs throughout the project lifecycle. High-Power Charging pillar has two active projects: (i) Next-Gen Profiles (NGP) and (ii) High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP). This presentation summarizes the progress made in both projects during the past six months focusing on specific topics. There will be two deep-dive technical meetings twice a year. Every deep-dive meeting will focus on different aspects of the project progress.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

2021 Annual Progress Report: Vertical GaN Device Development

This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than 6 dollars/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of 2.7 dollars/kW. New materials such as wide-bandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective co-optimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Rapid Electrochemical Diagnosis of Battery Health and Safety from Cells to Modules

Rapid electrochemical diagnosis of battery health and failure is critical for ensuring reliable battery performance and battery safety. Traditional battery health diagnostics such as capacity measurements and DC pulse tests are reliable and well-understood, however, these measurements of battery capacity and resistance do not capture all aspects of battery degradation. Other aspects of degradation, such as electrolyte decomposition, lithium-plating, and particle cracking are difficult to detect electrochemically but are crucial to measure to get a full picture of battery safety and flag out potential failures. In this work, lab- and field-aged commercial lithium-ion batteries and modules of various chemistries and formats are tested using a variety of traditional electrochemical characterization methods as well as using 2-minute pseudo-random DC pulse sequences at rest and during charge/discharge. The electrochemical measurements are compared to physical cell measurements, cell efficiency, drive cycle performance, physical and thermal heterogeneity, and qualitative safety metrics using statistical and machine-learning methods to discover if a comprehensive "battery health map" can be accurately identified using only rapid DC measurements.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗
NASA NTRS1990

Autonomous planetary rover at Carnegie Mellon

This report describes progress in research on an autonomous robot for planetary exploration. In 1989, the year covered by this report, a six-legged walking robot, the Ambler, was configured, designed, and constructed. This configuration was used to overcome shortcomings exhibited by existing wheeled and walking robot mechanisms. The fundamental advantage of the Ambler is that the actuators for body support are independent of those for propulsion; a subset of the planar joints propel the body, and the vertical actuators support and level the body over terrain. Models of the Ambler's dynamics were developed and the leveling control was studied. An integrated system capable of walking with a single leg over rugged terrain was implemented and tested. A prototype of an Ambler leg is suspended below a carriage that slides along rails. To walk, the system uses a laser scanner to find a clear, flat foothold, positions the leg above the foothold, contacts the terrain with the foot, and applies force enough to advance the carriage along the rails. Walking both forward and backward, the system has traversed hundreds of meters of rugged terrain including obstacles too tall to step over, trenches too deep to step in, closely spaced rocks, and sand hills. In addition, preliminary experiments were conducted with concurrent planning and execution, and a leg recovery planner that generates time and power efficient 3D trajectories using 2D search was developed. A Hero robot was used to demonstrate mobile manipulation. Indoor tasks include collecting cups from the lab floor, retrieving printer output, and recharging when its battery gets low. The robot monitors its environment, and handles exceptional conditions in a robust fashion, using vision to track the appearance and disappearance of cups, onboard sonars to detect imminent collisions, and monitors to detect the battery level.

Whittaker, William↗
DOE OSTI2023

Quantifying the Financial Impacts of Electric Vehicles on Utility Ratepayers and Shareholders [Slides]

Widespread electric vehicle (EV) adoption is critical for meeting economy-wide decarbonization goals and, as a result, states are considering enabling policies and rate designs to accelerate EV deployment. EVs can provide possible financial upside to electric utilities and ratepayers in several ways. For example, from the utility perspective, EVs could drive increased electricity sales and new earnings opportunities through increased capital investments. From the ratepayer perspective, increased electric loads from EVs could reduce average all-in retail rates. The degree to which there are net benefits or costs to shareholders and/or ratepayers depends on how EVs are integrated and managed through enabling grid investments and charging strategies. Using Berkeley Lab’s Financial Impacts of Distributed Energy Resources (FINDER) model that mimics the electric utility investment planning and ratemaking processes, we estimate the utility earnings and customer rate impacts of EVs using a bookend approach of “managed” (i.e., best case) and “mismanaged” (i.e., worst case) charging strategies for a generic summer-peaking, investor-owned, and vertically integrated utility. The analysis also examines the sensitivity of results to different assumptions of EV deployment characteristics, EV impacts on retail electricity sales, incremental distribution system costs, EV charging location, and utility EV enablement costs (i.e., utility costs to invest in EV charging, controls, and communication to deliver and administer EV programs). The results are intended to inform EV policies and deployment strategies that maximize utility system benefits and minimize ratepayer costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

A Snapshot of EV-Specific Rate Designs Among U.S. Investor-Owned Electric Utilities

EV-specific electric utility rates have a profound effect on the underlying economics motivating EV adoption. State utility regulators and electric utilities play a critical role in approving and designing rates, respectively. However, the nascence of the EV industry has resulted in regulators’ and utilities’ having very limited experience with EV-specific rate designs. This suggests there could be substantial benefit from efforts intended to provide a better understanding of how EV-specific rates are designed presently in the United States. To meet that need, Berkeley Lab researchers, with support from E9 Insight, developed a database of piloted, proposed, and offered rates among U.S. investor-owned utilities (IOUs) between 2012 and 2022. The database is comprised of 217 electric utility retail rates from IOUs in 38 states and the District of Columbia that either required proof of EV ownership or were otherwise designed for the purposes of reselling energy for use in EV charging (i.e., EV-specific rates). The analysis of the database identifies the EV-specific rate designs currently observed, infers a number of policy-driven objectives, and suggests a number of next steps for future research.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2011

HyTES: Thermal Imaging Spectrometer Development

The Jet Propulsion Laboratory has developed the Hyperspectral Thermal Emission Spectrometer (HyTES). It is an airborne pushbroom imaging spectrometer based on the Dyson optical configuration. First low altitude test flights are scheduled for later this year. HyTES uses a compact 7.5-12 micrometer m hyperspectral grating spectrometer in combination with a Quantum Well Infrared Photodetector (QWIP) and grating based spectrometer. The Dyson design allows for a very compact and optically fast system (F/1.6). Cooling requirements are minimized due to the single monolithic prism-like grating design. The configuration has the potential to be the optimal science-grade imaging spectroscopy solution for high altitude, lighter-than-air (HAA, LTA) vehicles and unmanned aerial vehicles (UAV) due to its small form factor and relatively low power requirements. The QWIP sensor allows for optimum spatial and spectral uniformity and provides adequate responsivity which allows for near 100mK noise equivalent temperature difference (NEDT) operation across the LWIR passband. The QWIP's repeatability and uniformity will be helpful for data integrity since currently an onboard calibrator is not planned. A calibration will be done before and after eight hour flights to gage any inconsistencies. This has been demonstrated with lab testing. Further test results show adequate NEDT, linearity as well as applicable earth science emissivity target results (Silicates, water) measured in direct sunlight.

remote sensing↗
NASA NTRS1996

ACTS Aeronautical Terminal Experiment System Description and Link Analysis

During the summer of 1994, the performance of an experimental mobile satellite communication system was demonstrated to industry and government representatives by the NASA Lewis Research Center (LeRC) and the Jet Propulsion Laboratory (JPL). The system was based on the advanced communications technology satellite (ACTS) and consisted of a K-/Ka-band active monolithic microwave integrated circuit (MMIC) phased array antenna system, ACTS mobile terminal (AMT) and link evaluation terminal (LET). A LeRC research aircraft, Learjet model 25, was outfitted with the active MMIC phased array antenna system and AMT and served as the experimental 20/30 Ghz aeronautical terminal. The LET at LeRC in Cleveland, OH, was interfaced with portions of fixed-AMT equipment and together provided the gateway station functions including ACTS interface and public service telephone network (PSTN) interface. The ACTS was operated in its microwave switch matrix (MSM) mode with a spot beam for the Learjet and another spot beam dedicated to the LET. The Learjet was flown over several major cities across the US and demonstrated the feasibility of a full-duplex compressed voice links for an aeronautical terminal through the 20/30 Ghz ACTS channel. This paper presents a technical description of the system including the MMIC phased array antenna system, AMT, Learjet, LET, and ACTS. The array antenna system consists of a 30 Ghz transmit array (LeRc/Texas Instruments) and two 20 Ghz receive arrays (USAF Rome Lab., Boeing, and Martin Marietta), each one very small with sufficient performance for a satellite voice link. The AMT consists of 2.4/4.8/9.6 Kbps voice coder/decoder, modem, PSTN interface and RF/IF converters. Link analysis is presented and compared to the actual performance data collected during the demonstration flights.

Sohn, Philip↗
NASA NTRS2016

CryoCart Restoration and Vacuum Pipe Construction

Propulsion systems that utilize hypergolic propellants have been used to power space vehicles since the beginning of the space program. Liquid methane and oxygen propulsion systems have emerged as an alternative and have proven to be more environmentally friendly. The incorporation of liquid methane/liquid oxygen (LOX) into the propulsion system has demonstrated an increase in engine performance, as well as a reduction in the volume, size and complexity of the system. Consequently, reducing the total mass of the vehicle which is a crucial aspect that is considered when planning space missions to both the Moon and Mars [1]. Project Morpheus has made significant advancements in liquid oxygen/liquid methane propulsion system technologies by incorporating a LOX/methane propulsion system to a vertical test bed. The vehicle consisted of a 5,000 lb main engine and four 20 lb remote control system (RCS) engines that utilize liquid methane/LOX as its propellant [1]. The vehicle completed successful flight testing at Kennedy Space Center in 2014 which marked the completion of the Morpheus project. Subsequent projects utilizing Morpheus' vertical test bed have been developed to make further advancements. One of the subsequent projects consisted of the addition of a smaller 2,000 lb main engine and a cold helium heat exchanger which would make it possible for a pressurant tank systems to be send to Mars or the Moon by significantly decreasing the overall mass and volume of the pressurant tank. The hot fire tests of the integrated system with the smaller main engine and cold helium heat exchanger were successful at sea level, but further studies are being conducted to better understand how the vertical test bed will behave under thermal-vacuum conditions. For this reason, the integrated vehicle will be taken to Plum Brook to be tested in a chamber capable of simulating these conditions. To ensure that the vehicle will function properly under vacuum conditions, testing will be first completed at the component level. During this process, the igniter of the main engine and the RCS thrusters will be tested under a vacuum. To complete the testing of the components, the test setup first needed to be finalized. The CryoCart is being used to feed the propellants to the test article. The CryoCart is a movable test set-up that was developed in 2009 to provide a mobile platform for testing oxygen/methane systems with hot-fire capability up to 100 lbf. The CryoCart consists of three different systems: Oxygen, Methane, and liquid Nitrogen. The Oxygen and Methane systems are placed into two different carts while the liquid nitrogen system is mainly located in the methane cart. Over the years, the CryoCart has been utilized for different projects and has undergone deterioration. For this reason, a new phase has been developed to rebuild it to working conditions once again. During my internship, I was aiding in the construction and restoration of the CryoCart. In the initial stages of the process, I updated the fluid and electrical schematics for the oxygen, methane, and test article systems. The original CryoCart consisted of an electrical panel that utilized electromechanical relays and a terminal to drive the igniter power and signal, as well as the main fuel and oxygen valves. This electrical panel connected to the CryoCart through various wire harnesses that could be found exiting from the CryoCart. First, it was determined how these harnesses connected to the electromechanical relays so that they worked correctly. Once the electrical system was understood, an alternative for the electromechanical relays and the Molex connectors used throughout the system was sought since these components can often prove to be unreliable. Solid State relays and MIL connectors were purchased to serve as replacements. Upon arrival of the parts, crimping and wiring was completed to install the new solid state relays and MIL connectors. During the replacement of the relays and connectors, system checks of the electrical system were ran to ensure that the system was working correctly. While completing system checks, the pressure transducers that were not functioning properly were also replaced and any issue with the wiring or signal was addressed. Once the electrical components were replaced, the restoration of the fluid system began. Parts of the tubing in the CryoCart had to be rebuild and often consisted of sizing, cutting, bending, filing, and sanding the tubing to prepare it to be flared. Many components had to be proof-tested to bring their certifications up to date, and several components had to be replaced. Various flex hoses, valves, and fittings were send to the Clean Lab because they were new, dirty, or had gone through proof-testing. Once they arrived from the cleaning lab they had to be put back to the system and leak checks and functional tests were conducted. In the Nitrogen system, the copper tubing located in the Oxygen cart was rebuild and Aerogel insulation was added to this section. A new gaseous nitrogen system was added to the CryoCart to purge the vacuum tube which will serve as the test chamber. Once the CryoCart was completed, construction of parts of the vacuum tube began. A flange was manufactured with welded fittings to hold the line of the vacuum pump as well as some extra fittings which will serve as extra inlets used to introduce fluid lines to the vacuum tube. Stress analysis was ran in this flange to ensure that it would not fail under vacuum conditions. The fluid lines leading from the air side of the vacuum to the test article were also constructed and added to the mount that had already been manufactured. Three different sets of tubing were constructed to accommodate the seven different RCS thruster and the main engine igniter that are going to be tested. Full electrical system checks were completed to ensure that all the wire harnesses and valves were functioning. Upon the completion of the CryoCart and the vacuum tube, hot fire testing for the RCS thrusters and the main engine igniter are going to begin. During this time any issues encountered with the engines or igniter will be addressed to ensure that the components function under vacuum conditions. After successful completion of testing, the vertical test bed, Morpheus, will be rebuilt and prepared to be sent to Plum Brook. In Plum Brook, the vehicle will be tested in the thermal-vacuum chamber to demonstrate that integrated lox-methane propulsion system operation in space-like conditions. This internship has allowed me the opportunity to gain valuable hands on experience and to develop skills that will aid in my education as well as in the workforce, while at the same time helping me determine that I would like to further pursue a career in propulsion engineering.

Chaidez, Mariana↗
NASA NTRS2015

Evolvable Cryogenics (ECRYO) Pressure Transducer Calibration Test

This paper provides a summary of the findings of recent activities conducted by Marshall Space Flight Center's (MSFC) In-Space Propulsion Branch and MSFC's Metrology and Calibration Lab to assess the performance of current "state of the art" pressure transducers for use in long duration storage and transfer of cryogenic propellants. A brief historical narrative in this paper describes the Evolvable Cryogenics program and the relevance of these activities to the program. This paper also provides a review of three separate test activities performed throughout this effort, including: (1) the calibration of several pressure transducer designs in a liquid nitrogen cryogenic environmental chamber, (2) the calibration of a pressure transducer in a liquid helium Dewar, and (3) the calibration of several pressure transducers at temperatures ranging from 20 to 70 degrees Kelvin (K) using a "cryostat" environmental chamber. These three separate test activities allowed for study of the sensors along a temperature range from 4 to 300 K. The combined data shows that both the slope and intercept of the sensor's calibration curve vary as a function of temperature. This homogeneous function is contrary to the linearly decreasing relationship assumed at the start of this investigation. Consequently, the data demonstrates the need for lookup tables to change the slope and intercept used by any data acquisition system. This ultimately would allow for more accurate pressure measurements at the desired temperature range. This paper concludes with a review of a request for information (RFI) survey conducted amongst different suppliers to determine the availability of current "state of the art" flight-qualified pressure transducers. The survey identifies requirements that are most difficult for the suppliers to meet, most notably the capability to validate the sensor's performance at temperatures below 70 K.

Diaz, Carlos E., Jr.↗
NASA NTRS2000

4.5-kW Hall Effect Thruster Evaluated

As part of an Interagency Agreement with the Air Force Research Lab (AFRL), a space simulation test of a Russian SPT 140 Hall Effect Thruster was completed in September 1999 at Vacuum Facility 6 at the NASA Glenn Research Center at Lewis Field. The thruster was subjected to a three-part test sequence that included thrust and performance characterization, electromagnetic interference, and plume contamination. SPT 140 is a 4.5-kW thruster developed under a joint agreement between AFRL, Atlantic Research Corp, and Space Systems/Loral, and was manufactured by the Fakal Experimental Design Bureau of Russia. All objectives were satisfied, and the thruster performed exceptionally well during the 120-hr test program, which comprised 33 engine firings. The Glenn testing provided a critical contribution to the thruster development effort, and the large volume and high pumping speed of this vacuum facility was key to the test s success. The low background pressure (1 10 6 torr) provided a more accurate representation of space vacuum than is possible in most vacuum chambers. The facility had been upgraded recently with new cryogenic pumps and sputter shielding to support the active electric propulsion program at Glenn. The Glenn test team was responsible for all test support equipment, including the thrust stand, power supplies, data acquisition, electromagnetic interference measurement equipment, and the contamination measurement system.

Mason, Lee S.↗
DOE OSTI2021

Fuel Properties and Kinetics

The Co-Optimization of Fuels and Engines (CoOptima) program is focused on a two-pronged approach to develop new, lower net-carbon fuels and advanced engine technologies in tandem. This effort brings nine national labs and several university and industry partners together to simultaneously identify new fuel candidates and to further engine technology development in the light-, medium-, and heavy-duty vehicle sectors with a focus on fuel economy and emission reduction. The fuel properties and kinetics project is aimed at achieving a better understanding of fuel property kinetics and how they impact engine performance such that more efficient and lower emitting engines can be made a reality. Several promising biofuel candidates were identified through tiered screening approaches and were evaluated utilizing unique bench-scale measurement techniques. Kinetic models were developed to describe autoignition and soot pre-cursor formation mechanisms to identify the most promising candidates that advanced various combustion strategies.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

High-Torque Heavy-Rare-Earth-Free Electric Motor Thermal Management

This project is part of a multi-lab Next-Generation Reliable Electric Drive Systems for Medium and Heavy-Duty Vehicles (NEXT-DRIVE) project led by Oak Ridge National Laboratory (ORNL), and including NREL, Sandia National Laboratories (SNL), and Ames Laboratory that leverages research expertise and facilities of these national labs to develop tools and approaches for reducing the design and development time of new electric drive technologies for medium and heavy-duty vehicles (MHDVs) and their associated costs while increasing reliability and asset utilization. The Next-Drive project aligns with the DOE's goals by introducing high-fidelity multi-physics and AI/ML-based modeling to design low-cost, highly reliable, and longer-lifetime drivetrains, aiming to achieve 25 years of progress in 5 years. The efforts of this project will focus on NEXT-DRIVE Task 4 (led by ORNL, NREL, and AMES) - developing high-fidelity modeling framework and identifying technologies enabling heavy-rare-earth-free electric motors for medium- and heavy-duty vehicles to achieve 1 million miles of operation. Contrary to conventional approaches that optimize the motor for power density, the focus will be to identify motor designs that achieve the best trade-off between motor power density and durable operation. NREL tasks include development of high-fidelity motor thermal models incorporating rotor windage losses and identification, evaluation and measurement of motor interface materials in key thermal pathways. The poster summarizes NREL's accomplishments for the first half of FY 2025 and outlines future plans.

33 ADVANCED PROPULSION SYSTEMS↗