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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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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Priors on red galaxy stochasticity from hybrid effective field theory

ABSTRACT We investigate the stochastic properties of typical red galaxy samples in a controlled numerical environment. We use halo occupation distribution (HOD) modelling to create mock realizations of three separate bright red galaxy samples consistent with data sets used for clustering and lensing analyses in modern galaxy surveys. Second-order Hybrid Effective Field Theory (HEFT) is used as a field-level forward model to describe the full statistical distribution of these tracer samples, and their stochastic power spectra are directly measured and compared to the Poisson shot-noise prediction. While all of the galaxy samples we consider are hosted within haloes with sub-Poisson stochasticity, we observe that the galaxy samples themselves possess stochasticities that range from sub-Poisson to super-Poisson, in agreement with predictions from the halo model. As an application of our methodology, we place priors on the expected degree of non-Poisson stochasticity in cosmological analyses using such samples. We expect these priors will be useful in reducing the complexity of the full parameter space for future analyses using second-order Lagrangian bias models. More generally, the techniques outlined here present the first application of HEFT methods to characterize models of the galaxy–halo connection at the field level, revealing new connections between once-disparate modelling frameworks.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Hydrologic applicability of satellite-based precipitation estimates for irrigation water management in the data-scarce region

Reliable precipitation estimates are crucial for planning and managing water resources, monitoring hydrologic extremes, and fulfilling irrigation water requirements. Accurate precipitation estimates are particularly challenging in complex mountain terrains, where monitoring gauges are often sparsely distributed due to their remote locations, and high installation and long-term operation costs. Recent advances in satellite-based precipitation estimates offer promising opportunities to improve our understanding of hydrologic processes and their applications for irrigation water management. Several datasets are available varying considerably in terms of their data sources, quality control methods, estimation procedure, and spatiotemporal resolutions. Choosing the most suitable dataset for a particular application is a complex task. In this study, we (1) evaluate the performance of six satellite-based precipitation estimates (SPEs): i) CHIRPS v2.0, ii) CMORPH v1.0, iii) ERA5, iv) IMERG v6, v) MSWEP v2.8, and vi) PERSIANN-CDR against the gauge precipitation using continuous statistical and categorical indices, (2) integrate SPEs with a calibrated semi-distributed hydrologic model to predict streamflow, and (3) demonstrate practical implications of improved streamflow prediction for irrigation water management in the central Himalayan region, Nepal. Our results illustrate that satellite-based precipitation estimates have competitive performance in capturing a wide range of rainfall characteristics, with demonstrated variability across river basins and time scales. Further, there are no significant discrepancies observed in satellite-based precipitation estimates for estimating irrigation water requirements for the three major crops (maize, wheat, and paddy) during the cropping period across the selected river basins, showing a greater promise for irrigation water management planning and decision making.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Radio AGN in nearby dwarf galaxies: the important role of AGN in dwarf galaxy evolution

ABSTRACT We combine deep optical and radio data, from the Hyper Suprime-Cam and the Low-Frequency Array (LOFAR), respectively, to study 78 radio active galactic nuclei (AGN) in nearby (z < 0.5) dwarf galaxies. Comparison to a control sample, matched in stellar mass and redshift, indicates that the AGN and controls reside in similar environments, show similar star formation rates (which trace gas availability) and exhibit a comparable incidence of tidal features (which indicate recent interactions). We explore the AGN properties by combining the predicted gas conditions in dwarfs from a cosmological hydrodynamical simulation with a Monte Carlo suite of simulated radio sources, based on a semi-analytical model for radio-galaxy evolution. In the subset of LOFAR-detectable simulated sources, which have a similar distribution of radio luminosities as our observed AGN, the median jet powers, ages, and accretion rates are ∼1035 W, ∼5 Myr, and ∼10−3.4 M⊙ yr−1, respectively. The median mechanical energy output of these sources is ∼100 times larger than the median binding energy expected in dwarf gas reservoirs, making AGN feedback plausible. Since special circumstances (in terms of environment, gas availability, and interactions) are not necessary for the presence of AGN, and the central gas masses are predicted to be an order of magnitude larger than that required to fuel the AGN, AGN triggering in dwarfs is likely to be stochastic and a common phenomenon. Together with the plausibility of energetic feedback, this suggests that AGN could be important drivers of dwarf galaxy evolution, as is the case in massive galaxies.

Davis, F. (ORCID:0000000285224980)↗
DOE OSTI2022

Non-growing Season Plant Nutrient Uptake Controls Arctic Tundra Vegetation Composition: Modeling Archive

This Modeling Archive is in support of a NGEE-Arctic publication: Riley et al. (2021) “Non-growing season plant nutrient uptake controls Arctic tundra vegetation composition under future climate” (Riley et al., 2021). The dataset contains “ecosys” model outputs reported in Riley et al. (2021) that examines the role of non-growing season (NGS) nutrient dynamics on 21st century vegetation composition. The study highlighted the importance of these nutrient dynamics on the emergent plant functional type distributions, focusing on their role in shrub expansion. The study showed that ignoring NGS nutrient dynamics led to a dramatic under-prediction of shrub expansion by year 2100, motivating the need to include these processes in Earth System Models. Included are modeled net primary production (NPP) and nitrogen (N) uptake for two scenarios: (1) baseline and (2) no NGS N uptake. The output is provided (1) at 25 km resolution across the North American tundra; (2) for years 2012 through 2100; and (3) PFT-specific. Dataset contains 20 NetCDF files in a zip file and one pdf.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy’s Office of Biological and Environmental Research. The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska. Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy’s Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

3D Printed Parahydrophobic Surfaces as Multireaction Platforms

We report Parahydrophobic surfaces (PHSs) composed of arrays of cubic μ-pillars with a double scale of roughness and variable wettability were systematically obtained in one step and a widely accessible stereolithographic Formlabs 3D printer. The wettability control was achieved by combining the geometrical parameters (H = height and P = pitch) and the surface modification with fluoroalkyl silane compounds. Homogeneous distribution of F and Si atoms onto the pillars was observed by XPS and SEM-EDAX. A nano-roughness on the heads of the pillars was achieved without any post-treatment. The smallest P values lead to surfaces with static contact angles (CAs) >150° regardless of the H utilized. Interestingly, the relationship 0.6 ≤ H/P ≤ 2.6 obtained here was in good agreement with the H/P values reported for nano- and submicron pillars. Furthermore, experimental CAs, advancing and receding CAs, were consistent with the theoretical prediction from the Cassie–Baxter model. Structures covered with perfluorodecyltriethoxysilane with high H and short P lead to PHSs. Conversely, structures covered with perfluorodecyltrimethoxysilane exhibited a superhydrophobic behavior. Finally, several aqueous reactions, such as precipitation, coordination complex, and nanoparticle synthesis, were carried out by placing the reactive agents as microdroplets on the parahydrophobic pillars, demonstrating the potential application as chemical multi-reaction array platforms for a large variety of relevant fields in microdroplet manipulation, microfluidics systems, and health monitoring, among others.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Towards fully predictive gyrokinetic full- f simulations: validation and triangularity studies in TCV

Designing economical magnetic confinement fusion power plants motivates computational tools that can estimate plasma behavior from engineering parameters without direct reliance on experimental measurement of the plasma profiles. In this work, we present full-f global long-wavelength gyrokinetic simulations of edge and scrape-off layer turbulence in tokamaks that use only magnetic geometry, heating power, and particle inventory as inputs. Unlike many modeling approaches that employ free parameters fitted to experimental data, raising uncertainties when extrapolating to reactor scales. This approach directly simulates turbulence and resulting profiles through gyrokinetics without such empirical adjustments. This is achieved via an adaptive sourcing algorithm in Gkeyll that strictly controls energy injection and emulates particle sourcing due to neutral recycling. We show that the simulated kinetic profiles compare reasonably well with Thomson scattering and Langmuir probe data for Tokamak á Configuration Variable (TCV) discharge #65125, and that the simulations reproduce characteristic features such as blob transport and self-organized electric fields. Applying the same framework to study triangularity effects suggests mechanisms contributing to the improved confinement reported for negative triangularity (NT). Simulations of TCV discharges #65125 and #65130 indicate that NT increases the E x B flow shear (by about 20% in these cases), which correlates with reduced turbulent losses and a modest change in the distribution of power exhaust to the vessel wall. While the physical models contain approximations that can be refined in future work, the predictive capability demonstrated here, evolving multiple profile relaxation times with kinetic electron and ion models in hundreds of GPU hours, indicates the feasibility of using Gkeyll to support design studies of fusion devices.

Hoffmann, Antoine Cyril David [Princeton Plasma Ph↗
DOE OSTI2020

Efficient Distance-based Global Sensitivity Analysis for Terrestrial Ecosystem Modeling

Sensitivity analysis in terrestrial ecosystem modeling is important for understanding controlling processes, guiding model development, and targeting new observations to reduce parameter and prediction uncertainty. Complex and computationally expensive terrestrial ecosystem models (TEM) limit the number of ensemble simulations, requiring sophisticated and efficient methods to analyze sensitivities of multiple model responses to different types of parameter uncertainties. In this study, we propose a distance-based global sensitivity analysis (DGSA) method. DGSA first classifies model response samples into a small set of discrete classes and then calculates the distance between parameter frequency distributions in different classes to measure the parameter sensitivity. The principle is that, if the parameter distribution is the same in each class, then the model response is insensitive to the parameter, while a large difference in the distributions indicates the parameter is influential to the response. Built on this idea, DGSA can be applied to analyze sensitivity of a single and a group of responses to different kinds of parameter uncertainties including continuous, discrete and even stochastic. Besides the main-effect sensitivity from a single parameter, DGSA can also quantify the sensitivity from parameter interactions. Additionally, DGSA is computationally efficient which can use a small number of model evaluations to obtain an accurate and statistically significant result. We applied DGSA to two TEMs, one having eight parameters and three kinds of model responses, and the other having 47 parameters and a long-period response. We demonstrated that DGSA can be used for sensitivity problems with multiple responses and high-dimensional parameters efficiently.

Lu, Dan↗
DOE OSTI2023

On the Low Risk of SSR in Type III Wind Turbines Operating in Grid-Forming Control: Preprint

We have shown in a previous work that the risk of sub-synchronous resonance (SSR) between a wind power plant with Type III wind turbines and series-compensated transmission lines is low when the wind turbines in the plant are operated in grid-forming mode, instead of the standard grid-following mode. The fundamental mechanism behind the improved damping characteristics is explained in this paper by modeling the positive and negative sequence impedances of Type III wind turbines for GFM operation mode. It is discovered that the GFM control naturally acts against the negative resistance of Type III wind turbines that results from an interaction between the proportional gain of the rotor-side converter current controller and negative slip. The developed sequence impedance models and improved damping behavior are verified using PSCAD simulations of a 2.5-MW Type III GFM wind turbine. The modeling predictions are also supported by experimentally measuring the sequence impedance response of a 2.5-MW Type III wind turbine during operation in GFL and GFM modes.

grid-following turbine↗
DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains.Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling.The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

A Learning-based Supervisory Control Architecture for Electric Vehicle Charging System Paired with Energy Storages

A Machine Learning-based predictive model is developed for optimal dispatching energy storage system integrated with Electric Vehicle battery charger. The model is effectively trained using transfer learning algorithm and successfully validated via measurement data to achieve high fidelity and accuracy. The study findings provide possibilities for future development of the presented approach to implement computational heavy predictive algorithms with multi-step predictions in emerging modular bidirectional charger topologies to realize vehicle-to-grid (V2G) technology. The online tuning can be explored using the new measurements obtained during the operation, henceforth, enhancing the controller performance for integrating multiple DERs into distribution power networks that shows huge interest for the utilities and regulatory agencies. Multiple operation scenatios have been evaluated and simulation results are discussed to verify intended performance of the proposed control solution.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Seminar 13 - Advanced Methods for Grid Integration of High-Performance Residential Communities

High-performance residential communities such as net-zero energy (NZE) and NZE-ready communities are emerging across the United States as many cities and states have committed to achieve ambitious energy efficiency and renewable energy goals between now and 2050. The achievement of these goals will transform the nation's communities into the holistic paradigms consisting of pervasive solar photovoltaics (PVs) and other renewable distributed energy resources, energy storage and flexible loads. However, integrating residential communities with high PV penetration may bring many challenges to the grid. For example, during many hours of the year, electric power is flowing out of PV-enabled homes and back into the grid. When this happens simultaneously in many nearby homes, distribution feeder voltage can be raised significantly. Intermittent solar power can also cause voltage flickers, leading to potential damages on both distribution feeder and home appliances. Existing solutions, such as PV curtailment, battery storage, and direct load control, are not able to address all the challenges in a cost-effective way. Better understanding is needed on how to deploy rooftop PV, how to predict building loads, and how to coordinate the homes in a community to enhance grid reliability. This seminar consists of four integral presentations that cover different aspects of a solution to these challenges. First, we will present an automated method to identify the best surfaces to deploy PV and size PV according to the PV penetration goals in a community. Second, we will present a streamlined way to create gray-box building models that are suitable for large-scale building-grid co-simulation. Next, we will present a data-driven method to estimate the end-use energy consumption to better coordinate the behind-the-meter resources to reduce utility cost, provide grid services, and improve renewable energy integration. Lastly, we will present a hierarchical control system that integrates the building models and the estimated non-dispatchable loads into the decision-making process to enhance the reliability and resilience of the residential community. Simulation results from an NZE-ready community in Fort Collins, Colorado will be presented in all four presentations and the guidelines on better grid integration of residential communities will be provided.

14 SOLAR ENERGY↗
DOE OSTI2026

Associative polymers with controlled sticker placement: How reversible bond distribution and density govern polymer dynamics

Associative polymers with precisely arranged stickers offer opportunities to program material properties with molecular precision. Yet, it remains unclear how the placement and fraction of stickers dictate structure, dynamics, and macroscopic properties. By developing a model unentangled polymer system with hydrogen-bonding stickers, we show that randomly distributed stickers neither form clusters nor change flow properties, whereas stickers placed at chain ends drive nanocluster formation even at low concentrations. Adding more end stickers produces a rubbery plateau spanning eight decades in frequency with two distinct relaxation timescales, in contrast to the single plateau predicted by the classic sticky Rouse model. These results demonstrate that sticker distribution dictates whether associative polymers undergo nanocluster formation or microphase separation, while substantial alterations in dynamics and viscoelasticity require both sticker aggregation and thermomechanical stability of associated domains. Our findings resolve a longstanding debate on associative polymer dynamics and provide molecular design rules for programmable soft materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Space and Time Dynamics of Transpiration in the East River Watershed: Biotic and Abiotic Controls

Alpine forests have important impacts on water resources by affecting how much of the precipitation that falls on a watershed is routed to streamflow or returned to the atmosphere as transpiration – so-called “green water”. In many of the high-altitude watersheds that supply critical water resources to the western US, it remains a challenge to predict how much water forests will utilize limiting the ability to predict both short and long term information on downstream water resources. The uncertainty emerges because transpiration varies between tree species, across landscapes and over time in ways that cannot readily be predicted from physically-based models for evaporation. In this project, we utilized a technique called sap flux to measure the rate of water use for three common species of fir, spruce and aspen distributed across a hillslope in the East River Watershed from 2019-2021. We also made ~weekly measurements of the concentration of stable isotopic tracers in transpiration to understand not only how much water was being used but whether it originated from summer rain or snowmelt. Firstly, our results show that the species tend to use similar amounts of total water but they achieve this similar cumulative water flux both by using water at different times of the year and by using different water sources. This shows the importance of including species-level information into models used to make seasonal streamflow predictions. Secondly, our results show that trees lower on the hillslope use older waters all through the summer whereas trees higher on the hillslope rely more heavily on recent summer rain. This means trees lower on the hillslope are less sensitive to year-to-year changes in summer climate. Lastly, we found that sites with dense forest stands displayed the largest amounts of year-to-year changes in transpiration and thus these high localized spots in the watershed are the primary drivers of changes in “green water” use. The results provide an unprecedented spatial and temporal picture of forest water use that confirms a number of fundamental hypotheses on hillslope ecohydrology that had not previously been tested against observations. Predictions of streamflow that will benefit from this work are highly valuable for agriculture management, flood control and ecological restoration efforts.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Simulating the Impact of Dynamic Rerouting on Metropolitan-scale Traffic Systems

The rapid introduction of mobile navigation aides that use real-time road network information to suggest alternate routes to drivers is making it more difficult for researchers and government transportation agencies to understand and predict the dynamics of congested transportation systems. Computer simulation is a key capability for these organizations to analyze hypothetical scenarios; however, the complexity of transportation systems makes it challenging for them to simulate very large geographical regions, such as multi-city metropolitan areas. In this article, we describe enhancements to the Mobiliti parallel traffic simulator to model dynamic rerouting behavior with the addition of vehicle controller actors and vehicle-to-controller reroute requests. The simulator is designed to support distributed-memory parallel execution using discrete event simulation and be scalable on high-performance computing platforms. We demonstrate the potential of the simulator by analyzing the impact of varying the population penetration rate of dynamic rerouting on the San Francisco Bay Area road network. Using high-performance parallel computing, we can simulate a day in the San Francisco Bay Area with 19 million vehicle trips with 50 percent dynamic rerouting penetration over a road network with 0.5 million nodes and 1 million links in less than three minutes. We present a sensitivity study on the dynamic rerouting parameters, discuss the simulator’s parallel scalability, and analyze system-level impacts of changing the dynamic rerouting penetration. Furthermore, we examine the varying effects on different functional classes and geographical regions and present a validation of the simulation results compared to real-world data.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Optimizing Control for Efficient Load Shifting with Thermal Energy Storage in Existing HVAC Systems

This project developed the integration of a direct-contact heat exchanger (DCHX) based thermal energy storage (TES) system with a chiller–air handling unit (AHU) plant to evaluate its potential for reducing building energy costs. Detailed physical models of the TES unit, building envelope, and HVAC components were developed alongside simplified control-oriented models to support both high-fidelity simulation and real-time optimization. Two control strategies were implemented and compared: a rule-based control (RBC) aligned with utility time-of-use (ToU) rates, and a model predictive control (MPC) framework leveraging forecasts of building load, weather, and internal gains. Simulation results show that the RBC strategy reduced daily electricity costs by around 30% by shifting cooling production from on-peak to off-peak hours. In contrast, the MPC strategy achieved significantly greater performance, reducing daily operating costs by up to 44% and peak-hour costs by more than 60%. Both strategies maintained indoor thermal comfort within acceptable limits, with MPC further improving load distribution and reducing equipment cycling. The outcomes confirm that TES integration, particularly when coordinated with advanced predictive control, can provide substantial cost savings and on-peak demand reduction. . These findings directly support the U.S. Department of Energy’s goals for grid-interactive efficient buildings and demonstrate the potential of TES-enabled HVAC systems for scalable deployment across the commercial building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Simulated plant-mediated oxygen input has strong impacts on fine-scale porewater biogeochemistry and weak impacts on integrated methane fluxes in coastal wetlands

Methane (CH 4 ) emissions from wetland ecosystems are controlled by redox conditions in the soil, which are currently underrepresented in Earth system models. Plant-mediated radial oxygen loss (ROL) can increase soil O 2 availability, affect local redox conditions, and cause heterogeneous distribution of redox-sensitive chemical species at the root scale, which would affect CH 4 emissions integrated over larger scales. In this study, we used a subsurface geochemical simulator (PFLOTRAN) to quantify the effects of incorporating either spatially homogeneous ROL or more complex heterogeneous ROL on model predictions of porewater solute concentration depth profiles (dissolved organic carbon, methane, sulfate, sulfide) and column integrated CH 4 fluxes for a tidal coastal wetland. From the heterogeneous ROL simulation, we obtained 18% higher column averaged CH 4 concentration at the rooting zone but 5% lower total CH 4 flux compared to simulations of the homogeneous ROL or without ROL. This difference is because lower CH 4 concentrations occurred in the same rhizosphere volume that was directly connected with plant-mediated transport of CH 4 from the rooting zone to the atmosphere. Sensitivity analysis indicated that the impacts of heterogeneous ROL on model predictions of porewater oxygen and sulfide concentrations will be more important under conditions of higher ROL fluxes or more heterogeneous root distribution (lower root densities). Despite the small impact on predicted CH 4 emissions, the simulated ROL drastically reduced porewater concentrations of sulfide, an effective phytotoxin, indicating that incorporating ROL combined with sulfur cycling into ecosystem models could potentially improve predictions of plant productivity in coastal wetland ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Anomalous Transport in Three-Dimensional Discrete Fracture Networks: Interplay Between Aperture Heterogeneity and Injection Modes

In this work, we study how the interplay between fracture aperture heterogeneity and tracer injection mode controls fluid flow and tracer transport in three-dimensional (3D) discrete fracture networks (DFNs). The direct 3-D DFN simulations show that tracer injection mode has substantial effects on tracer spreading across all levels of aperture heterogeneity. The key controlling factor for effective transport is the initial Lagrangian velocity distribution, which is determined by the interplay between injection mode and aperture heterogeneity. The fundamental difference between initial Lagrangian velocity distribution and domain-scale Eulerian velocity distribution plays a vital role in determining anomalous transport. We effectively capture the observed anomalous transport using an upscaled transport model that incorporates initial velocity distribution, stationary velocity distribution, velocity correlation length, and average advective tortuosity. With the upscaled transport model, we accurately capture the evolution of Lagrangian velocity distribution and predict longitudinal spreading in 3-D DFN.

58 GEOSCIENCES↗
DOE OSTI2022

Evaluation of High-Temperature Martensitic Steels for Heavy-Duty Diesel Piston Applications

Five different commercially available high-temperature martensitic steels were evaluated for use in a heavy-duty diesel engine piston application and compared to existing piston alloys 4140 and microalloyed steel 38MnSiVS5 (MAS). Finite element analyses (FEA) were performed to predict the temperature and stress distributions for severe engine operating conditions of interest, and thus aid in the selection of the candidate steels. Complementary material testing was conducted to evaluate the properties relevant to the material performance in a piston. The elevated temperature strength, strength evolution during thermal aging, and thermal property data were used as inputs into the FEA piston models. Additionally, the long-term oxidation performance was assessed relative to the predicted maximum operating temperature for each material using coupon samples in a controlled-atmosphere cyclic-oxidation test rig. A current commercial steel piston alloy, quenched and tempered martensitic steel 4140, was tested in a single-cylinder research engine for a baseline oxidation and mechanical performance assessment using an abbreviated (50h) durability test plan. The predicted suitability of a candidate piston material in an engine is primarily based on its elevated temperature strength, oxidation resistance, and the complex influence of thermal conductivity, the latter of which is substantially lower for the candidate materials considered in this research relative to the traditional alloys. Although the lower thermal conductivity causes the candidate alloys to operate in higher temperature ranges under identical engine operating conditions and piston geometries, increasing the likelihood of partially or completely negating their strength and oxidation resistance advantages relative to 4140 and MAS steels, this evaluation indicates that several of the candidate piston alloys are predicted to enable improved oxidation resistance under more severe engine operating conditions relative to the current piston materials. However, further evaluation is required to determine if the elevated temperature fatigue strength and durability of these alloys are suitable for more severe engine conditions.

36 MATERIALS SCIENCE↗