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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Online eco-routing for electric vehicles using combinatorial multi-armed bandit with estimated covariance

Identifying energy-efficient routes in real-time has significant implications for the energy-optimal operations of electric vehicles (EVs). Here, this study proposes a novel model for EV online eco-routing problem, which obtains the minimal expected energy consumption paths (MECPs) for multiple origin-destination (OD) pairs simultaneously. Specifically, we formulate the routing problem as a bandit problem and solve it with online algorithms. We extend the algorithms by implementing a path elimination mechanism to reduce the candidate path set and introducing the variance and covariance of the energy consumption to reduce the uncertainties. The numerical results show that the proposed algorithms can efficiently obtain near-optimal MECPs, and the solution is significantly better than the widely used shortest trip time path algorithm (STTP) and shortest trip distance path algorithm (SDP). The variation considering link energy covariance and path elimination generates paths that save 4.1% of energy compared to the SDP and 5.4% to the STTP.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Policy Framework to Improve Mobility Efficiency and Electrify Transportation in Tonga

The Kingdom of Tonga, like many small island developing states, is heavily dependent on imported fossil fuels to meet its current energy needs, especially for transportation. The Kingdom has requested a policy framework that benefits its land transportation sector by saving cost and time, increasing resilience, and reducing petroleum and greenhouse gas (GHG) emissions. This framework was developed by building on past work, namely the Tonga Energy Efficiency Master Plan 2020-2030 (TEEMP), the Tonga Energy Road Map 2021-2035 (TERMPLUS), and the Regional Electric Mobility Policy for Pacific Island Countries and Territories developed by the Pacific Centre for Renewable Energy and Energy Efficiency (PCREEE). The strengths, weaknesses, opportunities, and threats to Tonga's land transportation system were identified at stakeholder working group meetings in Tonga in June 2023. A set of appropriate policies that have been effective in relevant jurisdictions were then discussed and refined by the working group. The resulting 27 policies are defined according to intended outcomes, relationship to other proposed policies, applications in other relevant jurisdictions, hurdles to implementation, resilience impact, equity impact, and government revenue impact. Some of the policies are also accompanied by implementation recommendations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Comparison of Linear and Rotary Electric Machine Topologies for a Hybrid Hydraulic Electric Architecture of Off-Highway Vehicles

Electrification of off-highway vehicles offers the benefits of improved energy efficiency, enhanced controllability, and reduction in greenhouse gas emissions. However, progress towards electrification has been limited by the low power density of electric components compared to hydraulic components. A recently proposed hybrid hydraulic electric vehicle architecture provides a potential solution to these power density challenges by minimizing the required power rating of the electric components. This paper investigates the optimal design of linear and rotary electric machines for this new system architecture. Key performance metrics are identified for the electric machine, several variants of electric machines are analytically sized and compared for two different power levels, and an FEA-assisted design optimization is performed on promising candidates. Based on the optimization results, it is shown that an axial flux rotary machine is most suitable for implements requiring high power ratings, while the linear machine's form factor makes it a compelling candidate for lower power implements.

42 ENGINEERING↗
DOE OSTI2020

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

A 100-kW Wireless Power Transfer System Development Using Polyphase Electromagnetic Couplers

Wireless power transfer (WPT) is an essential technology enabling automated charging of electric vehicles with safety, convenience, and flexibility while having high efficiencies. High-power wireless charging systems will be one of the dominating charging technologies for electric vehicles (EVs) in an effort to eliminate range anxiety and reduce charging times similar to that of gas station refueling practice. Polyphase electromagnetic coupler with rotating fields is a new bipolar wireless charging pad technology that can significantly increase the surface power density (kW/m2) of wireless charging coils. This study proposes a 100-kW wireless power transfer system with a compact vehicle-side (receiver) coupler that reaches to about 0.905 MW/m2 surface power density with a transmitter rated for up to 300 kW with 0.68 MW/m2. High-frequency power electronics including the inverter and rectifier designs are included in this digest along with the hardware prototype developments and preliminary experimental results.

Onar, Omer↗
DOE OSTI2021

A data-driven operational model for traffic at the Dallas Fort Worth International Airport

Airports are on the front line of significant innovations, allowing the movement of more people and goods faster, cheaper, and with greater convenience. As air travel continues to grow, airports will face challenges in responding to increasing passenger vehicle traffic, which leads to lower operational efficiency, poor air quality, and security concerns. This paper evaluates methods for traffic demand forecasting combined with traffic microsimulation, which will allow airport operations staff to accurately predict traffic and congestion. Using two years of detailed data describing individual vehicle arrivals and departures, aircraft movements, and weather at Dallas-Fort Worth (DFW) International Airport, we evaluate multiple prediction methods including the Auto Regressive Integrated Moving Average (ARIMA) family of models, traditional machine learning models, and DeepAR, a modern recurrent neural network (RNN). We find that these algorithms are able to capture the diurnal trends in the surface traffic, and all do very well when predicting the next 30 minutes of demand. Longer forecast horizons are moderately effective, demonstrating the challenge of this problem and highlighting promising techniques as well as potential areas for improvement. Traffic demand is not the only factor that contributes to terminal congestion, because temporary changes to the road network, such as a lane closure, can make benign traffic demand highly congested. Combining a demand forecast with a traffic microsimulation framework provides a complete picture of traffic and its consequences. The result is an operational intelligence platform for exploring policy changes, as well as infrastructure expansion and disruption scenarios. To demonstrate the value of this approach, we present results from a case study at DFW Airport assessing the impact of a policy change for vehicle routing in high demand scenarios. This framework can assist airports like DFW as they tackle daily operational challenges, as well as explore the integration of emerging technology and expansion of their services into long term plans.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Durability of PGM catalyst MEAs of polymer electrolyte membrane fuel cells for heavy-duty vehicles

Polymer electrolyte membrane fuel cells (PEMFCs) are promising power sources for heavy-duty vehicles (HDVs) owing to cleanliness and efficiency. However, the degradation of membrane electrode assemblies (MEAs) under HDV conditions remains a huge challenge. Here, this work investigated MEA durability under HDV conditions using a US Department of Energy standard accelerated stress test for 180,000 cycles (equivalent to 1 million miles of HDV operation). Effects of catalyst Pt content on MEA durability were examined using homemade 30% Pt/C (H-Pt/C) and commercial 46% Pt/C (C-Pt/C) catalysts. Both MEAs experienced H 2 /air and H 2 /O 2 performance loss over cycles. Analysis with scanning transmission electron microscopy, X-ray diffraction, inductively coupled plasma mass spectrometry, and mercury intrusion porosimetry revealed severe degradation of Pt nanoparticles (NPs), support structures, and the catalyst layer. Two degradation stages for NPs were proposed: Ostwald ripening dominated the initial 60,000 cycles, followed by combined Ostwald ripening and particle migration. Measurements with ion chromatography, high-frequency resistance, and oxygen-diffusion resistance revealed degradation of membrane and ionomer, respectively.

25 ENERGY STORAGE↗
DOE OSTI2025

Numerical Investigation of Ammonia/n-Heptane Dual-Fuel Spray Flames Using Large Eddy Simulations

Diesel engines are extensively used in heavy-duty transportation, power generation, and marine vehicles due to their superior thermal efficiency and extended high-load operability compared to spark ignition (SI) engines. However, combustion in diesel engines is generally characterized by locally rich fuel–air mixtures and high combustion temperatures, causing significant amounts of soot and NO x emissions from these engines. Utilizing carbon-free alternative fuels and enhancing fuel efficiency represent promising strategies to mitigate greenhouse gas (GHG) and other emissions in the heavy-duty transportation sector. In this context, ammonia (NH 3 ), as a hydrogen carrier, has received significant attention as a viable substitute for hydrocarbon fuels due to its carbon-free composition, relatively high energy density, and well-established infrastructure. Many previous studies have considered combustion and emission characteristics of ammonia-hydrocarbon fuel blends in engines and simplified flames. But, detailed investigations on the effects of ammonia on the performance of hydrocarbon fuels under engine conditions are lacking. In the present study, we perform large eddy simulations (LES) of the ignition and flame processes in a constant-volume combustion reactor, where n-heptane is injected in an ammonia/air ambient mixture in a diesel-like environment. A detailed and validated reaction mechanism containing 302 species and 1981 reactions is employed. The Engine Combustion Network Spray H experimental data is used to validate the spray model under both non-reacting and reacting conditions. Dual-fuel combustion is simulated using the well-stirred reactor (WSR) approach. Results are presented for two spray cases: (1) single fuel (SF) with n-heptane injected into a mixture of air and combustion products and (2) dual-fuel (DF) with the injection of n-heptane in a mixture of air, ammonia, and combustion products. It is observed that the presence of ammonia has a significant effect on the ignition and flame development processes. With ammonia addition, both the first- and second-stage ignition delay times increase, but the effect of ammonia on the second-stage ignition is significantly more prominent. In addition, the ignition kernel size and growth rate decrease noticeably. For SF spray, the main ignition is characterized by multiple ignition kernels near the spray tip, whereas for DF spray, a single relatively small ignition kernel forms and grows slowly in the downstream direction. The flame development and the final quasi-steady flame structure are also modified due to ammonia. Here, the outcome of this research would enable a better understanding of ammonia–diesel dual-fuel spray flame behavior and guide the development of associated engine combustion strategies.

ammonia↗
DOE OSTI2023

Workshop on Sustainable Aviation Fuel-Use Research Opportunities

On February 15-16, 2022, the U.S. Department of Energy’s (DOE’s) Vehicle Technology Office (VTO) within Energy Efficiency and Renewable Energy (EERE) convened a workshop to assess the end-use research opportunities for Sustainable Aviation Fuels (SAF). This report summarizes the proceedings and findings of the workshop, which the U.S. Department of Energy’s Argonne National Laboratory hosted as a virtual event. During these two half-days, invited members of national laboratories, industry, government, and academia connected virtually to share perspectives on SAF research needs for improving end-use adoption.

09 BIOMASS FUELS↗
DOE OSTI2024

Synergistic Thermo-Microbial-Electrochemical (T-MEC) Approach for Drop-In Fuel Production from Wet Waste

This project successfully developed and demonstrated the synergistic thermo-microbial-electrochemical (T-MEC) process, converting food waste into sustainable biofuels while achieving self-sustaining wastewater treatment and hydrogen production. By integrating hydrothermal liquefaction (HTL) and microbial electrolysis cells (MECs), the project advanced waste-to-fuel technology and expanded the understanding of sustainable waste valorization. It established a scalable framework for achieving high carbon efficiency, effective pollutant removal, and energy recovery, showcasing the potential of combining biological, thermal, and electrochemical systems to optimize resource recovery and reduce environmental impacts. The project demonstrated the technical effectiveness of the T-MEC process, achieving over 50% improvement in carbon efficiency and reducing waste processing costs by more than 25% compared to anaerobic digestion (AD). The HTL pilot reactor processed food waste at 90 kg/h, producing up to 200 L/day of biocrude oil with high conversion efficiency. A critical desalting step in pretreatment prevented catalyst fouling, enabling efficient hydrotreating with 100% deoxygenation and denitrogenation and sulfur reduction to <15 ppm. This positioned the kerosene fraction as a strong candidate for sustainable aviation fuel (SAF). The MECs achieved rapid startup, 86.4% COD removal, and hydrogen production rates of 1.8 L H 2 /L cat /day, among the highest recorded for pilot-scale systems. The integrated process achieved 65% carbon efficiency to biocrude and 58% to finished fuels, outperforming AD's 41% and 33% efficiencies for biogas and natural gas vehicle fuels. System analysis highlighted economic potential, with minimum fuel selling prices (MFSP) decreasing from $\$$25/GGE at 5 tpd to $\$$10/GGE at 500 tpd due to economies of scale. Future work will focus on reducing MEC material and membrane costs, enhancing performance through higher current densities, and creating tailored operational strategies for diverse feedstocks. Optimization of the integrated system will improve scalability and feasibility, positioning the T-MEC process as a competitive solution for converting wet waste into sustainable fuels and clean water. Beyond its technical and economic achievements, the project offers significant public benefits. The T-MEC process provides a sustainable alternative to landfilling and incineration, reducing greenhouse gas emissions and conserving resources. Converting waste into SAF and renewable fuels supports decarbonization in the transportation sector, advancing energy independence and reducing reliance on fossil fuels. Additionally, the process minimizes environmental pollutants, transforming them into valuable products like hydrogen and fuels, contributing to a cleaner and more sustainable future.

09 BIOMASS FUELS↗
DOE OSTI2026

MEP Core Tools

This slide deck provides an update on the progress of the project titled "MEP Core Tools" funded by the Energy Efficient Mobility Systems program in the Vehicle Technologies Office at the Department of Energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Codes and standards work that are in line with the previous two topic areas.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗
DOE OSTI2023

Electric Vehicles at Scale (EVs@Scale) Laboratory Consortium Deep-Dive Technical Meetings: High Power Charging (HPC) Summary Report

Electric vehicle (EV) adoption will change the composition of EV charging load to higher-power charging as more medium- (MD) and heavy-duty (HD) applications are electrified, and as all vocations, including light-duty (LD) vehicles, are capable of faster charging. These shifts provide the opportunity for high-power charging (HPC) and facility equipment to evolve and improve efficiency, cost, and space. High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project designs and develops a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration approaches and technology solutions. The project addresses (1) interconnection and management of a grid-tied inverter; (2) development of a DC distribution system that is responsible for system energy management, interoperability, and DC protection; (3) modular DC/DC conversion for vehicle charging; (4) EV charging interface and DC/DC integration; and (5) smart charge control and vehicle-to-edge (vehicle-to-building [V2B], vehicle-to-everything [V2X]) capability. This summary presentation is the first technical progress output of the project. It provides insight for the first deep-dive technical meeting outputs in terms of research presentations and also includes summary of the discussions occurred in the follow-up breakout sessions. The summary presentation covers three technical areas: (1) HPC: State of the art power architectures and the design of the power electronics, (2) Modeling, energy management, and power control in the HPC station, and (3) Next Generation Profiles for high power charging characterization.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Tutorial - Electric Motor and Integrated Traction Drive Thermal Management

The share of vehicles with fully electric propulsion systems is constantly increasing, and so is their traction drive power. The continuous push to increase power of electric vehicle (EV) traction drives necessitates their efficient cooling to prevent damage to temperature sensitive components of the drive system and achieving higher power outputs in a smaller footprint. With increasing power and power density of electric traction drives, their thermal management is becoming increasingly challenging. This tutorial will provide an overview of thermal management approaches for electric motors and power electronics in EV applications. It will review examples of current industry solutions for power-dense electric motor cooling, power electronics (inverter) cooling, their integration concepts and thermal management system solutions. We'll look at the advantages and challenges of power electronics integration into a single traction drive unit and respective thermal management system concepts. We'll talk about barriers to implementation of a unified thermal management system. The tutorial will also review key aspects of thermal management system design: modeling and simulation using FEA and CFD tools, experimental characterization, and general workflow for thermal management system evaluation.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2026

Understanding Electric Vehicle Range and Charging Needs: Interactions Between Ambient Temperature, Commute Patterns, and State-of-Charge Usage

Electric vehicle (EV) performance can vary substantially under real-world operating conditions, particularly due to ambient temperature effects on energy consumption, battery behavior, and thermal management requirements. This study quantifies how weather conditions, daily driving patterns, and State-of-Charge (SOC) usage strategies jointly influence EV driving range, charging frequency, and overall energy efficiency. A detailed and experimentally validated Autonomie vehicle model is developed, integrating a powertrain, a mono-zonal cabin model, and a battery electro-thermal model. Three battery sizes (200-, 300-, and 400-mile homologated ranges) are assessed across five commute profiles (20–200 miles) and six ambient temperatures (−18 °C to 50 °C), including scenarios with and without preconditioning. Results show that extreme temperatures could significantly decrease the maximum achievable range by up to 55% in cold conditions (−18 °C) and 40% in hot conditions (50 °C), relative to moderate conditions. Larger battery packs retain a greater fraction of their nominal range under thermal stress, while smaller packs experience sharper relative penalties due to the higher contribution of thermal loads to total energy demand. The analysis further demonstrates that limiting operation to partial SOC windows (e.g., 80–20%), a common real-world practice, significantly reduces achievable range and increases charging frequency, particularly in cold weather. Thermal preconditioning while plugged in is shown to mitigate these effects for short trips, reducing energy consumption by up to 31% in hot conditions and 7% in cold conditions. The findings demonstrate how climate, SOC usage behavior, and thermal management jointly shape the practical driving capability of EVs, highlighting the importance of efficient thermal management and realistic user charging strategies for ensuring reliable EV operation across diverse climatic scenarios.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

A Systematic Comparison for Consistent Scenario Development Using Microscopic Simulation Software

This study aims to explore a methodology that enables the development of consistent traffic micro simulation for emerging traffic and vehicle control technologies for improved mobility and energy efficiency across different modeling platforms. Researchers might study the same application on different platforms and have the need to benchmark across platforms. However, there lacks a systematic study on simulation software comparison, especially for emerging mobility and energy efficiency applications. For this, a systematic scenario development and evaluation approach is presented and demonstrated to compare scenarios generated in different traffic microsimulation platforms. Network-level and vehicle-level trip performance results of the traffic scenario are evaluated in three microscopic simulation platforms - VISSIM, AIMSUN, and SUMO. The results indicate that the network-level performance is consistent among the three software suites except when the demand is high, where the energy consumption performance varies.

Saroj, Abhilasha [ORNL] (ORCID:0000000191178063)↗
DOE OSTI2025

Packaging a 650V/400A GaN Half-bridge Power Module with Ultra-low Parasitics for Electric Vehicle Drive Applications

This paper proposes a compact and efficient half-bridge power module with three 650 V / 150 A GaN dies in parallel. The power module incorporates a main power printed circuit board (PCB), an interface PCB, and a flex PCB to achieve low parasitics in both power loop and gate-side connection, resolving the issue of high parasitics typically encountered with wire bonding in high-current applications. Additionally, the interface PCB decouples the design constraints between the power loop and the gate loops. The proposed design is optimized with a vertical loop configuration to reduce power loop inductance through magnetic flux cancellation. Finite element analysis indicates that the power loop inductance is 0.58 nH at 100 MHz, while the maximum die junction temperature reaches 131 °C under an ambient temperature of 65 °C and a load current of 385 A. The proposed multi-piece PCB structure reduces the inductance of the drive circuit to minimize EMI and to mitigate false triggering. At the same time, it reduces impedance mismatches across different driver circuits, thereby achieving dynamic current sharing in multi-chip parallel configurations. Under simulation conditions of 400 V / 385 A, the current imbalance among chips was limited to 5 A. A 400 V / 385 A double-pulse test was conducted to experimentally validate the performance of the proposed power module.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Recycling Disassembled Automotive Plastic Components for New Vehicle Components: Enabling the Automotive Circular Economy

As the automotive industry increasingly relies on plastic components to meet fuel efficiency and emissions targets, the challenge of managing end-of-life vehicle (ELV) plastics continues to grow. Currently, more than 80% of ELV plastics in the U.S. are landfilled due to limited economic incentives and technical barriers to recycling. This study examines a mechanical recycling pathway for thermoplastic components disassembled from ELVs and assesses their usability for reintegration into new vehicle parts. Four representative materials were chosen based on material labels embedded in recovered parts and aligned with their virgin industrial equivalents: polypropylene (PP), 10% talc-filled PP (PP-T10), 20% talc-filled PP (PP-T20), and a 20% glass-/mineral-filled polyamide (PA6 + GF7 + MF13). The materials underwent shredding, drying, and injection molding before being characterized by particle size analysis, density measurement, thermal analysis (TGA, DSC), mechanical testing, and heat deflection temperature (HDT) evaluation. The results in this work indicated that minor differences in crystallinity were observed and small differences between model materials and ELV materials could have contributed to these changes. Mechanical testing revealed that neat polypropylene suffered a 15–20% reduction in stiffness and tensile strength, but talc-filled polypropylene and glass/mineral-filled nylon retained >90% of their modulus, strength, and heat deflection temperature values relative to virgin controls. Differences between virgin and ELV materials could have been attributed to use life degradation, contamination during use life, or even chemical/processing differences in model materials and ELV materials. However, these findings suggest that mechanically recycled, disassembled ELV plastics can retain sufficient structural performance to support circularity efforts in the automotive sector.

automotive recycling↗