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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
DOE OSTI2020

FY 2019 DOE-EERE Materials Vehicle Technologies Office Consolidated Report

The Materials Technology Program supports the Vehicle Technologies Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The propulsion materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The lightweight materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron and traditional steel components with lightweight materials such as advanced high-strength steels, magnesium alloys, aluminum alloys, and fiber-reinforced polymer composites can directly reduce a vehicle’s fuel consumption. By 2025, Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

FY2019 Materials Annual Progress Report

The Materials Technology Program supports the Vehicle Technologies Office’s (VTO’s) mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The propulsion materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The lightweight materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron and traditional steel components with lightweight materials such as advanced high-strength steels, magnesium (Mg) alloys, aluminum (Al) alloys, and fiber-reinforced polymer composites can directly reduce a vehicle’s fuel consumption. By 2025, Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty (LD) vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

A comprehensive final summary of the MCNP calculations performed concerning the UW 137 Cs release event

This document combines and supersedes earlier reports (e.g. LA-UR-19-32358 and LA-UR-20- 22216) that discussed MCNP-calculated conversion factors (count rate per unit activity per unit area) for collimated 2”x2” NaI detectors (Ludlum model 44-10 and Thermo model SPA3) in contact with various surfaces of interest to the University of Washington 137 Cs release event. These surfaces include: Exterior surface of round and rectangular ducts, Exterior surface of outdoor brick work, Exterior surface of cast iron pipes, Exterior surface of an O 2 filter assembly For each surface, the calculated conversion factors allowed inferences on 137 Cs activity on interior surfaces based on exterior contact measurements of the 662 keV photopeak count rate. The MCNP calculations included the effect of attached collimators (i.e. either a Pb/Sb-based Ludlum or a W-based “Rees” model) on detector response. As a consequence, the conversion factors only apply to the appropriate collimated 2”x2” NaI detector operated in pulse height analysis (PHA) mode. Other assumptions affecting the calculations and valid application of the conversion factors will be outlined below.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

FY2020 Materials Annual Progress Report

The Materials Technology subprogram supports the Vehicle Technologies Office’s (VTO’s) mission to accelerate the deployment of clean energy technology toward achieving net-zero emissions in the transportation sector. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The Lightweight Materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron (Fe) and traditional steel components with lightweight materials—such as advanced high-strength steels (AHSS), magnesium (Mg) alloys, aluminum (Al) alloys, and fiber-reinforced polymer composites—can directly reduce a vehicle’s fuel consumption. By 2025, the Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty (LD) vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Mitigate Stress Corrosion Cracking (SCC) in High-Strength Al castings (CRADA 508)

This project will develop approaches to overcome the barriers to simultaneous high-strength and high resistance to stress corrosion cracking (SCC) in Al casting alloys. Thus, success in this project will enable fabrication of light-weight components that are otherwise made of either heavier cast iron, or lower-strength Al alloys which need to be oversized (and hence, are heavier) to compensate for lower strength. This project will leverage the availability of advanced analytical instruments and scientific expertise available only through the LightMAT Consortium. If successful, this project has the potential to enable light-weighting of multiple components in light-duty cars and trucks across all makes and models.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Los Alamos National Laboratory Wetland Assessment for the Replacement Water Lines from Technical Area 48 to Technical Area 55 Project

The National Nuclear Security Administration (NNSA), a semi-autonomous agency within the U.S. Department of Energy (DOE), is proposing to take action at Los Alamos National Laboratory (LANL) near a wetland at Technical Area (TA) 48 and under a wetland at TA-55. The project proposes to install two 12-inch water lines along an alignment from TA-48 to Pecos Road on the east side of TA-55 (Figure 1). The proposed water lines will replace aging cast iron pipes that provide water for fire suppression to buildings within TA-55, and potable water to other areas in the Pajarito Corridor. NNSA has prepared this wetland assessment in accordance with 10 Code of Federal Regulations (CFR) Part 1022 Compliance with Wetland and Wetland Environmental Review Requirements (10 CFR Part 1022) (CFR 2003) which was promulgated to implement DOE requirements under Executive Order 11988 Wetland Management (EO 1977). A wetland is defined in 10 CFR 1022 as “the lowlands adjoining inland and coastal waters and relatively flat areas and flood prone areas of offshore islands,” and a base wetland as “the 100-year wetland, that is, a wetland with a 1.0 percent chance of flooding in any given year (CFR 2003).” This wetland assessment evaluates potential impacts to wetland values and functions from implementation of the proposed action, identifies alternatives to the Proposed Action, and allows for meaningful public comment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Non-Destructive In-Process Assessment of Thermal Spray Repairs

This exploratory project, entitled “Non-Destructive In-process Assessment of Thermal Spray Repairs,” evaluated the capabilities and limitations of four non-destructive testing (NDE) technologies for detection of defects in as-sprayed thermal spray coatings: acousto-ultrasonics, vibro-thermography, thermal wave infrared (IR) imaging, and flash IR thermography. The project goal was to identify a single technology suitable for use as an in-process inspection for two common classes of defects in thermal spray coatings, porosity and disbonds. Two rounds of test coupons were fabricated with intentionally seeded defects in AISI 420 stainless steel coatings deposited by twin wire arc (TWA) spray onto gray cast iron substrates. These standardized test coupons allowed the sensitivity of the four NDE methods to be directly compared. The results indicated that the acousto-ultrasonic method will not meet requirements for accuracy, inspection time, and reproducibility, while the vibrothermography method will not meet requirements for integration within remanufacturing cells and process flows. The IR methods, thermal wave imaging and flash thermography, both exhibited acceptable accuracy and reproducibility; however, the former method does not meet the requirement for inspection time. Flash IR thermography met all requirements in the initial round of testing, and that result was confirmed in a second round of testing on samples with a larger, more complex geometry. A final recommendation for further development of flash IR thermography was therefore made based upon i) detection performance, and ii) feasibility of deployment into the target application of resurfacing CAT engine blocks and headers.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Equitable Energy Transition Planning in Holyoke, Massachusetts: A Technical Analysis for Strategic Gas Decommissioning and Grid Resiliency

Buildings account for 30% of the emissions in Massachusetts and are the largest source of emissions in the United States, along with transportation. Pipeline-delivered methane gas is the dominant heating source in Massachusetts, representing 51% of heating in the state. The current gas network in Massachusetts and across many other US states is aging, a relic of the coal gas era, with thousands of miles of cast iron and unprotected steel pipes that are considered leak prone. Even newer plastic pipes are subject to degradation and in need of replacement, an upgrade that averages $2.8 million per mile of pipeline replacement across investor-owned utilities in Massachusetts.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Performance of a Printed Bimetallic (Stainless Steel and Bronze) Engine Head Operating under Stoichiometric and Lean Spark Ignited (SI) Combustion of Natural Gas

Additive manufacturing was used to fabricate a head for an automotive-scale single-cylinder engine operating on natural gas. The head was consisted of a bimetallic composition of stainless steel and bronze. The engine performance using the bimetallic head was compared against the stock cast iron head. The heads were tested at two speeds (1200 and 1800 rpm), two brake mean effective pressures (6 and 10 bar), and two equivalence ratios (0.7 and 1.0). The bimetallic head showed good durability over the test and produced equivalent efficiencies, exhaust temperatures, and heat rejection to the coolant to the stock head. Higher combustion temperatures and advanced combustion phasing resulted from use with the bimetallic head. The implication is that with optimization of the valve timing, an efficiency benefit may be realized with the bimetallic head.

42 ENGINEERING↗
DOE OSTI2023

Shear Assisted Processing and Extrusion of Unhomogenized Aluminum Alloy 6063 Castings with High Iron Content

Shear Assisted Processing and Extrusion (ShAPE) was used to fabricate aluminum 6063 tubing directly from secondary scrap. Trimmings from an automotive manufacturing facility were cast into billets spiked with iron (0.3 wt% Fe) to explore the tolerance of ShAPE to Fe contamination. Billets were extruded in the unhomogenized condition to form tubing with an outer diameter of 12 mm and wall thickness of 2 mm. Tensile properties reached 0.2% YS = 206 MPa, UTS = 238 MPa, and U.E. = 16.3% in the T6 temper. Performance exceeds the ASTM minimum standard and is on par with ASM typical values for conventional extrusion of primary aluminum billets in the fully homogenized condition. Microstructural characterization shows extensive refinement of grain size along with dispersion and refinement of Fe-Al-Si intermetallic phases. This study suggests that ShAPE extrusion may offer a lower carbon manufacturing pathway through direct recycling of secondary aluminum scrap and elimination of the billet homogenization step.

solid phase processing, AA 6063, extrusion, Shear ↗
DOE OSTI2025

Project "Right Way" Next Generation Melt Project: Phase 1 Performance Report Narrative (PRN)

In November 2024, AMERICAN entered into a Cooperative Agreement with the Office of Clean Energy Demonstrations (OCED) regarding the Industrial Decarbonization and Emissions Reduction Demonstration-To-Deployment Funding Opportunity for the “Right Way” Next Generation Melt Project (“Project”). This report encompasses initial planning and analysis activities to ensure that the project is viable.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Lightweight nodular iron crankshaft for heavy duty engine

An automobile vehicle crankshaft including a crankshaft casting of a nodular iron. The crankshaft casting includes multiple main journals coaxially aligned on a common crankshaft casting axis. Multiple crankpin journals are fixedly connected to the main journals by individual webs. Multiple lightening holes have individual ones of the multiple lightening holes integrally formed within individual ones of the crankpin journals during casting. A bubble space is located proximate to a mid-portion of selected ones of the multiple lightening holes of the crankpin journals. The bubble space locally increases a passage size of the selected ones of the multiple lightening holes and reduces a mass of the individual ones of the crankpin journals.

Klemstine, David C.↗
DOE OSTI2022

Applied magnetic field synthesis and processing of iron nitride magnetic materials

Techniques are disclosed concerning applied magnetic field synthesis and processing of iron nitride magnetic materials. Some methods concern casting a material including iron in the presence of an applied magnetic field to form a workpiece including at least one ironbased phase domain including uniaxial magnetic anisotropy, wherein the applied magnetic field has a strength of at least about 0.01 Tesla (T). Also disclosed are workpieces made by such methods, apparatus for making such workpieces and bulk materials made by such methods.

Wang, Jian-Ping↗
DOE OSTI2022

Effect of Micro-Structural Dispersity of SiMo Ductile Iron on High Temperature Performance during Static Oxidation

High silicon and molybdenum (SiMo) ductile iron is commonly used for car exhaust systems, and its micro-structural dispersity depends on intrinsic parameters, which include alloy composition and inoculation efficiency, as well as extrinsic factors, such as casting wall thickness and molding material, which define cooling rate during solidification. Micro-structural dispersity is referred to as the degree of heterogeneity of sizes of structural constituencies within the microstructure. A variation in the micro-structural dispersity could impact the high temperature performance of SiMo ductile iron during static oxidation and transient thermo-mechanical loading conditions. In this study, static high temperature tests were performed on SiMo ductile iron solidified in a casting with varying wall thicknesses from 5 mm to 100 mm. The faster solidified specimens (taken from near chilled casting surfaces) had extremely high micro-structural dispersity as compared to the thicker section samples. After thermal exposure, each of the samples were characterized using 2D sections and 3D µCT images, and the results indicated an order of magnitude difference in graphite phase dispersity. The surface degradation was quantified after static oxidation experiments were implemented at temperature intervals between 650 °C and 800 °C. Non-destructive µCT 3D analysis and SEM/EDS were performed on cross sections and used to quantify the scale topology and structure. Carbon analysis was used to decouple the scale formation and decarburization phenomena that occurred within the samples. These methods enabled the quantification of the oxidation of the SiMo cast iron with different micro-structural dispersity levels after being exposed to high temperature static oxidation. Additionally, the complex material behavior during oxidation-assisted transient thermo-mechanical loading will be presented in a separate article.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Near Net Shape Workshop Report

In 2021, President Biden issued Executive Order (EO) 14017, spurring the federal government to build more secure and diverse U.S. supply chains, including energy supply chains, to ensure economic prosperity and national security (White House 2021). In response to EO 14017, the U.S. Department of Energy (DOE) published America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition (Igogo 2022) to outline the challenges and opportunities facing the energy supply chain along with key strategies to secure America’s position as a clean energy superpower in the years and decades to come. The expansion of domestic manufacturing capabilities is identified as one of the common risks and vulnerabilities for which DOE should develop comprehensive strategies to secure supply chains for the clean energy transition. The report states that “examples of manufacturing capabilities of concern include … large iron and steel castings for wind turbines, hydropower turbines, and nuclear reactor components.”

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗