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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Property optimized energy absorber for automotive bumpers utilizing multi-material and structural design strategies

This study proposes a novel design for automotive bumper using optimized lattice structures and multi-materials to balance low-speed collision and high-speed pedestrian impact performance. Different blends of 20 % carbon fiber-reinforced acrylonitrile butadiene styrene with thermoplastic polyurethane were used to tailor material properties. The energy absorber features lattice structures with customized mechanical responses, created by varying the incline angle θ from 0 to 180°. We conducted 576 finite element simulations on a half-scale model to optimize energy absorption and stiffness, leading to 66 optimized designs that met both low-speed and high-speed impact criteria. Two sub-scale optimized energy absorbers with different peak forces—both meeting low-speed impact requirements—were 3D printed and validated through drop-weight testing. The one with lower peak stress demonstrated a more compliant response, exhibiting approximately 90 % lower initial peak force and an increase in energy absorption of around 33 % (from 24 J to 32 J). Compared to the baseline triangular lattice, the optimized absorber increased energy absorption by 68 % from (19 J to 32 J) and reduced peak stress by 70 %. It also showed near-complete recovery with minimal fractures, making it suitable for repeated use. This design improves safety while offering a lightweight, durable, and cost-effective bumper system.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Extreme Temperature Performance of Automotive-Grade Small Signal Bipolar Junction Transistors

Electronics designed for space exploration missions must display efficient and reliable operation under extreme temperature conditions. For example, lunar outposts, Mars rovers and landers, James Webb Space Telescope, Europa orbiter, and deep space probes represent examples of missions where extreme temperatures and thermal cycling are encountered. Switching transistors, small signal as well as power level devices, are widely used in electronic controllers, data instrumentation, and power management and distribution systems. Little is known, however, about their performance in extreme temperature environments beyond their specified operating range; in particular under cryogenic conditions. This report summarizes preliminary results obtained on the evaluation of commercial-off-the-shelf (COTS) automotive-grade NPN small signal transistors over a wide temperature range and thermal cycling. The investigations were carried out to establish a baseline on functionality of these transistors and to determine suitability for use outside their recommended temperature limits.

Thermal Cycling↗
DOE OSTI2024

Leveraging automotive fuel cells can supply zero-emission peak power in the near-term

An increasingly decarbonized yet resilient power grid requires the corresponding build-out of dispatchable zero-emission resources to supply peak power. However, there is a recognized dearth of solutions which can serve multi-day peak demand events both cost-effectively and with near-term deployability. Here, we find that pairing low-cost automotive fuel cells with hydrogen storage in salt caverns can serve as a peaker plant at less than 500 US$/kW at present, a fraction of the cost of conventional fossil fuel-fired peakers. We demonstrate the peaker’s value for long duration storage by comparing it with pumped hydro and assessing its profitability within Texas’ energy-only market region. Although deployment of these peakers is constrained by the presence of salt caverns, we show that a number of sites in the United States and Europe are endowed with suitable salt formations, while utilizing hydrogen storage in pressurized containers could form a location-agnostic peak power solution.

25 ENERGY STORAGE↗
DOE OSTI2026

Circular economy pathways for decarbonizing aluminum and steel automotive body sheet components in the United States

Decarbonizing vehicle production is essential to reducing automotive sector emissions. This study quantifies greenhouse gas (GHG) emissions from aluminum and steel auto-body sheet components produced in the US. It evaluates the effectiveness of circular economy (CE) strategies (greater closed-loop recycling of pre-consumer scrap, post-consumer scrap, and increased manufacturing yields) to reduce supply chain emissions across different process technology and electricity grid decarbonization pathways. We combine dynamic material flow analysis (2025–2050) with cradle-to-gate life-cycle modeling to assess production emissions and the potential reductions associated with the CE strategies under frozen, moderate, and aggressive technology and grid decarbonization scenarios. Current emissions intensities are estimated at approximately 12.3 kg.CO₂eq/kg of aluminum and 4.3 kg.CO₂eq/kg of steel sheet embedded in the vehicle. Under the frozen decarbonization scenario and current levels of circularity, annual emissions attributable to US aluminum and steel auto-body sheet supply chains could rise by 54 % and 18 % respectively by 2050. Rapid deployment of the CE strategies can cut these annual emissions in 2050 by 52 % for aluminum and 44 % for steel. However, scrap quality constraints lead to saturation points, limiting these benefits unless addressed. Aggressive deployment of low-carbon production technologies and a low-carbon grid reduces the relative benefit of implementing the CE strategies; however, even under the aggressive technology and grid decarbonization scenario, the CE strategies reduce annual emissions by a further 23 %-54 % by 2050. These findings highlight the urgent need to integrate CE strategies into the sheet metal supply chain to support decarbonization efforts and help meet climate targets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Transformation of CeO 2 Nanoparticles into Atomically Dispersed Ce Cations Leads to Enhanced Reactivity for Automotive Emissions Control

Nanosized cerium oxide (CeO 2 ) has been extensively used as the oxygen storage component in automotive emission control systems. However, the possible influence of atomically dispersed Ce in these catalysts has not been recognized. Here, in this study, we demonstrate the controllable transformation of ceria nanoparticles into isolated cerium cations on γ-Al 2 O 3 via reductive atom trapping in 10% H 2 at 800 °C, achieving over half-monolayer coverage. Dispersed Ce 1 ions anchored by surface penta- and octa-coordinated Al sites exhibit outstanding thermal stability in air up to 500 °C, enabling further loading of active metals with well-defined catalyst structures. With this strategy, supported single-atom Rh 1 surrounded by dispersed Ce 1 is confirmed to exhibit much superior performance to Rh 1 on bare Al 2 O 3 or nanocrystalline CeO 2 in catalyzing NO reduction by CO, exhibiting a striking one-order-of-magnitude increase in activity. Dispersed Ce 1 exhibits greatly enhanced oxygen transfer capability compared to ceria nanoparticles and introduces a modified reaction mechanism that involves an adjacent Rh 1 –Ce 1 motif, resulting in a greatly decreased activation barrier (from 192 to 96 kJ/mol). The reactivity enhancements are also seen with Ce 1 -promoted Pt nanoparticles for oxidation of CO and hydrocarbons.

Jiang, Dong [Washington State Univ., Pullman, WA (↗
DOE OSTI2025

Enhancing Automotive Intrusion Detection Through Multi-Modal Fusion: A CAN FD-LiDAR Approach

As vehicles become smarter and more autonomous, they increasingly depend on advanced sensors and communication technologies to operate securely. However, such growing dependence on technology—whether it’s CAN (Controller Area Network) for internal communication or LiDAR (Light Detection and Ranging) for sensing the world around them—also expands the attack surface for the types of cyber attacks. Traditional intrusion detection systems (IDS) typically monitor these systems in isolation, limiting their ability to detect sophisticated, crosssystem attacks. To address this, we propose a multi-modal fusion approach that combines real-world CAN FD signals (from the HCRL dataset) with LiDAR features (from the nuScenes dataset) to enhance attack detection. Our method employs a twostage ensemble approach. Calibrated XGBoost and LightGBM models initially process CAN FD (Fuzzing Data) and LiDAR data independently, detecting timing anomalies and space abnormalities. They are subsequently logarithmically combined with a logistic regression meta-model along with 17 engineered features capturing cross-modal behavior, prediction conflicts, and nonlinear interactions. This approach achieves an AUC of 0.87 and an F1-score of 0.82, surpassing single-modality baselines and early fusion methods, at merely 2 ms inference latency. Compared with deep learning competitors, it is 3 times more efficient, providing a lightweight, interpretable, and real time solution to automotive cybersecurity.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Coupled Multiphysics Modeling of Lithium-Ion Batteries for Automotive Crashworthiness Applications

Considerable advances have been made in battery safety models, but achieving predictive accuracy across a wide range of conditions continues to be challenging. Interactions between dynamically evolving mechanical, electrical, and thermal state variables make model prediction difficult during mechanical abuse scenarios. In this study, we develop a physics-based modeling approach that allows for choosing between different mechanical and electrochemical models depending on the required level of analysis. We demonstrate the use of this approach to connect cell-level abuse response to electrode-level and particle-level transport phenomena. A pseudo-two-dimensional model and simplified single-particle models are calibrated to electrical-thermal cycling data and applied to mechanically induced short-circuit scenarios to understand how the choice of electrochemical model affects the model prediction under abuse scenarios. These models are implemented using user-defined subroutines on ls-dyna finite element software and can be coupled with existing automotive crash safety models.

analysis and design of components↗
DOE OSTI2025

Machine learning-driven design and self-sensing capabilities of automotive bumper lattices for adaptive impact response

We present a novel approach to design an automotive bumper energy absorber using carbon fiber reinforced polymer composites, optimized to meet conflicting performance requirements for two distinct impact scenarios. The design must satisfy both a low-speed (2.5 mph) pendulum intrusion test, simulating vehicle-to-vehicle collisions, and a high-speed (25 mph) leg flexion test, replicating pedestrian impacts. These tests demand opposing deformation characteristics: high flexibility (deformation < 85 mm) for the former and high stiffness (deformation < 22 mm) for the latter. To address these contradictory requirements, we developed a machine learning (ML) framework for inverse optimization of lattice designs and material selection. Unlike traditional iterative design processes, our ML model directly outputs optimal design parameters and material choices based on target performance inputs. The energy absorber was fabricated using advanced additive manufacturing techniques, including extrusion deposition and digital light processing. The integration of carbon fibers provides multifunctionality to the bumper structure, enabling self-sensing capabilities through changes in electrical resistivity under compression. This electrical response demonstrates high repeatability under multiple cycles at 2% compression and exhibits distinct signatures during crack formation under high deformation. This research offers adaptive performance through innovative design methodologies and smart material integration. The approach has potential applications in various fields requiring adaptive energy absorption and real-time structural health monitoring.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗
DOE OSTI2024

Circular Economy for Automotive Shredder Residue

Vehicle production has grown substantially worldwide, and subsequently, End-of-Life (EoL) vehicles entering retirement will grow as well. For example, China, the largest passenger car market worldwide, is expected to have 26.3 million passenger vehicles retiring by 2030. Most vehicles are shredded at EoL to recover metals for the robust metal recycling industry, leaving behind a slew of unwanted materials called automotive shredder residue (ASR) on the order of millions of tonnes every year. Additionally, the average weight of vehicles has gone up to 2600 lbs (1180 Kg) for a small passenger internal combustion engine (ICE) vehicles, 4000 lbs (1814 Kg) for large ICE vehicles, and the electric vehicle (EV) versions are substantially heavier at 1000 lbs (454 Kg) or more compared to combustion engine counterparts. While the increase in weight in EVs is increasing primarily due to the batteries needed to power the car, the materials being substituted into either type of vehicle to reduce weight are polymers and composites.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

A Vertical GaN-Based Neutral-Pointless Three-Level Inverter for High-Performance Automotive Traction Applications

Silicon Carbide (SiC) MOSFETs have emerged as a dominant solution for electric vehicle traction inverters because of their superior power density and efficiency compared to Silicon (Si) counterparts. However, SiC devices possess inherent switching speed limitations that constrain the maximum switching frequency and hinder further power density and efficiency improvements. To address these limitations, this paper proposes a vertical Gallium Nitride (vGaN) based X-type Neutral-Pointless (NPL.X) three-level (3L) inverter for an 800V, 200 kW traction system. Integrating 700V vGaN technology within the NPL.X 3L topology enables improved drive efficiency and higher switching frequencies, resulting in enhanced power density and output power quality. To evaluate the performance benefits, this work conducts a comprehensive loss characterization of the vGaN￾based NPL.X topology, providing a direct comparison with a SiC￾based two level (2L) inverter. The results show that the proposed vGaN-based inverter achieves superior efficiency, particularly within the low-torque regions that dominate standard automotive drive cycles. The proposed vGaN-based inverter represents a critical advancement toward high-power-density and high efficiency traction drives

Halawa, Ali [Purdue Univ., West Lafayette, IN (Uni↗
NASA NTRS1961

AUTOMOTIVE IMPACT

Automotive impact - crash conditions, human tolerance

IMPACT ACCELERATION↗
NASA NTRS1972

NASA-EPA automotive thermal reactor technology program

The status of the NASA-EPA automotive thermal reactor technology program is summarized. This program is concerned primarily with materials evaluation, reactor design, and combustion kinetics. From engine dynamometer tests of candidate metals and coatings, two ferritic iron alloys (GE 1541 and Armco 18-SR) and a nickel-base alloy (Inconel 601) offer promise for reactor use. None of the coatings evaluated warrant further consideration. Development studies on a ceramic thermal reactor appear promising based on initial vehicle road tests. A chemical kinetic study has shown that gas temperatures of at least 900 K to 1000 K are required for the effective cleanup of carbon monoxide and hydrocarbons, but that higher temperatures require shorter combustion times and thus may permit smaller reactors.

Blankenship, C. P.↗
NASA NTRS1973

Effect of timed secondary-air injection on automotive emissions

A single cylinder of an automotive V-8 engine was fitted with an electronically timed system for the pulsed injection of secondary air. A straight-tube exhaust minimized any mixing other than that produced by secondary-air pulsing. The device was operated over a range of engine loads and speeds. Effects attributable to secondary-air pulsing were found, but emission levels were generally no better than using the engine's own injection system. Under nontypical fast-idle, no-load conditions, emission levels were reduced by roughly a factor of 2.

Coffin, K. P.↗
NASA NTRS1975

Experimentally-determined external heat loss of automotive gas turbine engine

An external heat balance was conducted on a 150 HP two-shaft automotive gas turbine engine. The engine was enclosed in a calorimeter box and the temperature change of cooling air passing through the box was measured. Cooling airflow ranges of 1.6 to 2.1 lb-per-second and 0.8 to 1.1 lb-per-second were used. The engine housing heat loss increased as the cooling airflow through the calorimeter box was increased, as would be the case in a moving automobile. The heat balance between the total energy input and the sum of shaft power output and various losses compared within 30 percent at engine idle speeds and within 7 percent at full power.

Meng, P. R.↗
NASA NTRS1976

Strainrange partitioning behavior of an automotive turbine alloy

This report addresses Strainrange Partitioning, an advanced life prediction analysis procedure, as applied to CA-101 (cast IN 792 + Hf), an alloy proposed for turbine disks in automotive gas turbine engines. The methodology was successful in predicting specimen life under thermal-mechanical cycling, to within a factor of + or - 2.

Annis, C. G.↗
NASA NTRS1976

An improved automotive brake lining using fibrous potassium titanate

Simultaneous fade reduction and wear improvement of a commercial automotive brake lining were achieved by adding fibrous potassium titanate. The dependence of friction and wear characteristics on quantitative variations in potassium titanate, asbestos, phenolic binder, and organic and inorganic modifiers was evaluated.

Mansfield, J. A.↗