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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Additively manufactured and cast high-temperature aluminum alloys for electric vehicle brake rotor application

Electric vehicle brake rotors demand lightweight, high thermal conductivity materials with good resistance to wear, creep, salt corrosion, and thermal fade, all of which present challenges to the traditionally used cast iron. In this work, we investigated the braking performance of recently developed high-temperature aluminum alloys in both cast and 3D printed forms, that possess excellent microstructural and mechanical stability at elevated temperatures. Three aluminum alloys, Al-6Cu-Mn-Zr, Al-9Cu-Mn-Zr, and Al-Ce-Ni-Mn-Zr and a reference cast iron were tested on a sub-scale brake tester against a commercial brake pad material over a range of sliding speeds between 2 and 15 m/s. The performance of these alloys was evaluated for wear resistance, friction behavior, temperature elevation, and surface morphological change. Although all three candidate alloys had lower wear-resistance than cast iron, Al-Ce-Ni-Mn-Zr showed a significantly reduced wear rate in comparison to the Al-Cu-Mn-Zr alloys. Moreover, Al-Ce-Ni-Mn-Zr alloy had the most consistent friction behavior at all sliding speeds and good fade resistance, as the coefficient of friction did not dramatically decrease with temperature rise but stayed within a desirable range of 0.35–0.50 instead. The superior wear resistance and braking performance of the Al-Ce-Ni-Mn-Zr alloy were attributed to its higher hardness, and high temperature yield strength and creep resistance compared with the Al-Cu-Mn-Zr alloys. In conclusion, the results suggest that the braking performance of these aluminum alloys could be further enhanced by increasing the hardness and forming a more stable transfer layer on the sliding surface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Design and Analysis of a 200 kW Dynamic Wireless Charging System for Electric Vehicles

Dynamic wireless charging of electric vehicles can significantly alleviate or eliminate range anxiety while reducing the required on-board battery capacity. To achieve an electric vehicle charging balance with minimal infrastructure costs, power transfer levels around 200 kW are required. In this paper, a system architecture with a modularized power electronics and optimized power transfer couplers was adopted to enable efficient power transfer. A DC/DC converter was used for secondary-side charging control of the battery. The system performance was validated in an experimental setup at 120 kW with 91.31% efficiency from the DC input on the primary side to the vehicle battery.

Xue, Lincoln↗
DOE OSTI2022

Assessment of Light-Duty Plug-in Electric Vehicles in the United States, 2010 – 2021

The number of plug-in electric vehicles (PEVs) sold in the United States has consistently grown since 2010, reaching 4% of the light-duty vehicle market in 2021. This report examines how the characteristics for these PEVs has changed over this decade, evaluating range, energy efficiency, costs, and performance. Given the vehicle characteristics, this report estimates miles driven, electricity consumption, petroleum reduction, and greenhouse gas emissions attributable to electric vehicles. This report also explores vehicle manufacturing and battery production, considering supply chains from battery cells to assembly. Over 2.1 million PEVs have been sold in the United States through December 2021, with 1.3 million of these all fully-electric battery electric vehicles (BEV), and 800,000 plug-in hybrid electric vehicles (PHEV) which have the capability of using gasoline. The sales-weighted average range for BEVs reached 290 miles in 2021 and 28 miles for PHEVs. We estimate that electric vehicles have driven 68 billion miles on electricity since 2010, thereby reducing national gasoline consumption by 0.54% in 2021 and 2.5 billion gallons cumulatively through 2021. In 2021, PEVs used 6.1 terawatt-hours of electricity to drive 19.1 billion miles, offsetting 700 million gallons of gasoline. We find that this fuel switching reduced consumer fuel costs by $1.3 billion in 2021. Since 2010, 65% of PEVs sold in the United States have been assembled domestically, and over 110 gigawatt-hours of lithium-ion batteries have been installed in vehicles to date.

25 ENERGY STORAGE↗
DOE OSTI2021

There's No Place Like Home: Residential Parking, Electrical Access, and Implications for the Future of Electric Vehicle Charging Infrastructure

In March 2021, the cumulative sale of plug-in electric vehicles (PEVs), including plug-in hybrid electric vehicles (PHEV) and battery electric vehicles (BEV), reached 1.8 million in the United States (Argonne National Laboratory 2021). However, PEV adoption is still in its infancy; its market share has just reached around 3% of new light-duty vehicle (LDV) sales by the end of 2020 (Alliance for Automotive Innovation 2021). Current trends suggest that PEV market share in the United States is increasing. The U.S. Energy Information Administration's (EIA's) 2020 Annual Energy Outlook forecasts PEV registrations to exceed 8 million vehicles by 2030 (AEO 2020). PEV adoption is expected to be led by states that are regulating the sale of zero emission vehicles (ZEVs) (California Air Resources Board). California continues to push for more aggressive ZEV regulations; the state recently issued an executive order aimed at 100% of LDV sales being ZEVs by 2035 (Office of Governor Newsom). At the federal level, the Biden administration has shown great ambition in encouraging broader electric vehicle (EV) adoption, including setting the goal of installing 500,000 new chargers nationwide (The White House 2021). Access to charging infrastructure is consistently cited as one of the primary barriers to the increased sale of PHEVs and BEVs (Carley et al. 2019). In the United States, PEV charging options are often described using a pyramid structure, with residential charging as the foundation, workplace charging in the middle, and public charging on top (Figure 1). The existing electricity system, which generates, transmits, and distributes electric fuel to residential households, has helped PEVs partially overcome the "chicken and egg" conundrum that has haunted other alternative fuels. Viable home access to electric charging is also an important equity issue, because non-residential PEV charging options (e.g., workplace or public charging stations) are generally more expensive. Households without residential charging access may experience higher total cost of PEV ownership if non-residential charging options are more costly.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Modeling charging infrastructure impact on the electric vehicle market in China

The plug-in electric vehicle (PEV) is deemed as a critical technological revolution, and the governments are imposing various vehicle policies to promote its development. Meanwhile, the market success of PEVs depends on many aspects. The study reported herein integrates one’s use of charging infrastructure at home, public place and workplace into the market dynamics analysis tool, New Energy and Oil Consumption Credits (NEOCC) model, to systematically assess the charging infrastructure (home parking ratio, public charging opportunity, and charging costs) impact on PEV ownership costs and analyze how the PEV market shares may be affected by the attributes of the charging infrastructure. Compared to the charging infrastructure, the impact of battery costs is incontrovertibly decisive on PEV market shares, the charging infrastructure is still non-negligible in the PEV market dynamics. The simulation results find that the public charging infrastructure has more effectiveness on promoting the PEV sales in the PEV emerging market than it does in the PEV mature market. However, the improvement of charging infrastructure does not necessarily lead to a larger PEV market if the charging infrastructure incentives do not coordinate well with other PEV policies. Besides, the increase of public charging opportunities has limited motivations on the growth of public PEV fleets, which are highly correlated to the number of public fast charging stations or outlets. It also finds that more home parking spaces can stimulate more sales of personal plug-in hybrid electric vehicles instead of personal battery electric vehicles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Domestic Sales Mix of Plug-In Electric Vehicles by Trim Variant and Vehicle Characteristics

As plug-in electric vehicles (PEVs) take up a larger share of the United States vehicle market, their variety increases as well. Since many electric vehicle manufacturers offer multiple PEV trim variants, the distribution of vehicle characteristics such as battery capacity, all-electric range, electricity consumption, and curb weight cannot be determined by sales data alone. Sales data and vehicle registration data were analyzed to quantify and map the trim variant distribution of PEV models from nine automakers. With this information, we quantify national sales-weighted characteristics of fourteen different models over ten years, including battery capacity, fuel economy, and vehicle weight. We find a positive correlation between share of all-wheel drive variants for Tesla vehicles and average annual snowfall, and general uniformity nationwide in other vehicle characteristics. The estimated trim variant distributions will be useful in informing decisions regarding materials recycling and EV impact on the energy grid, and this study found that the total installed battery capacity in PEV in the U.S. was 76 GWh through 2020.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Impact of electric vehicle charging on the power demand of retail buildings

As electric vehicle penetration increases, charging is expected to have a significant impact on the grid. Electric vehicle charging stations will greatly affect a building site's power demand, especially with the onset of fast charging with power levels as high as 350 kW per charger. Here, we assess how electric vehicle charging stations would impact a retail big box grocery store, exploring numerous station sizes, charging power levels, and utilization factors in various climate zones and seasons. We measure the effect of charging by assessing changes in monthly peak power demand, electricity usage, and annual electricity bill, computed using three distinct rate structures. We find that an electric vehicle station has the potential to dwarf a big box building's power demand if behind the same meter, increasing monthly peak power demand at the site by over 250%. Cold-climate areas paired with rate structures incorporating high demand charges are most susceptible for significant changes to the annual electricity bill, with increases as high as 88%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Electric Vehicle Efficiency Ratios for Light-Duty Vehicles Registered in the United States

Electric vehicles (EVs) use energy more efficiently than gasoline vehicles. This is one of their primary attributes, enabling other benefits such as improved torque and reduced operating costs and greenhouse gas emissions. An electric vehicle efficiency ratio (EVER) is therefore important when calculating the financial and environmental benefits of EVs, calculating the impact that EVs have on a manufacturer's Corporate Average Fuel Economy rating, calculating credits in trading schemes such as California's Low Carbon Fuel Standard, fuel price leveling, designing electricity tariffs from utility-owned public charging infrastructure, creating EV alternatives to gasoline excise taxes, and more.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Depot-Based Vehicle Data for National Analysis of Medium- and Heavy-Duty Electric Vehicle Charging

Medium- and heavy-duty vehicles (MHDVs) are a major source of greenhouse gases and local criteria air pollutants. Electrifying MHDVs may reduce these harmful emissions, which disproportionately impact disadvantaged communities. Due to their relatively high per-vehicle energy needs, consistent fleet operations, and frequent colocation of multiple vehicles at depots, MHDVs may have more spatially and temporally concentrated charging demands than light-duty passenger electric vehicles. That charging concentration means their electrification may require careful advance planning and coordination to manage potential impacts to the electrical grid via charge management or infrastructure upgrades. However, MHDV duty cycles and parking schedules are highly variable across vocations of operation, and there is a shortage of nationally representative, vocationally diverse public data describing typical MHDV operations. This report summarizes the methodology - designed with national representativeness in mind - used to create a new set of data describing typical daily driving distances, dwell durations, and normalized electric vehicle depot charging load curves for MHDVs. The dataset reflects the subset of MHDV operating patterns that may originate from a consistent depot each day and rely on the same depot for charging. In addition to trucks with depot-centric vocational patterns, the data describes operations of transit buses and school buses, each with a depot-centric focus. The dataset is available to the public and suitable for national analysis. It can inform research, infrastructure planning, and policymaking regarding the electrification of MHDVs.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Electric Drive Technology Trends, Challenges, and Opportunities for Future Electric Vehicles

The transition to electric road transport technologies requires electric traction drive systems to offer improved performances and capabilities, such as fuel efficiency (in terms of MPGe, i.e., miles per gallon of gasoline-equivalent), extended range, and fast-charging options. The enhanced electrification and transformed mobility are translating to a demand for higher power and more efficient electric traction drive systems that lead to better fuel economy for a given battery charge. To accelerate the mass-market adoption of electrified transportation, the U.S. Department of Energy (DOE), in collaboration with the automotive industry, has announced the technical targets for light-duty electric vehicles (EVs) for 2025. This article discusses the electric drive technology trends for passenger electric and hybrid EVs with commercially available solutions in terms of materials, electric machine and inverter designs, maximum speed, component cooling, power density, and performance. Additionally, the emerging materials and technologies for power electronics and electric motors are presented, identifying the challenges and opportunities for even more aggressive designs to meet the need for next-generation EVs. Some innovative drive and motor designs with the potential to meet the DOE 2025 targets are also discussed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Review of Electric Vehicle Charger Cybersecurity Vulnerabilities, Potential Impacts, and Defenses

Worldwide growth in electric vehicle use is prompting new installations of private and public electric vehicle supply equipment (EVSE). EVSE devices support the electrification of the transportation industry but also represent a linchpin for power systems and transportation infrastructures. Cybersecurity researchers have recently identified several vulnerabilities that exist in EVSE devices, communications to electric vehicles (EVs), and upstream services, such as EVSE vendor cloud services, third party systems, and grid operators. The potential impact of attacks on these systems stretches from localized, relatively minor effects to long-term national disruptions. Fortunately, there is a strong and expanding collection of information technology (IT) and operational technology (OT) cybersecurity best practices that may be applied to the EVSE environment to secure this equipment. In this paper, we survey publicly disclosed EVSE vulnerabilities, the impact of EV charger cyberattacks, and proposed security protections for EV charging technologies.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Deployment of plug-in electric vehicles in China and the USA: issues and opportunities, foreword

Plug-in electric vehicles (PEVs), including battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs), have been promoted globally for their emission reductions and energy conservation. In addition to financial incentives for PEVs in many countries (Stephens et al. 2018), emission and energy regulatory systems provide additional incentives for PEVs in the USA, Europe, and China (European Union 2014; Innovation Center for Energy and Transportation 2019; U.S. EPA and NHTSA 2012). These incentives, together with PEV technology advances and cost reductions, have caused PEV sales to grow exponentially in many countries and global regions; PEV stocks totaled more than 5 million by the end of 2018 (Fig. 1). The International Energy Agency (2019) projects that PEV sales will grow even more quickly through 2030 to reach a total global PEV stock of 130 million to 250 million.

China↗
DOE OSTI2023

Light-duty Plug-in Electric Vehicles in China: Evolution, Competition, and Outlook

China's plug-in electric vehicle (PEV) market with stocks at 7.8 million is the world's largest in 2021, and it accounts for half of the global PEV growth in 2021. The PEV market in China has dramatically evolved since the pandemic in 2020: over 20% of all new PEV sales are from China by mid-2022. Recent features of PEV market dynamics, consumer acceptance, policies, and infrastructure have important implications for both the global energy market and manufacturing stakeholders. From the perspective of demand pull-supply push, this study analyzes China's PEV industry with a market dynamics framework by reviewing sales, product and brand, infrastructure, and government policies from the last few years and outlooking the development of the new government’s 14th Five-Year Plan (2021-2025). From the demand side, small-sized sedans and compact sport utility vehicles with increased electric ranges are both popular for PEVs, and the electric range of over 60% of new battery electric vehicles in 2021 has been longer than 400 km. From the supply side, although foreign brands like Tesla are still competitive, the products by Chinese domestic automakers like BYD are becoming more attractive and cannibalizing the high-end market. However, the production capacity and cost of PEVs may be limited by the upstream of the supply chain – the battery manufacturing and supply chain inflation. In addition, it is also uncertain how much sales demand impacts will be caused by the potential global economic recession. The government firmly supports electrification and decarbonization of the vehicle industry by emphasizing the importance of the vehicle industry for promoting the greenhouse gas net zero by 2060. The dual-credit policy is regarded as the most critical regulation in a bid to restrain fuel consumption and promote PEV share. Still, the market is facing some technological obstacles, such as battery safety and driving range anxiety, before real prosperity. In addition, the Chinese electric vehicle market is seeing a trend toward the development of new technologies such as vehicle-to-X, autonomous driving, and connected vehicles.

Hao, Xu↗
DOE OSTI2022

Model-Based Framework to Optimize Charger Station Deployment for Battery Electric Vehicles

The development of battery electric vehicles (BEVs) is accelerating due to their environmental advantages over gasoline and diesel-powered vehicles, including a decrease in air pollution and an increase in energy efficiency. The deployment of charging infrastructure will need to increase to keep pace with demand, especially for large commercial vehicles for which few public chargers currently exist. In this paper, a new flexible framework is proposed for optimizing the placement of charging stations for BEVs, within which different physical models and optimization techniques may be used. Furthermore, a set of metrics is suggested to help enforce complex constraints and facilitate direct comparison between different optimization techniques. Unlike many existing charger placement techniques, the proposed method directly considers the historical driving patterns on a vehicle-by-vehicle basis, using transparent models to assess impacts of candidate charger placements, thus improving the explainability of the results. In the developed framework, modeled BEVs are first generated along the road network to mimic historical traffic data and are simulated traveling along a given route according to a simplified vehicle model. During the simulation, the charger placement problem is initially relaxed to allow vehicles to charge at any node along the road network, and vehicle states are tracked to assess areas of high charging demand. Charging stations are then placed based on the results of the relaxed simulation, and suggested placements are evaluated via road network simulation with fixed charger locations. This proposed framework is applied to a sample problem of placing charging stations along five major highway corridors for Class 8 over-the-road electric trucks. A novel mixed integer programming (MIP) formulation is proposed to optimize charger placements based upon the expected charging demand. Constraints were imposed on the final placement results to limit expected wait times at each station and ensure a minimum threshold of trucking routes are viable for BEVs. The results demonstrate the flexibility and potential effectiveness of the developed model-based framework for scalable charger station deployment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Regional Emissions Analysis of Light-Duty Battery Electric Vehicles

Light-duty battery electric vehicles (BEVs) can reduce both greenhouse gas (GHG) and criteria air pollutant (CAPs) emissions, when compared to gasoline vehicles. However, research has found that while today’s BEVs typically reduce GHGs, they can increase certain CAPs, though with significant regional variability based on the electric grid mix. In addition, the environmental performance of electric and gasoline vehicles is not static, as key factors driving emissions have undergone significant changes recently and are expected to continue to evolve. In this study, we perform a cradle-to-grave life cycle analysis using state-level generation mix and vehicle operation emission data. We generated state-level emission factors using a projection from 2020 to 2050 for three light-duty vehicle types. We found that BEVs currently provide GHG benefits in nearly every state, with the median state’s benefit being between approximately 50% to 60% lower than gasoline counterparts. However, gasoline vehicles currently have lower total NOx, urban NOx, total PM 2.5 , and urban PM 2.5 in 33%; 15%; 70%; and 10% of states, respectively. BEV emissions will decrease in 2050 due to a cleaner grid, but the relative benefits when compared to gasoline vehicles do not change significantly, as gasoline vehicles are also improving over this time.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Triple Effect Economics: How Do Electric Vehicles, Solar Photovoltaics, and Work-from-Home Transform Household Electricity Cost?

Solutions for deep decarbonization need to be affordable as well as sustainable to garner widespread adoption. The past two decades have seen the introduction of new technologies and paradigms such as electric vehicles (EVs), solar photovoltaics (PVs), and increased work-from-home (WFH), which impact a household's overall energy consumption and cost in different ways. However, much attention has not been paid to explore the joint impact these technologies have on a household's electricity cost burden. Leveraging the 2020 Residential Energy Consumption Survey (RECS), this study presents an integrated model to unravel the extent to which the bundled adoption of EV-PV and stay-at-home decisions impact the total electricity cost of households. National level RECS data revealed that, compared to the baseline (i.e., households that did not own any of these technologies), households that own EVs, PVs, and engage in WFH observed a 13.5% decline in their electricity bills, despite a 25% increase in electricity consumption. The model results indicated that bundled adoption of EVs-PVs reduces electricity costs more significantly for a household, compared to the increased costs imposed by more household members staying at home. This holistic assessment presents an opportunity for decision makers to contextualize the changing energy costs and design effective strategies to foster a sustainable and cost saving mechanism. Policies such as bundled incentivization to motivate co-adoption, education about energy-management strategies, and add-on subsidies to adopt energy-efficient appliances, will not only accelerate decarbonization but increase household financial savings.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2020

Midwest EVOLVE (Midwest Electric Vehicle Opportunities: Learning, eVents, Experience)

The Midwest Electric Vehicle Opportunities: Learning, eVents, Experience (Midwest EVOLVE) project was a 45 month, seven-state effort to introduce electric vehicles to the public, workplaces, corporate fleets and auto dealership staff. Midwest EVOLVE projects were planned and completed in the following states: Illinois, Indiana, Michigan, Minnesota, North Dakota, Ohio, and Wisconsin. The project was coordinated by the American Lung Association of the Upper Midwest (ALAUM), dba Twin Cities Clean Cities Coalition (TC4).

33 ADVANCED PROPULSION SYSTEMS↗