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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Energy consumption and charging load profiles from long-haul truck electrification in the United States

Abstract The urgent need to decarbonize the transportation sector combined with falling battery prices has spurred industry and policy interest in long-haul truck electrification. The charging behavior and resulting loads from electrified long-haul freight trucks are crucial for the smooth operation of the electric grid and have far-reaching environmental impacts (e.g., greenhouse gas and other air pollutant emissions). However, the aggregate energy impact of a fleetwide shift to electrified long-haul freight trucking has not been explored. This study combines electric truck design scenarios, bottom-up truck weight modeling, vehicle energy modeling, large-scale truck traffic data, and simulation of likely operation and charging behaviors to estimate end-use energy consumption and location-specific hourly charging loads for a national fleet of long-haul electric trucks. Relative to a fleet of future diesel trucks, electrification would reduce direct end-use energy consumption by 0.9 × 10 18 J (0.9 quadrillion BTU), but electrification might increase life cycle energy consumption depending on the electricity source. The electricity required to charge long-haul electric trucks is equivalent to five percent of annual electricity consumption in the United States (US). The simulated truck charging loads peak during the day across the US grid regions, but the charging peaks’ exact timing is sensitive to when trucks are dispatched for operation. The load shapes suggest that electric trucks’ charging loads can coincide with peaks in solar power generation, and planning could enable on- or off-site integration between truck charging stations and renewable electricity generation.

Tong, Fan (ORCID:0000000346613956)↗

NASA NTRS1980

Shock-tube studies of radiative base heating of Jovian probe

A 6.4-cm-diameter scale model of the Jovian entry vehicle is tested in an electric-arc-driven shock tube and a 5-cm-diameter sphere model is tested in a combustion-driven shock tube and in an electric-arc-driven shock tunnel. The radiative heat-transfer rate and pressure on the front and the base regions are measured in the absence of ablation with sensors imbedded in the models in a stream consisting of 10% hydrogen in a bath of either neon or argon. The measured radiative heat-transfer rates and pressures range to about 22 kW/sq cm and 12 atm, respectively, at the front stagnation point. The ratio of the radiative heat-transfer rate at the base stagnation point to that at the front stagnation point is found to be about 1/4 for the sphere at Mach 1.8, about 1/30 for the sphere at Mach 4.8, and about 1/6 for the scale model at Mach 1.7. The present experimental results agree well with the theoretical predictions of Park, thus indicating that Park's theory is valid.

Shirai, H.↗

NASA NTRSDate not supplied

Acoustic Testing of the Joby Aviation Propeller in the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel

The advanced air mobility sector has progressed in recent years with electric vertical take-Off and landing vehicles at the forefront. In response, the NASA Advanced Air Mobility Project has initiated the Advanced Air Mobility National Campaign to partner with industry to progress this emerging market. This resulted in NASA’s Revolutionary Vertical Lift Technology project to participate to progress research efforts for software tool validation for these advanced air mobility vehicle configurations. Noise has been identified as one of the main obstacles to succeeding in this emerging market for community acceptance. To further understand electric vertical take-Off and landing vehicle noise, an isolated Joby Aviation S4 propeller was tested in the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel to aid in providing high quality performance, loads, and acoustic data. Details of test hardware and setup are described with a focus on acoustics, which includes facility, test model, microphone locations, and data acquisition system details. Additionally, the data processing techniques and completed test matrix for acoustic points are provided. To aid in identifying potential acoustic reflections, an acoustic reflection test was performed prior to the start of the test and highlighted the presence of reflections at every microphone location. Acoustic results are provided for various flight regimes for sweeps of blade pitch, RPM, flow angle, and wind speed. These results show an optimum RPM for a specific thrust level for noise, and further reductions in RPM can increase noise levels. This dataset will be used to evaluate and improve computational tools.

Aviation Propeller↗

DOE OSTI2020

Future material demand for automotive lithium-based batteries

The world is shifting to electric vehicles to mitigate climate change. Here, we quantify the future demand for key battery materials, considering potential electric vehicle fleet and battery chemistry developments as well as second-use and recycling of electric vehicle batteries. We find that in a lithium nickel cobalt manganese oxide dominated battery scenario, demand is estimated to increase by factors of 18–20 for lithium, 17–19 for cobalt, 28–31 for nickel, and 15–20 for most other materials from 2020 to 2050, requiring a drastic expansion of lithium, cobalt, and nickel supply chains and likely additional resource discovery. However, uncertainties are large. Key factors are the development of the electric vehicles fleet and battery capacity requirements per vehicle. If other battery chemistries were used at large scale, e.g. lithium iron phosphate or novel lithium-sulphur or lithium-air batteries, the demand for cobalt and nickel would be substantially smaller. Closed-loop recycling plays a minor, but increasingly important role for reducing primary material demand until 2050, however, advances in recycling are necessary to economically recover battery-grade materials from end-of-life batteries. Second-use of electric vehicles batteries further delays recycling potentials.

25 ENERGY STORAGE↗

DOE OSTI2022

Evaluating an Eco-Cooperative Automated Control System

The paper evaluates an Eco-Cooperative Automated Control (Eco-CAC) system on a large-scale network considering a combination of internal combustion engine vehicles (ICEVs), hybrid electric vehicles (HEVs), and battery-only electric vehicles (BEVs) in a microscopic traffic simulation environment. We used a novel integrated control system that: (1) routes ICEVs, HEVs, and BEVs in a fuel/energy-efficient manner; (2) selects vehicle speeds based on anticipated traffic network evolution; (3) minimizes vehicle fuel/energy consumption near signalized intersections; and (4) intelligently modulates the longitudinal motion of vehicles along freeways within a cooperative platoon to minimize fuel/energy consumption. The study tested the system using the INTEGRATION software on the Los Angeles (LA), U.S., downtown network for three different demand levels: no congestion, mild congestion, and heavy congestion. The results demonstrated that the Eco-CAC system effectively reduces vehicle fuel and energy consumption, travel time, total delay, and stopped delay in heavily congested conditions. However, different vehicle compositions produced different results. In particular, the maximum energy consumption savings for BEVs (36.9%) for a current vehicle composition occurred at a 10% market penetration rate (MPR) of connected automated vehicles (CAVs) in mild congestion, while the maximum savings for a future vehicle composition (35.5%) occurred at a 50% CAV MPR in no congestion. The system reduced fuel consumption for ICEVs and HEVs by up to 5.4% and 6.3% at a 25% CAV MPR in heavy congestion for current and future vehicle compositions, respectively. However, the system increased total fuel consumption by up to 4.6% at a 50% CAV MPR in no congestion for a current vehicle composition. The study demonstrates that the effectiveness of the Eco-CAC system depends on traffic conditions, including congestion level, network configuration, CAV MPR, and vehicle composition.

Engineering↗

DOE OSTI2021

Behind-the-Meter Storage [Slides]

This is an overview of the work happening with Behind-the-Meter Storage. NREL is the Project Lead for Behind-the-Meter storage. The goal of this research is to produce behind-the-meter battery solutions deployed at scale to meet the functional requirement of high-power electric-vehicle charging.

25 ENERGY STORAGE↗

DOE OSTI2024

PHEV Distribution Grid Integration and Smart Systems Testing: Cooperative Research and Development Final Report

To continue NREL's mission, which includes preparing technologies and markets with "speed and scale," NREL researchers will collaborate with Toyota on plug-in electric vehicle technology. Toyota will provide a collection of plug-in hybrid electric vehicles ("PHEVs" [and ultimately including PEVs], collectively, the "Vehicles") to conduct infrastructure interaction testing at NREL facilities. NREL will use available resources in the Vehicle Testing and Integration Facility (VTIF), its staff parking garage with numerous commercial Electric Vehicle Supply Equipment ("EVSEs"), and its Energy Systems Integration Facility (ESIF) to safely execute research experiments that highlight potential distribution system power quality challenges related to plug-in electric vehicles. The expected outcome of this project is a better understanding of the correlation of individual vehicle power quality attributes to a system of vehicles on a distribution network. The data collected and the simulations conducted will be used to guide future experiments and project development that aid in the deployment of plug-in electric vehicles ("PEV").

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Evaluating China’s Passenger Vehicle Market under the Vehicle Policies of 2021–2023

China is well known for its determination on large-scale vehicle electrification, which currently is mainly driven by fuel economy and electric vehicle policies mixed with the extensive charging infrastructure support and monetary incentives from the government. This study adopted the New Energy and Oil Consumption Credits (NEOCC) model 2020 version, a vehicle policy analysis tool developed by the Oak Ridge National Laboratory, in order to systematically quantify the potential impacts of the “Passenger Cars Corporate Average Fuel Consumption and New Energy Vehicle Credit Regulation”, which is a revised version released in June 2020 for the timeframe 2021–2023, the so-called dual credit policy (2021–2023). It was found that, under the dual credit policy (2021–2023), the sales of hybrid electric vehicles could reach 0.91 million by the end of 2023, which would increase much faster than they did in 2018–2020. The annual sales share of plug-in electric vehicles (PEVs) could reach 11.7%, and the PEV stocks could achieve 11.70 million by the end of 2023 if it keeps the expansion to the level of how it was in 2017. In addition, the BEVs with long electric range (such as 400 km) and the plug-in hybrid electric SUVs could be the most popular PEV types.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Electric light-duty vehicles have decarbonization potential but may not reduce other environmental problems

Electric vehicles are promoted as ‘clean’ technologies and offer promising reductions in transportation emissions. Nevertheless, their environmental benefits critically depend on the local electricity grid mix and the type of emission being considered. Here, we conduct a comparative life cycle assessment of the four dominant light-duty vehicle categories at both the global scale and in three representative countries: Norway, the US, and China. By analyzing different environmental indicators, particularly global warming potential and respiratory effects, and quantifying related parametric uncertainties, we reveal that the advantages of electric vehicles vary across these regions and across environmental impact types. While electric vehicles offer considerable decarbonization potential as the grid mix becomes cleaner, they might not mitigate other environmental impacts, such as increased respiratory effects on rural, low-income communities. Our results support stakeholders in identifying environmentally friendly vehicle and policy options while considering multiple factors, and emphasize the importance of tailored approaches over one-size-fits-all solutions in sustainable transportation.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Highly Resolved Projections of Passenger Electric Vehicle Charging Loads for the Contiguous United States: Results From and Methods Behind Bottom-Up Simulations of County-Specific Household Electric Vehicle Charging Load (Hourly 8760) Profiles Projected Through 2050 for Differentiated Household and Vehicle Types

This report documents enhancements made to the TEMPO (Transportation Energy & Mobility Pathway Options TM ) model to project spatially, demographically, and temporally resolved national-scale EV charging load profiles and describes three scenarios and corresponding datasets created for the NREL demand-side grid (dsgrid) project in support of bulk power systems modeling. In brief, TEMPO was enhanced to disaggregate national and annual energy demand projections into household and county-level projections of passenger electric vehicle (EV) hourly charging load profiles (8760 profiles), accounting for consumer, travel, and temperature variations that impact EV energy demand. In alignment with NREL's forward-looking grid modeling, three scenarios for EV adoption covering 2020-2050 were created-- Annual Energy Outlook (AEO) Reference Case, Electrification Futures Study (EFS) High Electrification, and All EV Sales by 2035 --and associated datasets have been included in the dsgrid platform for public use.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Sustainable hydrogen manufacturing via renewable-integrated intensified process for refueling stations

The widescale consumer adoption of hydrogen fuel cell electric vehicles (HFCEVs) is currently hindered by the high cost of small-scale hydrogen generation and the lack of extensive hydrogen refueling infrastructure. Natural gas-based hydrogen is cheaper when produced in large volumes but is also associated with high CO 2 emissions. To counter these challenges, we propose a hybrid approach where both natural gas and renewables are integrated in a synergistic manner using a dynamic process intensification technology that can be deployed on-site for meeting local demands of refueling stations. The technology is based on sorption enhanced steam methane reforming (SE-SMR) that utilizes a combination of reaction with in-situ CO 2 adsorption for enhancing process modularity, productivity and efficiency thereby outperforming conventional SMR at small scale. We develop a mixed integer linear programming (MILP)-based optimization framework for simultaneous design and scheduling of the SE-SMR process. The simultaneous optimization provides a synergistic combination whereby the renewables allow sustainable hydrogen manufacturing and the dynamic SE-SMR allows optimal use of the intermittency of the renewables. The U.S. nationwide analysis indicates that for futuristic renewable prices and a hydrogen production capacity of 2 ton/day, hydrogen can be produced at 50% less cost compared to the current cost of small-scale hydrogen generation. Finally, the city-wise analysis with varying hydrogen demand shows that even with just 5% HFCEV market penetration level, hydrogen production cost less than $3/kg can be obtained at small scales across the United States with even cheaper hydrogen for large cities.

08 HYDROGEN↗

DOE OSTI2025

Mechanically induced thermal runaway severity analysis of Li-ion batteries and continuous energy release monitoring

The large-scale deployment of Li-ion batteries in stationary energy storage and electrical vehicle applications demands a strong focus on safety, particularly on the thermal runaway risk and severity evaluation. A standardized single-side mechanical indentation test protocol was developed to induce an internal short-circuit (ISC) and evaluate cells' thermal runaway severity at different state of charge (SOC). The observed hazard severity (OHS in five categories) and evaluated scores in this work have a comprehensive consideration of each cell's capacity, initial voltage, SOC, temperature and voltage change, allowing a better evaluation of the cells' thermal runaway potential. This method was applied to about 200 Li-ion batteries in order to build an extensive thermal runaway database covering various SOCs, capacities and chemistries. In this study, we monitored the transitions of stored electrochemical energy and applied mechanical energy into both thermal energy and acoustic emissions (AE). The surface temperature and mechanical failures were monitored by infrared imaging and AE to capture critical events within battery cells throughout the mechanical indentation tests. Furthermore, the initial temperature maps can predict two types of follow-up events: thermal runaway or gradual heat release via conduction. Analyzing each cell's severity, AEs, and leveraging the evolving database offer insights into predicting occurrences of thermal runaway. The test method, thermal runaway severity evaluation and prediction, and the corresponding database provide battery designers, manufacturers, and end-users a clear overview of Li-ion batteries' thermal runaway potential under mechanical abuse, advancing the safety design of Li-ion batteries.

Acoustic emission↗

NASA NTRS1992

Power processing units for high power solar electric propulsion

An evaluation of high-power processing units (PPUs) for multimegawatt solar electric propulsion (SEP) vehicles using advanced ion thrusters is presented. Significant savings of scale are possible for PPUs used to supply power to ion thrusters operating at 0.1 to 1.5 MWe per thruster. The PPU specific mass is found to be strongly sensitive to variations in the ion thruster's power per thruster and moderately sensitive to variations in the thruster's screen voltage due to varying the I(sp) of the thruster. Each PPU consists of a dc-to-dc converter to increase the voltage from the 500 V dc of the photovoltaic power system to the 5 to 13 kV dc required by the ion thrusters.

Frisbee, Robert H.↗

DOE OSTI2023

EVs@Scale Next-Gen Profiles - Fleet Utilization 2023

As U.S. fleet operators begin transitioning to electric vehicles (EVs), critical questions arise regarding how to manage this shift without disrupting fleet operations or placing undue stress on the electric grid. A major challenge for fleets is maintaining effective operational schedules while accommodating charging requirements, particularly with high-power charging (HPC) infrastructure, which presents grid stability concerns for utilities. Proposed solutions such as charging substations, megawatt charging systems (MCS), and smart charge management systems (SCMS) offer potential pathways forward, but their effectiveness depends on alignment with real-world fleet behavior and operational constraints. This report investigates the charging and utilization behavior of EV and EVSE fleets actively employing HPC technologies by conducting detailed case study analyses based on telematics data. A suite of predefined metrics—covering charging, routing, and other operational behaviors—is developed to evaluate the impact of fleet activities on grid infrastructure and identify opportunities for optimization. Results highlight variations in charging behavior across fleets, such as weekday versus weekend usage, diurnal charging trends, and the role of operational predictability in enabling SCMS effectiveness. While SCMS can help lower costs and improve energy efficiency for fleets with stable schedules, they may be insufficient for fleets with highly variable or long-haul operations, which may require more robust solutions like MCS. Visualization of aggregated hourly energy metrics reveals that while fleet behaviors are diverse, there are common temporal patterns that could inform infrastructure planning and energy management. These insights emphasize the need for fleet-specific charging strategies that minimize grid impact while supporting reliable fleet operations. Additionally, the report underscores the broader economic stakes of electrification, particularly in high-value markets such as freight, where misaligned transitions could stall EV adoption. By examining current EV and EVSE fleet deployments using predetermined standardized metrics, this study offers a foundation for developing technologies and operational frameworks that support scalable, grid-compatible electrification across a variety of fleet types while establishing a baseline understanding of operational behaviors. In doing so, we aim to ensure that future charging solutions reflect actual fleet needs and grid constraints—an essential step toward maintaining operational continuity and achieving a successful transition to electric fleet operations.

Charging↗

DOE OSTI2021

A Review and Outlook on Energy Consumption Estimation Models for Electric Vehicles

Electric vehicles (EVs) are critical to the transition to a low-carbon transportation system. The successful adoption of EVs heavily depends on energy consumption models that can accurately and reliably estimate electricity consumption. This paper reviews the state-of-the-art of EV energy consumption models, aiming to provide guidance for future development of EV applications. Here, we summarize influential variables of EV energy consumption into four categories: vehicle component, vehicle dynamics, traffic and environment related factors. We classify and discuss EV energy consumption models in terms of modeling scale (microscopic vs. macroscopic) and methodology (data-driven vs. rule-based). Our review shows trends of increasing macroscopic models that can be used to estimate trip-level EV energy consumption and increasing data-driven models that utilized machine learning technologies to estimate EV energy consumption based on large volume real-world data. We identify research gaps for EV energy consumption models, including the development of energy estimation models for modes other than personal vehicles (e.g., electric buses, electric trucks, and electric non-road vehicles); the development of energy estimation models that are suitable for applications related to vehicle-to-grid integration; and the development of multi-scale energy estimation models as a holistic modeling approach.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2016

Experimental Evaluation of the Scale Model Method to Simulate Lunar Vehicle Dynamics

As compared to driving on Earth, the presence of lower gravity and uneven terrain on planetary bodies makes high speed driving difficult. In order to maintain ground contact and control vehicles need to be designed with special attention to dynamic response. The challenge of maintaining control on the Moon was evident during high speed operations of the Lunar Roving Vehicle (LRV) on Apollo 16, as at one point all four tires were off the ground; this event has been referred to as the Lunar Grand Prix. Ultimately, computer simulation should be used to examine these phenomena during the vehicle design process; however, experimental techniques are required for the validation and elucidation of key issues. The objectives of this study were to evaluate the methodology for developing a scale model of a lunar vehicle using similitude relationships and to test how vehicle configuration, six or eight wheel pods, and local tire compliance, soft or stiff, affect the vehicles dynamic performance. A wheel pod consists of a drive and steering transmission and wheel. The Lunar Electric Rover (LER), a human driven vehicle with a pressurized cabin, was selected as an example for which a scale model was built. The scaled vehicle was driven over an obstacle and the dynamic response was observed and then scaled to represent the full-size vehicle in lunar gravity. Loss of ground contact, in terms of vehicle travel distance with tires off the ground, was examined. As expected, local tire compliance allowed ground contact to be maintained over a greater distance. However, switching from a six-tire configuration to an eight-tire configuration with reduced suspension stiffness had a negative effect on ground contact. It is hypothesized that this was due to the increased number or frequency of impacts. The development and testing of this scale model provided practical lessons for future low-gravity vehicle development.

Moon↗

DOE OSTI2020

Grid Impact Analysis of Heavy-Duty Electric Vehicle Charging Stations

This paper presents a grid impact analysis of heavy-duty electric vehicle (EV) charging stations. In this work, heavy-duty EVs have battery capacities high enough to provide a range of 250-500 miles on a single charge, such as long-haul trucks. Heavy-duty EVs will require extremely fast charging rates to reduce charging time and will induce very high charging loads (at the multiple-megawatt scale) if several vehicles charge at the same time. Therefore, analysis is needed to understand the impact of charging station loads on the electric power grid and set the baseline for developing mitigation plans and necessary system upgrades. We develop a systematic procedure to analyze the potential impact of the placement of charging stations on the grid. Charging load is modeled using a DC fast-charging station model. A voltage load sensitivity matrix approach is leveraged to investigate the challenges of placing charging stations on the feeder. Given the charging load profiles and suggested charging station locations, time-series simulations are performed on various connection points on the feeder to understand the impact. The analysis is performed on both the IEEE 34-bus system and a realistic feeder from California. Initial mitigation solutions are developed based on insights from this analysis.

47 OTHER INSTRUMENTATION↗

NASA NTRS2019

Feasibility of Electrified Propulsion for Ultra-Efficient Commercial Aircraft Final Report

MIT, Aurora Flight Sciences, and USC have collaborated to assess the feasibility of electric, hybridelectric, and turbo-electric propulsion for ultra-efficient commercial transportation. The work has drawn on the team expertise in disciplines related to aircraft design, propulsion-airframe integration, electric machines and systems, engineering system design, and optimization. A parametric trade space analysis has been carried out to assess vehicle performance across a range of transport missions and propulsion architectures to establish how electrified propulsion systems scale. An optimization approach to vehicle conceptual design modeling was taken to enable rapid multidisciplinary design space exploration and sensitivity analysis. The results of the analysis indicate vehicle aero-propulsive integration benefits enabled by electrification are required to offset the increased weight and loss associated with the electric system and achieve enhanced performance; the report describes the conceptual configurations than can offer such enhancements. The main contribution of the present work is the definition of electric vehicle design attributes for potential efficiency improvements at different scales. Based on these results, key areas for future research are identified, and extensions to the trade space analysis suitable for higher fidelity electrified commercial aircraft design and analysis have been developed.

Hall, D.K.↗