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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Single-atom automobile exhaust catalysts

Single-atom catalysts (SACs) with isolated metal centers are attracting great research interest because of their maximized metal utilization rates and unique structures. In the last decade, significant efforts have been made to design highly efficient and costeffective SACs with applications in automobile exhaust aftertreatment. SACs have not only demonstrated their high potential for improving the catalytic performance of current automobile exhaust catalysts but also provided an ideal platform for understanding the origins of catalyst reactivity. In this review, we summarize the general strategies for promoting the reactivity of metal SACs while maintaining their thermal stability during exhaust-abatement-related reactions. Highlights are provided on well-performed SACs for CO oxidation, unburnt hydrocarbon (HC) oxidation, and the selective catalytic reduction of NOx. The reaction mechanism and structure– performance relationship of SAC during these reactions are also discussed. Finally, perspectives are given on the trending research fields for designing more efficient single-atom automobile exhaust catalysts in the future.

Lu, Yubing↗
DOE OSTI2014

Contribution of Road Grade to the Energy Use of Modern Automobiles Across Large Datasets of Real-World Drive Cycles: Preprint

Understanding the real-world power demand of modern automobiles is of critical importance to engineers using modeling and simulation to inform the intelligent design of increasingly efficient powertrains. Increased use of global positioning system (GPS) devices has made large scale data collection of vehicle speed (and associated power demand) a reality. While the availability of real-world GPS data has improved the industry's understanding of in-use vehicle power demand, relatively little attention has been paid to the incremental power requirements imposed by road grade. This analysis quantifies the incremental efficiency impacts of real-world road grade by appending high fidelity elevation profiles to GPS speed traces and performing a large simulation study. Employing a large real-world dataset from the National Renewable Energy Laboratory's Transportation Secure Data Center, vehicle powertrain simulations are performed with and without road grade under five vehicle models. Aggregate results of this study suggest that road grade could be responsible for 1% to 3% of fuel use in light-duty automobiles.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Restoring Worn Components in Automobile Timing Mechanisms

In operation, the end of the valve tappet in an automobile’s timing mechanism undergoes not only wear but also fatigue crumbling. Several methods of removing the worn cast-iron layer are proposed to restore the gas-distributor components.

42 ENGINEERING↗
DOE OSTI2017

Advanced Lithium Batteries for Automobile Applications at ABAA-9

The battery-electrified vehicle industry is booming since the last decade, orientated by consumers’ growing demand for ''green'' cars with zero-emission of the greenhouse gases and the speedy-but-silent driving experience. Aiming for advanced battery technology to support electric vehicles, the International Conference on Advanced Lithium Batteries for Automobile Applications (ABAA) was launched in 2008. This paper describes the activities at ABAA-9.

25 ENERGY STORAGE↗
DOE OSTI2020

Circular economy framework for automobiles: Closing energy and material loops

Abstract Corporations, including automotive manufacturers, are increasingly exploring extended circular economy strategies as a means to enhance the sustainability of their products. The circular economy paradigm focuses on reducing nonrenewable materials and energy, promoting renewable feedstocks and energy, and keeping products/materials in use across the life cycle of a system. As such, life cycle environmental burdens associated with vehicle manufacturing, use, and disposal could potentially be reduced through circular economy strategies; however, no such comprehensive circular economy framework currently exists for the automotive industry. We develop the first circular economy schematic of automobiles, derived from the Ellen MacArthur Foundation's framework. Further, we characterize the current automotive circular economy using metrics of renewable energy and recycled materials. Specifically, for current U.S. average sedans, we find that internal combustion engine vehicles (ICEVs) use ∼6% renewable life cycle primary energy and 27% recycled materials; for battery electric vehicles (BEVs), these measures are ∼8% and 21%, respectively. On a vehicle‐miles‐traveled basis, BEVs use ∼47% less nonrenewable life cycle primary energy than ICEVs, highlighting the importance of electrification as a strategy for automotive manufacturers to reduce environmental burdens. Our proposed circular economy framework is then applied to Ford Motor Company's sustainability programs and initiatives as an example. This schematic aims to provide a starting point for the automotive industry to operationalize circular economy strategies, the application of which could advance its overall sustainability performance.

Aguilar Esteva, Laura C.↗
DOE OSTI2025

Unsupervised Image-Based Classification of Corrosion Severity in Automobile Engine Connecting Rods

Corrosion in engine connecting rods is a critical issue in the automotive industry, potentially leading to catastrophic engine failure, monetary losses, and safety hazards. The labor shortage in the industry further emphasizes the need for fast, accurate, and automated corrosion detection methods to ensure appropriate surface treatments can be applied to restore component integrity. We present an unsupervised image-based framework for classifying corrosion severity in automobile engine connecting rods using short-wave infrared (SWIR) and telecentric grayscale imaging. We employ the structural similarity index measure (SSIM) as a dissimilarity metric and the k-medians clustering algorithm for classification. Our algorithm achieves an overall accuracy of 80.64% for SWIR images, with 100% accuracy in classifying highly corroded samples. For grayscale images, the method attains an overall accuracy of 77.42%, with 90.91% accuracy for highly corroded samples. The method’s ability to work with different imaging modalities and its high accuracy in identifying severe corrosion cases make it a promising tool for automated corrosion assessment in the automotive industry, potentially improving efficiency and safety in engine component maintenance.

42 ENGINEERING↗
DOE OSTI2013

Building Surface Science Capacity to Serve the Automobile Industry in Southeastern Michigan, final report

This project, “Building Surface Science Capacity to Serve the Automobile Industry in Southeastern Michigan” was carried out in two phases: (1) the 2009 – 2012 renovation of space in the new EMU Science Complex, which included the Surface Science Laboratory (SSL), a very vigorous research lab at EMU that carries on a variety of research projects to serve the auto and other industries in Michigan; and (2) the 2013 purchase of several pieces of equipment to further enhance the research capability of the SSL. The funding granted by the DoE was proposed to “renovate the space in the Science Complex to include SSL and purchase equipment for tribological and electrochemical impedance measurements in the lab, thus SSL will serve the auto and other industries in Michigan better.” We believe we have fully accomplished the mission.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2020

A case study of replacing pneumatic tools with battery-powered ones at an automobile assembly plant

Compressed air is ubiquitous in manufacturing facilities and vital for the proper operation of numerous types of manufacturing equipment and processes, but compressed air systems are highly inefficient. One way of reducing compressed air usage and the associated electricity consumption is to replace pneumatic tools with battery-powered ones. This paper studied the energy cost savings and return on investment (ROI) of replacing pneumatic torque wrenches with battery-powered ones at a typical automobile assembly plant. With a total triggered time of 400.6 hours and an assumed electricity rate of $0.10/kWh, the annual energy cost savings was estimated to be $104/year per tool. The simple payback period and ROI were 5.8 years and 17.3%, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Diagnostics and Recycling of Discarded Automobile Components

Recycling of metal from discarded auto components is expedient and economically efficient. Uses of metal from discarded components are proposed. Information is presented regarding the mechanical properties of structural steels widely used in the auto industry. Technology for recycling of the metal in truck components is identified.

42 ENGINEERING↗
DOE OSTI2018

Effect of Deoxidation Process on Inclusion and Fatigue Performance of Spring Steel for Automobile Suspension

55SiCrA spring steel was smelted in a vacuum induction levitation furnace. The liquid steel was treated by Si deoxidation, Al modification with Ca treatment and Al modification, and the steel samples were obtained with deformable Al 2 O 3 -SiO 2 -CaO-MgO inclusions closely contacted with steel matrix, Al 2 O 3 -CaO-CaS-SiO 2 -MgO inclusions surrounded by small voids or Al 2 O 3 (> 80 pct)-SiO 2 -CaO-MgO inclusions surrounded by big voids, respectively. Effect of three types of inclusions on steel fatigue cracks was studied. The perpendicular and transverse fatigue cracks around the three types of inclusions leading to fracture were found to vary in behavior. Under the applied stress amplitude of 775 MPa, the fatigue lives of the three spring steels decreased from 4.0 × 10 7 to 3.8 × 10 7 , and to 3.1 × 10 7 cycles. For the applied stress amplitude of 750 MPa, the fatigue lives of the three spring steels decreased from 5.2 × 10 7 to 4.1 × 10 7 , and to 3.4 × 10 7 cycles. Based on the voids around inclusions, the equivalent size of initial fatigue crack has been newly defined as √(((area inclusion )/((1-CC)))), where the contraction coefficient CC of inclusion was introduced. A reliable forecast model of the critical size of inclusion leading to fracture was established by the incorporation of actual width b inclusion or diameter d inclusion of internal inclusion; the model prediction was found to be in agreement with experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Workability of High-Strength Automobile Steel at High Temperatures Using Hot Processing Maps and Electron Backscatter Diffraction

Hot deformation behavior of a high-strength steel Docol 1500 Bor was investigated by compression tests on a thermal–mechanical simulator Gleeble 3500. The workability of tested steel was analyzed by building processing maps at three strains based on the test results of flow stresses. The essential deformation mechanism was further studied based on the deformation texture analysis on a scanning electronic microscope with a TSL-OIM™EBSD system. It was found that that strain can affect the workability of the tested steel remarkably. At the engineering strain of 0.6, obvious textures in martensite mainly include recrystallization textures <110>//ND and other texture components <110>//RD and {001} <100>, etc. Dynamic recrystallization and recrystallization texture component <111>//ND in deformed austenite can contribute to increasing the workability of a steel Docol 1500 Bor. Finally, the optimized deformation conditions of the tested steel were obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Technological growth of fuel efficiency in european automobile market 1975–2015

This paper looks at the technological growth of new car fleet fuel efficiency in the European Union between 1975 and 2015. According to the analysis results, from1975 to 2006 the fuel efficiency technology improvements were largely offset by vehicles' increased weight, engine size, and consumer amenities such as acceleration capacity. After 2006, downsizing in weight and engine capacity was observed in new car fleet, while fuel consumption decreased by 32% between 2006 and 2015. We adopt a statistical method and find that from 1975 to 2015, a 1% increase in weight would result in 0.3 to 0.5% increments in fuel consumption per 100 km, and a 1% reduction in 0-100 km/h acceleration time would increase fuel consumption by about 0.3%. Impacts of other attributes on fuel consumption are also assessed. To meet the European Union's 2021 fuel consumption target, downsizing of cars, as well as at least maintaining fuel efficiency technology growth trend observed between 2005 and 2015, are needed. Lastly, government policies on controlling improvement in acceleration performance or promoting alternative fuel vehicles are also important to achieve European Union 2021 target.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Automobile and Technology Lifecycle-Based Assignment (ATLAS) v2.0.12

ATLAS is a comprehensive vehicle transaction and technology adoption microsimulator. ATLAS evolves the fleet mix of individual households by simulating the transaction (vehicle addition, disposal, and replacement) and choice (vehicle type, vintage, powertrain, and tenure) decisions in response to the co-evolving demographics, land use, and vehicle technology simulations. Different from the existing vehicle models that are either static or aggregated (e.g. stock model), ATLAS is fully disaggregated and dynamic following a sequential and circumstantial decision-making trajectory. This fine-grained approach not only enhances the realism of the simulation but also provides a nuanced understanding of the dynamics inherent in vehicle fleet evolution. ATLAS outputs are fully compatible with subsequent agent-based transportation modeling system and can enable distributional effect analysis regarding the fleet turnover among heterogeneous populations. ATLAS expands the typical new sale focused vehicle choice modeling to including used vehicle transactions that are of increasing interests to understanding the vehicle adoption behavior among lower income households.

Jin, Ling↗
DOE OSTI2019

Specific Energy Analysis for the Manufacturing of Light-Weight Automobile Body

This manuscript analyses the specific energy requirements to produce two hybridised vehicle structures on current automotive assembly lines. It provides quantitative and specific electric (kWhr/vehicle) and fossil-fuel (MMBtu/vehicle) energy predictions of the body-in-white (BIW) manufacturing processes including body panel forming, welding, painting, and final assembly, in addition to the facility heating ventilation and air conditioning or HVAC consumption. Two hybridised BIW design criteria are analysed; the first is based on minimising the added cost per unit weight saved (+$/-kg), while the second is based on maximising the percentage of weight saved (% -kg). Also a new criterion; that is the added specific-energy per unit weight-saved or (+kWhr/vehicle/-kg) is proposed. The light-weight structures comprise body parts made of aluminium and steel. To compute energy consumptions, the study utilises the energy performance index (EPI) stochastic model in addition to complementing it with a panel-forming energy model. Cost analysis is also provided for all the major vehicle body-panels using an in-house Excel macro. The study reverse engineers a passenger vehicle BIW using a full-size coordinate measuring machine (CMM). The presented work further highlights the monetary value of the associated emissions when increasing the specific energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2014

Development of the Prototype Thermo-Stabilization System for Accumulator (Automobile Storage) Batteries

The project aim is the creation of the innovative thermal management system of the Li-Ion batteries. To maintain an acceptable temperature range in a battery pack with uniform temperature distribution within the cell and also between the cells. Also, the battery pack has to meet the vehicle requirements such as compact, lightweight, low cost, and easy assembly.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2016

Rapid Carbon Fiber Prepreg Molding Technology for Automobile Structural Parts - "SEAHAWKS"

Carbon fiber reinforced plastics (CFRP) offer a variety of potential benefits to automotive parts vs. metals, mainly in the form of light-weighting, part consolidation, and corrosion resistance. However, complexities of composite manufacturing and lack of robust supply chain evolution and integration have hindered technological advancements to overcome high manufacturing costs, slow production rates and prolonged time to market. As a result, the use of CFRP in automotive structural parts has been limited to expensive “low to medium” volume platforms. The project overall investigates a concept of ecosystem-based composite manufacturing that enables rapid implementation of an integrated manufacturing system. Through partnering with individual organizations in the prepreg supply chain along with their respective technological advancements in materials, part designs, tool, equipment, recycling and repair, this project’s objective is to integrate these technologies into a manufacturing system through optimizing them individually and as a whole. Upon a successful delivery of a finished composite component to market, all associated technologies are evolved to production readiness levels not only individually but also in part of the integrated manufacturing system itself. Risks are mitigated effectively, as development costs and successes (and/or failures) are shared among all organizations. As a result, further cost reduction of the finished component is anticipated. Toray Composites (America) Inc. led the effort along with 13 other organizations to investigate and validate the concept. Phase I of this project via flat panel demonstrations focused on molding aspects of the integrated manufacturing system from several combinations of prepreg materials and molding methods used such as hydraulic press, RapidClave®, heated composite light tool (HCLT), light induction tool (LIT) and Quickstep. Other aspects such as automation equipment, recycling and component identification to further investigate and validate the concept via component demonstration in Phase II were also explored. It was found that several prepreg/process combinations could achieve a 3-6 min cure cycle time with panel thickness from 0.8 to 2.4 mm. This can be achieved under compaction pressure as low as vacuum, leading to composite panels that are void free, have good to excellent molded surfaces, Tg (by G’onset of DMA) ranging from 120-190 °C, and mechanical performance comparable to conventional autoclave cure.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Development of a Thin-Wall Magnesium side door Inner Panel for Automobiles

Cast magnesium side door inner panels can provide a good combination of weight, functional, manufacturing and economical requirements. However, several challenges exist including casting technology for thin-wall part design, multi-material incompatibility and relatively low strength vs steel. A project has been initiated, supported by the US Department of Energy, to design and develop a lightweight frame-under-glass door having a thin-wall, full die-cast, magnesium inner panel. This development project is the first of its kind within North America. Phase I of the project is now complete and the 2.0mm magnesium design, through casting process enablers, has met or exceeded all stiffness requirements, with significant mass reduction and part consolidation. In addition, a corrosion mitigation strategy has been established using industry-accepted galvanic isolation methods and coating technologies.

36 MATERIALS SCIENCE↗