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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 OSTI2022

Durability Study of a High-Pressure Common Rail Fuel Injection System Using Lubricity Additive-Dosed Gasoline-Like Fuel—Improved Endurance with Upgraded Hardware

Gasoline compression ignition (GCI) is a promising combustion technology that can help the commercial transportation sector achieve operational flexibility and meet upcoming criteria pollutant regulations. However, high-pressure fuel injection systems (>1000 bar) are needed to enable GCI and fully realize its benefits compared to conventional diesel combustion. This work is a continuation of previous durability studies that identified three key technical risks after running gasoline-like fuel through a heavy-duty, common rail injection system: (i) cavitation damage to the inlet check valve of the high-pressure pump, (ii) loss of injector fueling capacity, (iii) cavitation erosion of the injector nozzle holes. Upgraded hardware solutions were tested on a consistent 400- to 800-hour NATO durability cycle with the same gasoline-like fuel as previous studies. The upgraded pump showed no signs of abnormal wear or cavitation damage to the inlet check valve. In contrast to previous studies, there were no signs of pump performance degradation observed after 400 hours of testing. Material selection and design upgrades were also made to the injector which, only showed a 6.5% loss in fueling capacity after 800 hours of durability testing compared to 49.3% previously. Finally, geometric nozzle hole features such as higher inlet radius of curvature and higher K-factor were found to correlate with reduced cavitation erosion. However, mitigation of eccentric radial needle motion (i.e., wobble) is likely needed to further suppress cavitation. In general, the results from this study indicate there are viable hardware-based solutions for improving the endurance of high-pressure systems when running with gasoline-like fuel.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

gearbox↗
DOE OSTI2023

A Revised International Standard for Gearboxes in Wind Turbine Systems: Preprint

Gearbox and wind turbine design and application standards have contributed significantly to improvements in reliability over the past two decades. The International Electrotechnical Commission (IEC) 61400-4 standard of wind turbine gearbox design is currently being revised by a joint working group (JWG) of experts in IEC TC 88 (wind energy) and International Organization for Standardization (ISO) TC60 (gears) to further that effort. Experts from ISO TC4 (rolling bearings) and ISO TC28 (lubricants) have actively participated. This revision has implemented lessons learned from industry use of edition 1 since its publication in 2012. The main document, IEC 61400-4, was pared down to essential design requirements and application-specific recommendations along with a design verification framework. The JWG leveraged concurrent development of other standards, such as IEC 61400-8 on wind turbine structures, to replace edition 1 content. These are described along with how this works with the IEC Renewable Energy certification scheme for wind turbines (IECRE-WE). The JWG recognized the interest in maintaining informative parts of edition 1 including annexes on wind turbine architecture and loads, bearing and gear arrangements, bearing selection, lubrication system descriptions and lubricant performance recommendations. This information was retained in two technical reports: IEC/TR 61400-4-2 Lubrication and IEC/TR 61400-4-3 Explanatory Notes. Additionally, a technical specification, IEC/TS 61400-4-1, was drafted to provide a reliability calculation method for comparing different design options or conditions. Salient elements of these documents are described. All four documents were recently distributed for IEC/ISO review, ballot, and comment. Publication is expected in 2023.

ENGINEERING,WIND ENERGY↗
DOE OSTI2025

Assessing the Impact of Lubrication on Efficiency and Life Cycle Economics of the US Wind Turbine Fleet: Cooperative Research and Development (Final Report)

As with any mechanical system, lubrication plays a key role in the performance of wind turbines used to generate electricity. The lubricant design offers a way to optimize the competing requirements of efficiency, component reliability, and maintenance strategy. This project will estimate the impact of improved lubrication on the levelized cost of energy of the US wind turbine fleet as a means of identifying opportunities for disruptive innovation or system-level optimization. The models developed will provide a clear understanding of the benefits and potential for advanced lubrication of wind turbines. The project will enable identification of high value targets for wind turbine component suppliers and a roadmap that highlights where the greatest return on technology investment can be achieved. This will promote efficient resource allocation in areas of new technology development.

17 WIND ENERGY↗
DOE OSTI2021

Gearbox Reliability Collaborative 1.5 (GRC1.5) Project: Joint Industry Megawatt Scale Gearbox Field Tests: Cooperative Research and Development (Final Report) CRADA Number CRD-16-00608

A new DOE/NREL industry collaboration called the Gearbox Reliability Collaborative 1.5 (GRC1.5) will undertake field testing on a commercial multi-megawatt wind turbine gearbox to collect loading data as installed in the turbine to thoroughly characterize gearbox loads and responses during actual in-field conditions. A chief outcome is to provide publicly available operational loading data to the industry. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the gearbox; thus, facilitating improvements in the gearbox components, lubrication system, power converter or turbine controller.

17 WIND ENERGY↗
DOE OSTI2021

Drivetrain Reliability Collaborative 1.5 (DRC1.5) Project: Joint Industry Megawatt Scale Gearbox Field Tests: Cooperative Research and Development (Final Report) CRADA Number CRD-17-00702

A new Department of Energy (DOE)/NREL industry collaboration called the Drivetrain Reliability Collaborative 1.5 (DRC1.5) will undertake field testing on a commercial multi-megawatt wind turbine drivetrain to collect loading data as installed in the turbine to thoroughly characterize drivetrain loads and responses during actual in-field conditions. A chief outcome is to provide publicly available operational loading data to the industry. This will provide a greater understanding of steady-state, transient, and fault response for both the input and output of the drivetrain; thus, facilitating improvements in the drivetrain components, lubrication system, power converter or turbine controller.

17 WIND ENERGY↗
DOE OSTI2022

Silicone modified lubricant

A silicone modified lubricant includes a Group I, II, III, IV or V base oil in combination with a minor amount of a silicone oil. Further, the lubricant includes a dispersant such as a dispersant olefin copolymer which maintains the silicone oil dispersed in the base oil. The silicone oil reduces the surface tension of the lubricant thereby reducing power loss. Preferably the lubricant formation has a surface tension less than 28 mN/m, making it particularly suitable for dip lubrication systems.

Kolekar, Anant S.↗
DOE OSTI2023

Lubricant impacts on piston deposit formation in the Enterprise marine diesel research engine

The impact of lubricant formulation on piston deposits was studied using the Enterprise, a reduced-scale, single-cylinder, two-stroke crosshead marine diesel research engine. The Enterprise engine was specially designed for marine diesel lubricant research, with a custom reduced-scale cylinder lubricant injection system and extensive instrumentation of thermal boundary conditions on both the liner and piston. Lubricant conditions typical of full-scale marine diesel engines are obtained by matching mean piston speed, liner temperature profile, and combustion metrics to realistic values.Piston deposit thicknesses were measured after a set period of operation, with a focus on lubricant-based deposits on the lands and ring grooves, using both optical and contact-based measurement techniques. Engine operation for each lubricant was conducted according to a standardized protocol, with precise control of engine speed and load, cylinder lubricant injection rate, coolant temperatures, and system oil temperature; the liner and piston temperatures are continuously monitored during operation. After operation with each lubricant was completed, the engine was disassembled, and the piston and ring deposits were characterized. The piston was then thoroughly cleaned, and the lubricant system flushed, between each lubricant formulation being evaluated. The impacts on piston deposits of the lubricants being evaluated can thus be accurately quantified and are described herein.

Kaul, Brian↗
DOE OSTI2023

MoVN-Cu Coatings for In Situ Tribocatalytic Formation of Carbon-Rich Tribofilms in Low-Viscosity Fuels

Inhibiting the tribological failure of mechanical assemblies which rely on fuels for lubrication is an obstacle to maintaining the lifetime of these systems with low-viscosity and low-lubricity fuels. Here in the present study, a MoVN-Cu nanocomposite coating was tribologically evaluated for durability in high- and low-viscosity fuels as a function of temperature, load, and sliding velocity conditions. The results indicate that the MoVN-Cu coating is effective in decreasing wear and friction relative to an uncoated steel surface. Raman spectroscopy, transmission electron microscopy, and electron-dispersive spectroscopy analysis of the MoVN-Cu worn surfaces confirmed the presence of an amorphous carbon-rich tribofilm which provides easy shearing and low friction during sliding. Further, the characterization of the formed tribofilm revealed the presence of nanoscale copper clusters overlapping with the carbon peak intensities supporting the tribocatalytic origin of the surface protection. The tribological assessment of the MoVN-Cu coating reveals that the coefficient of friction decreased with increasing material wear and initial contact pressure. These findings suggest that MoVN-Cu is a promising protective coating for fuel-lubricated assemblies due to its adaptive ability to replenish lubricious tribofilms from hydrocarbon environments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Engine Operating Conditions, Fuel Property Effects, and Associated Fuel–Wall Interaction Dependencies of Stochastic Preignition

This work for the Coordinating Research Council (CRC) explores dependencies on the opportunity for fuel to impinge on internal engine surfaces (i.e., fuel–wall impingement) as a function of fuel properties and engine operating conditions and correlates these data with measurements of stochastic preignition (SPI) propensity. SPI rates are directly coupled with laser–induced florescence measurements of dye-doped fuel dilution measurements of the engine lubricant, which provides a surrogate for fuel–wall impingement. Literature suggests that SPI may have several dependencies, one being fuel–wall impingement. However, it remains unknown if fuel-wall impingement is a fundamental predictor and source of SPI or is simply a causational factor of SPI. In this study, these relationships on SPI and fuel-wall impingement are explored using 4 fuels at 8 operating conditions per fuel, for 32 total test points. The fuels were directly injected at two different injection timings: an earlier injection timing that initially targets the piston crown and a later injection timing that targets the cylinder liner. At each injection timing, the engine was operated at both 90°C and 70°C coolant and lubricant temperatures, and 185 and 200 kPa absolute intake manifold pressure. This work serves as an exploratory effort to down select conditions and provide initial fuel properties of interest for a secondary study to explore fuel property specific effects on fuel-wall interaction and SPI propensity. Significant findings from this initial operating condition and fuel property exploratory work are: 1. reduced engine operating coolant and lubricant temperatures, along with 2. retarded injection timings were required to increase SPI propensity. Moreover, at these conditions some fuel specific effects were also observed; specifically, increased ethanol content increased measured dye–wall (i.e., fuel–wall) interaction. However, despite increased dye–wall interaction, the increased volatility of the ethanol containing fuels also reduced the estimated fuel retention in the top-ring zone and associated measured SPI propensity. Thus, the findings of this unique approach to explore relationships between fuel-wall impingement and SPI highlight that SPI propensity is more directly proportional to retained fuel, and not simply fuel–wall impingement. Furthermore, fuel retention was found to be directly influenced by complex fuel property and engine operating condition relationships. Either retarded injection timings and/or increased fuel volatility increased fuel wall-impingement, while less volatile fuels and/or reduced coolant temperatures increased fuel retention. Therefore, for a given operating condition, the data highlights that greater volatile fuels exhibit increased fuel wall impingement without increased fuel retention or SPI propensity, while less volatile fuels could exhibit reduced fuel-wall impingement but increased fuel retention and SPI propensity rates.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Harnessing Machine Learning to Predict MoS 2 Solid Lubricant Performance

Physical vapor deposited (PVD) molybdenum disulfide (MoS 2 ) solid lubricant coatings are an exemplar material system for machine learning methods due to small changes in process variables often causing large variations in microstructure and mechanical/tribological properties. Here, in this work, a gradient boosted regression tree machine learning method is applied to an existing experimental data set containing process, microstructure, and property information to create deeper insights into the process-structure–property relationships for molybdenum disulfide (MoS 2 ) solid lubricant coatings. The optimized and cross-validated models show good predictive capabilities for density, reduced modulus, hardness, wear rate, and initial coefficients of friction. The contribution of individual deposition variables (i.e., argon pressure, deposition power, target conditioning) on coating properties is highlighted through feature importance. The process-property relationships established herein show linear and non-linear relationships and highlight the influence of uncontrolled deposition variables (i.e., target conditioning) on the tribological performance.

MoS2↗
DOE OSTI2020

2020 Annual Merit Review, Vehicle Technologies Office

The 2020 U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy’s (EERE) Vehicle Technologies Office (VTO) Annual Merit Review (AMR) was held June 1-4, 2020, virtually, due to extenuating circumstances resulting from the global Coronavirus (COVID-19) pandemic. The review encompassed work done by VTO: 292 individual activities were reviewed by 334 reviewers. Exactly 1,133 individual review responses were received for the VTO technical reviews. The objective of the meeting was to review the accomplishments and plans for VTO over the previous 12 months, and provide an opportunity for industry, government, and academia to give inputs to DOE with a structured and formal methodology. The meeting also provided attendees with a virtual forum for interaction and technology information transfer.

25 ENERGY STORAGE↗
DOE OSTI2020

Enabling Lean and Stoichiometric Gasoline Direct Injection Engines through Mitigation of Nanoparticle Emissions

This project had the objective to efficiently reduce particulate mass (PM) and particulate number (PN) from lean and stoichiometric gasoline direction injection engines used in light duty vehicle applications. It also sought to use suspended particle instruments to measure the effective density, illustrating a pathway for new methods for accurately measuring soot mass at low concentration. The three-year effort took a systems level approach to evaluate fuel and lubricant impacts on GDI soot formation in lean and stoichiometric operation and to evaluate the impact of these factors on soot filtration aftertreatment in three-way catalyst-coated gasoline particulate filters (GPFs).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Waste plastic- and coke-derived flash graphene as lubricant additives

Lubricants play an essential role in reducing wear in mechanical systems. Carbon nanomaterial additives, such as graphene, have been found to significantly improve tribological performance when used as lubricant additives. Here, in this study, post-consumer plastic and metallurgical coke are converted into turbostratic flash graphene (FG) through flash Joule heating (FJH). The FG is then added to either poly(alpha olefin) 6 or 9 (PAO 6 or PAO 9). Adding waste plastic-derived FG (WPFG) and metallurgical coke-derived FG (MCFG) to lubricants resulted in a significant decrease in the coefficient of friction (CoF), wear scar diameter (WSD), and roughness during four-ball testing. WPFG and MCFG decrease the CoF in PAO 9 by 6% and 9% at 0.1 mg mL -1 , respectively, and in PAO 6 by 23% and 6% at 0.5 mg mL -1 , respectively. WPFG and MCFG decrease the WSD of steel balls in PAO 9 by 14% and 8% at 0.5 mg mL -1 , respectively, and in PAO 6 by 12% and 14% at 0.5 mg mL -1 , respectively, by forming a coating-like layer between the metal surfaces. Roughness decreased by 38% and 32% for WPFG and MCFG in PAO 6, respectively, and by 35% and 29% for WPFG and MCFG in PAO 9, respectively. Finally, preliminary life cycle analyses demonstrate that production of FG produces up to 99% less greenhouse gas emissions, requires 98% less energy, and consumes 99.9% less water when compared to conventional production techniques of graphene. Hence, metallurgical coke and waste plastic are shown to be ready feedstocks for high-quality FG lubricant additives.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Electrically Accelerated Mechanochemical Film Formation by a Phosphonium Phosphate Ionic Liquid: An In Situ Chemical Kinetics Investigation

Powertrains in electric vehicles are exposed to stray currents that accelerate wear and cause failure of mechanical components. These durability issues are further aggravated when using low-viscosity lubricants, which are desired for energy efficiency but create harsher contact conditions at sliding interfaces. This study investigates a phosphonium phosphate ionic liquid as a performance-enhancing additive in a low-viscosity base oil for lubricating electrified sliding interfaces. Ionic liquids can adsorb and react on contact interfaces via stress-assisted chemical reactions, generating nanometric tribofilms that provide protection against wear. However, the effect of electric fields on the mechanochemistry of ionic liquids is poorly understood, hindering their adoption in lubricants for electrified powertrains. This article reports an in situ optical interferometry study of ionic liquid derived tribofilm growth kinetics at stressed sliding/rolling interfaces under direct currents. The application of electric currents accelerated tribofilm formation up to a critical current density (∼1.4 A/mm 2 ), beyond which pitting-induced wear dominated. The tribofilms were composed of iron phosphates, iron oxides, and carbon species, with iron oxides becoming predominant under applied currents. These tribofilms prevented the scuffing failure of steel surfaces under electrified conditions. Based on the results, a kinetic model is proposed that integrates electric current effect into the classical stress-assisted thermal activation framework to allow prediction of tribofilm growth at electrified sliding contacts. This framework provides crucial guidance for designing next-generation lubricants for electrified transportation and power generation systems.

additives↗
DOE OSTI2022

Macroscale superlubricity by a sacrificial carbon nanotube coating

Superlubricity, i.e., coefficient of friction (COF) below 0.01, was earlier limited to microscale in controlled environments in the earlier literature and more recently realized for macroscale sliding of ceramic or carbon surfaces lubricated by water or other polar fluids. However, there is lack of report of superlubricity for the most common bearing system, i.e., steel-steel contact in non-polar oil lubrication. Here, in this work, we present ultra-low COF of 0.001–0.007 by using a sacrificial coating composed of vertically-aligned carbon nanotubes (CNTs) for macroscale steel-steel sliding under minimum quantity lubrication (MQL) of a polyalphaolefin (PAO) oil in the ambient environment. Raman spectroscopy and electron microscopy analyses detected graphene-containing tribofilms on both the steel surfaces, which was produced by the fractured CNT flakes and metallic wear debris during running-in. The in situ formed graphene-graphene contact interface presumably possesses a low shear resistance leading to superlubricity. The presence of oil, despite as little as one droplet, has proven to be crucial. Such a superlubricity performance has shown good sustainability in extended testing of more than 500,000 cycles and strong ability of accommodating changes in sliding conditions. Results here demonstrate feasibility with fundamental insights for achieving ambient environment macroscale superlubricity.

36 MATERIALS SCIENCE↗