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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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DOE OSTI2020

A map of roadmaps for zero and low energy and carbon buildings worldwide

Formulation of targets and establishing which factors in different contexts will achieve these targets are critical to successful decarbonization of the building sector. To contribute to this, we have performed an evidence map of roadmaps for zero and low energy and carbon buildings (ZLECB) worldwide, including a list and classification of documents in an on-line geographical map, a description of gaps, and a narrative review of the knowledge gluts. We have retrieved 1219 scientific documents from Scopus, extracted metadata from 274 documents, and identified 117 roadmaps, policies or plans from 27 countries worldwide. We find that there is a coverage bias towards more developed regions. The identified scientific studies are mostly recommendations to policy makers, different types of case studies, and demonstration projects. The geographical inequalities found in the coverage of the scientific literature are even more extreme in the coverage of the roadmaps. These underexplored world regions represent an area for further investigation and increased research/policy attention. Our review of the more substantial amount of literature and roadmaps for developed regions shows differences in target metrics and enforcement mechanisms but that all regions dedicate some efforts at national and local levels. Roadmaps generally focus more on new and public buildings than existing buildings, despite the fact that the latter are naturally larger in number and total floor area, and perform less energy efficiently. A combination of efficiency, technical upgrades, and renewable generation is generally proposed in the roadmaps, with behavioral measures only reflected in the use of information and communication technologies, and minimal focus being placed on lifecycle perspectives. We conclude that insufficient progress is being made in the implementation of ZLECB. More work is needed to couple the existing climate goals, with realistic, enforceable policies to make the carbon savings a reality for different contexts and stakeholders worldwide.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Characterizing manufacturing wastewater in the United States for the purpose of analyzing energy requirements for reuse

This paper seeks to inform an improved understanding of the energy tradeoff associated with on-site manufacturing water reuse in the United States from a lifecycle perspective, in part by developing an analytical framework for understanding when this tradeoff for reuse is beneficial. We survey the literature to assess the current state of reuse and its motives and barriers in the United States, before synthesizing information from publicly available EPA data on contaminants in US manufacturing wastewaters and technologies for treating them. Using the available data, we derive a set of “ubiquitous contaminants” among the top ten in terms of mass discharged in more than half of US manufacturing subsectors (NAICS 31–33) according to EPA permit data. We also present information on proven treatment trains and their energy requirements. We then compare water quality requirements for specific contaminants in reclaimed water to those characteristic of wastewater streams currently being discharged from manufacturing plants into surface waters to highlight sectors with reuse opportunities that could require little cost to realize, such as primary metals and, to a lesser extent, petroleum and coal products. We conclude by highlighting data limitations that need to be rectified before applying the framework more broadly and discussing how these data gaps could be filled. Better understanding the relationship between energy and water in the context of on-site manufacturing water reuse would allow manufacturers to improve resiliency by reducing regulatory, physical, and reputational risks while lessening their footprint on local watersheds.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

A Lagrangian perspective on tropical anvil cloud lifecycle in present and future climate

The evolution of tropical anvil clouds from their origin in deep convective cores to their slow decay determines the climatic effects of clouds in tropical convective regions. Despite the relevance of anvil clouds for climate and responses of clouds to global warming, processes dominating their evolution are not well understood. Currently available observational data reveal instantaneous snapshots of anvil cloud properties, but cannot provide a process-based perspective on anvil evolution. We therefore conduct simulations with the high resolution version of the Exascale Earth System Model in which we track mesoscale convective systems over the Tropical Western Pacific and compute trajectories that follow air parcels detrained from peaks of convective activity. With this approach we gain new insight into the anvil cloud evolution both in present day and future climate. Comparison with geostationary satellite data shows that the model is able to simulate maritime mesoscale convective systems reasonably well. Trajectory results indicate that anvil cloud lifetime is about 15 hours with no significant change in a warmer climate. The anvil ice mixing ratio is larger in a warmer climate due to a larger source of ice by detrainment and larger depositional growth leading to a more negative net cloud radiative effect along detrained trajectories. However, the increases in sources are counteracted by increases in sinks of ice, particularly snow formation and sedimentation. Furthermore, we find that the mean anvil cloud feedback along trajectories is positive and consistent with results from more traditional cloud feedback calculation methods.

climate, weather, mesocale cellular convection↗

DOE OSTI2023

Tackling Grand Challenges in Wind Energy through a Socio-Technical Perspective

Wind power has an important role to play in tackling climate change. Key challenges in wind energy science and innovation must be overcome to increase the penetration and capability of this technology. However, the success of these efforts heavily depends on how society engages with the development of wind power infrastructure. Consequently, grand challenges exist in both technical and social domains, yet little research has made substantial efforts in connecting them. Here we review the social science and humanities literature on wind energy to illustrate the social dimensions of previously identified technical challenges. We suggest that a socio-technical lens enables an interdisciplinary approach to overcome the prevalent tendency of silo thinking in wind energy research and use it to explore socio-technical grand challenges related to the design, planning, development, operational and end-of-life phases of wind energy. Finally, we provide an outlook for research, practice and innovation, including an interdisciplinary and socio-technical research agenda for wind energy science, renewable energy developments and science policy in general.

end-of-life↗

DOE OSTI2021

Uncertainties in Atmospheric River Lifecycles by Detection Algorithms: Climatology and Variability

Atmospheric rivers (ARs) are long and narrow filaments of vapor transport that are responsible for most poleward moisture transport outside of the tropics. Many AR detection algorithms have been developed to automatically identify ARs in climate data. The diversity of these algorithms has introduced appreciable uncertainties in quantitative measures of AR properties and thereby impedes the construction of a unified and internally consistent climatology of ARs. This paper compares nine global AR detection algorithms from the perspective of AR lifecycles following the propagation of ARs from origin to termination in the MERRA2 reanalysis over the period 1980–2017. Uncertainties in AR lifecycle characteristics, including event number, lifetime, intensity, and frequency distribution are discussed. Notably, the number of AR events per year in the Northern Hemisphere can vary by a factor of 5 with different algorithms. Although all algorithms show that the maximum AR origin (termination) frequency is located over the western (eastern) portion of ocean basins, significant disagreements appear in regional distribution. Spreads are large in AR lifetime and intensity. Here, the number of landfalling AR events produced by the algorithms can vary from 16 to 80 events per year, although the agreement improves for stronger ARs. By examining the ARs' connections with the Madden-Julian Oscillation and El Niño Southern Oscillation, we find that the overall responses of ARs (such as changes in AR frequency, origin, and landfall activity) to climate variability are consistent among algorithms.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

The Role of the Digital Thread for Security, Resilience, and Adaptability in Manufacturing

The manufacturing sector is dramatically evolving with recent technical and digital advances. Among these, the digital thread is revolutionizing manufacturing operations well beyond the historic downloading of programs to computer numerically controlled (CNC) machine tools and the uploading of edited programs from CNC controllers. The digital thread is “the communication framework that enables a connected data flow and integrated view of the asset’s data throughout its lifecycle across traditionally siloed functional perspectives” (Leiva 2016). It is pervasive around the world and has changed the way society operates; for example, map apps are used to provide time-optimal directions to destinations using real-time traffic feedback. The digital thread makes it possible to digitally verify products, ensure that the latest technologies are deployed across the entire manufacturing ecosystem, and strengthen the workforce by making each individual more efficient and effective. These three foundational advanced manufacturing concepts will ensure a next-generation secure, resilient, and adaptable manufacturing ecosystem and sustainably support current and future needs of society (Lynn et al. 2020).

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

What drives embodied carbon policy? A global perspective on adoption

Abstract Embodied carbon refers to the greenhouse gas emission associated with the lifecycle of buildings. Embodied carbon policies are critical for addressing the environmental impact of construction materials and advancing climate goals. Despite their importance, the adoption of embodied carbon policies has been limited globally, influenced by economic, environmental, institutional, and trade factors. This study employs structural equation modeling to analyze 37 countries, testing ten hypotheses across four categorical factors. The base model reveals the significant influence of environmental vulnerability and institutional frameworks on policy adoption, while robustness models confirm the critical role of trade dependencies and economic competitiveness in shaping national embodied carbon strategies. Findings underscore that countries with high climate vulnerability and strong institutional support are more likely to adopt embodied carbon policies. Conversely, trade-reliant nations face challenges balancing competitiveness and sustainability. Policy implications suggest the need for international collaboration to align trade policies with carbon reduction goals, targeted support for vulnerable nations, and the integration of embodied carbon considerations into existing climate frameworks. These results offer a roadmap for policymakers to design more effective and equitable embodied carbon policies, fostering global progress toward sustainable construction and decarbonization.

Hu, Ming (ORCID:0000000325831161)↗

DOE OSTI2023

Balancing growth amidst salt stress – lifestyle perspectives from the extremophyte model Schrenkiella parvula

Schrenkiella parvula, a leading extremophyte model in Brassicaceae, can grow and complete its lifecycle under multiple environmental stresses, including high salinity. Yet, the key physiological and structural traits underlying its stress-adapted lifestyle are unknown along with trade-offs when surviving salt stress at the expense of growth and reproduction. We aimed to identify the influential adaptive trait responses that lead to stress-resilient and uncompromised growth across developmental stages when treated with salt at levels known to inhibit growth in Arabidopsis and most crops. Its resilient growth was promoted by traits that synergistically allowed primary root growth in seedlings, the expansion of xylem vessels across the root-shoot continuum, and a high capacity to maintain tissue water levels by developing thicker succulent leaves while enabling photosynthesis during salt stress. A successful transition from vegetative to reproductive phase was initiated by salt-induced early flowering, resulting in viable seeds. Self-fertilization in salt-induced early flowering was dependent upon filament elongation in flowers otherwise aborted in the absence of salt during comparable plant ages. Furthermore, the maintenance of leaf water status promoting growth, and early flowering to ensure reproductive success in a changing environment, were among the most influential traits that contributed to the extremophytic lifestyle of S. parvula.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

Visualization Tool for Comparing Low-Carbon Energy Options

This project developed a web based visualization tool for comparing current and future nuclear fuel cycle options to low-carbon and conventional energy technologies in the United States. While nuclear power is well established as the gold-standard for baseload power production and also as the technology with the lowest overall carbon intensity of any commercial form of electricity generation. This project develop a web-based tool for electricity producers and consumers to compare renewable and conventional energy technologies to the conventional and advanced nuclear fuel cycle options. The work leveraged data on land use, carbon intensity, unit cost and pricing data for renewables from the open literature. Input data from the Advanced Fuel Cycle Cost Basis report will be used for current and advanced nuclear power systems. We coupled these data to energy flow and lifecycle models for user-selected energy generation and storage types. We will display economic comparisons from the perspectives of generators and consumers, as well as carbon production, land use, and reliability comparisons.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

The future of ship engines: Renewable fuels and enabling technologies for decarbonization

Shipping is one of the most efficient transportation modes for moving freight globally. International regulations concerning decarbonization and emission reduction goals drive rapid innovations to meet the 2030 and 2050 greenhouse gas reduction targets. The internal combustion engines used for marine vessels are among the most efficient energy conversion systems. Internal combustion engines dominate the propulsion system architectures for marine shipping, and current marine engines will continue to serve for several decades. However, to meet the aggressive goals of low-carbon-intensity shipping, there is an impetus for further efficiency improvement and achieving net zero greenhouse gas emissions. These factors drive the advancements in engine technologies, low-carbon fuels and fueling infrastructure, and emissions control systems. This editorial presents a perspective on the future of ship engines and the role of low-life cycle-carbon-fuels in decarbonizing the marine shipping sector. A selection of zero-carbon, net-zero carbon, and low-lifecycle-carbon-fuels are reviewed. This work focuses on the opportunities and challenges of displacing distillate fossil fuels for decarbonizing marine shipping. In conclusion, enabling technologies such as next-generation air handling, fuel injection systems, and advanced combustion modes are discussed in the context of their role in the future of low-CO 2 intensity shipping.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Robotics for HVAC applications: A critical review and future perspectives

Recent advances in artificial intelligence (AI), enhanced computational capabilities, and innovations in sensors and hardware have driven the increasing development and application of robots in heating, ventilation, and air conditioning (HVAC) systems. We selected and reviewed 101 studies published between 2005 and 2025, sourced from IEEE Xplore, Scopus, Web of Science, and the ACM Digital Library. To analyze these works, we developed a five-dimensional analytical framework (morphology, sensing, navigation, task execution, and system integration), inspired by the Springer Handbook of Robotics and tailored specifically for robotic applications in HVAC. Based on the reviewed studies, six distinct tasks spanning the entire HVAC lifecycle have been identified. Among the six tasks, inspection and maintenance dominate (59 %), followed by indoor monitoring and auditing (21 %), whereas leakage detection, comfort support, and installation/retrofit remain less explored. To address the identified gaps, this review proposes future research directions including investigating robot-aware HVAC design principles, developing multimodal HVAC sensing and data fusion techniques, enhancing robot training and hardware capabilities, and expanding robotic applications beyond Maintenance and Operations (M&O). The findings from this review inform future robotics research for HVAC applications and ultimately enhance system affordability, energy efficiency, resilience or reliability, and occupant environmental comfort. Moreover, it seeks to inspire researchers to explore the intersections of robotics, computer science, building science, and HVAC engineering fostering advancements in this multidisciplinary field.

AI↗

DOE OSTI2025

Microbial Pathways for Cost-Effective Low-Carbon Renewable Indigoidine

Indigoidine is a bioadvantaged platform molecule with diverse applications, including use as a textile dye, biotransistor, biosolar cell, biosensor, and food coloring. There are multiple microbial hosts and carbon sources that can be used and optimized for its production, yet there is limited guidance for which options have the greatest commercial potential. Here, we consider five different host microbes and combine genome-scale metabolic models with techno-economic and lifecycle assessment models. Pseudomonas putida currently outperforms synthetic indigo production and other indigoidine-producing hosts, using glucose, xylose, and lignin-derived aromatics to produce indigoidine at a minimum selling price of $2.9/kg and a greenhouse gas (GHG) footprint of 3.5 kgCO 2e /kg. Optimizing pathways-achieving 90% of the theoretical indigoidine yield from sugars and aromatics-can reduce costs 6-7-fold and GHG emissions 3-10-fold. From a cost perspective, microbes that co-utilize aromatics are advantageous, while selecting hosts that coproduce other value-added molecules can reduce GHG emissions. System-wide improvements and the use of a low-cost, low-carbon nitrogen source are crucial for commercial viability in all cases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Global warming intensity of biofuel derived from switchgrass grown on marginal land in Michigan

Energy crops for biofuel production, especially switchgrass (Panicum virgatum), are of interest from a climate change perspective. Here, we use outputs from a crop growth model and life cycle assessment (LCA) to examine the global warming intensity (GWI; g CO 2 MJ –1 ) and greenhouse gas (GHG) mitigation potential (Mg CO 2 year –1 ) of biofuel systems based on a spatially explicit analysis of switchgrass grown on marginal land (abandoned former cropland) in Michigan, USA. We find that marginal lands in Michigan can annually produce over 0.57 hm 3 of liquid biofuel derived from nitrogen-fertilized switchgrass, mitigating 1.2–1.5 Tg of CO 2 year –1 . About 96% of these biofuels can meet the Renewable Fuel Standard (60% reduction in lifecycle GHG emissions compared with conventional gasoline; GWI ≤37.2 g CO 2 MJ –1 ). Furthermore, 73%–75% of these biofuels are carbon-negative (GWI less than zero) due to enhanced soil organic carbon (SOC) sequestration. However, simulations indicate that SOC levels would fail to increase and even decrease on the 11% of lands where SOC stocks >>200 Mg C ha –1 , leading to carbon intensities greater than gasoline. Results highlight the strong climate mitigation potential of switchgrass grown on marginal lands as well as the needs to avoid carbon rich soils such as histosols and wetlands and to ensure that productivity will be sufficient to provide net mitigation.

09 BIOMASS FUELS↗

DOE OSTI2020

Projected increase of the East Asian summer monsoon ( Meiyu ) in Taiwan by climate models with variable performance

Abstract The active phase of the East Asian summer monsoon (EASM) in Taiwan during May and June, known as Meiyu , produces substantial precipitation for water uses in all sectors of society. Following a companion study that analysed the historical increase in the Meiyu precipitation, the present study conducted model evaluation and diagnosis based on the EASM lifecycle over Taiwan. Higher and lower skill groups were identified from 17 Couple Model Intercomparison Project Phase 5 (CMIP5) models, with five models in each group. Despite the difference in model performance, both groups projected a substantial increase in the Meiyu precipitation over Taiwan. In the higher skill group, weak circulation changes and reduced low‐level convergence point to a synoptically unfavourable condition for precipitation. In the lower skill group, intensified low‐level southwesterly winds associated with a deepened upper level trough enhance moisture pooling. Thus, the projected increase in Meiyu precipitation will likely occur through the combined effects of (1) the extension of a strengthened North Pacific anticyclone enhancing southwesterlies; and (2) more systematically, the Clausius–Clapeyron relationship that increases precipitation intensity in a warmer climate. The overall increase in the Meiyu precipitation projected by climate models of variable performance supports the observed tendency toward more intense rainfall in Taiwan and puts its early June 2017 extreme precipitation events into perspective.

Tung, Yu‐Shiang↗

DOE OSTI2026

Measurements of TRACER pre-convective conditions and mesoscale circulations using small unmanned aircraft systems (sUAS)

Improved comprehension of the physical processes governing convective cloud formation and lifecycle are of critical importance for understanding and predicting future climate states. The influence of these clouds on the planetary energy budget, including on precipitation, is significant. Things are particularly complex in coastal regimes, where gradients in aerosol particle properties, localized circulations such as sea breezes, and large population centers are found. To date, numerical models struggle to accurately represent these critical clouds and are therefore challenged to provide a realistic view on the planetary energy budget. Through the proposed research, we deployed two uncrewed aircraft systems (UAS) equipped with a variety of instruments alongside sensors deployed by the US Department of Energy Atmospheric Radiation Measurement (ARM) program for the TRACER (Tracking Aerosol Convection Interactions Experiment) field campaign. The two small UAS platforms consisted of a CU RAAVEN fixed-wing airplane and an OU CopterSonde system, with the copter collecting frequent vertical profiles of thermodynamic and kinematic variables such as temperature, pressure, wind and humidity. At the same time, the fixed-wing captured horizontal gradients of these quantities and aerosol size distribution. These systems were deployed south of the Houston metro area, in an area that is impacted by the Gulf of Mexico sea breeze on a daily basis. These observations offer enhanced and complementary perspectives to those provided by the DOE ARM Mobile Facility (AMF) which is was deployed in southeast Houston, and an ancillary site in a more rural location west of the urban Houston area. Quality-controlled versions of the UAS data were collected and posted on the DOE ARM data archive after the conclusion of the campaign where they are accessible by the research community and general public. The UAS perspective offers revolutionary insight into key spatial and temporal effects that have not been evaluated previously.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Constitutive Model Development for Aging Polymer Encapsulants (ASC P&EM FY2021 L2 Milestone 7836)

This SAND report fulfills the completion requirements for the ASC Physics and Engineering Modeling Level 2 Milestone 7836 during Fiscal Year 2021. The Sandia Simplified potential energy clock (SPEC) non-linear viscoelastic constitutive model was developed to predict a whole host of polymer glass physical behaviors in order to provide a tool to assess the effects of stress on these materials over their lifecycle. Polymer glasses are used extensively in applications such as electronics packaging, where encapsulants and adhesives can be critical to device performance. In this work, the focus is on assessing the performance of the model in predicting material evolution associated with long-term physical aging, an area that the model has not been fully vetted in. These predictions are key to utilizing models to help demonstrate electronics packaging component reliability over decades long service lives, a task that is very costly and time consuming to execute experimentally. The initiating hypothesis for the work was that a model calibration process can be defined that enables confidence in physical aging predictions under ND relevant environments and timescales without sacrificing other predictive capabilities. To test the hypothesis, an extensive suite of calibration and aging data was assembled from a combination of prior work and collaborating projects (Aging and Lifetimes as well as the DoD Joint Munitions Program) for two mission relevant epoxy encapsulants, 828DGEBA/DEA and 828DGEBA/T403. Multiple model calibration processes were developed and evaluated against the entire set of data for each material. A qualitative assessment of each calibration's ability to predict the wide range of aging responses was key to ranking the calibrations against each other. During this evaluation, predictions that were identified as non-physical, i.e., demonstrated something that was qualitatively different than known material behavior, were heavily weighted against the calibration performance. Thus, unphysical predictions for one aspect of aging response could generate a lower overall rating for a calibration process even if that process generated better quantitative predictions for another aspect of aging response. This insurance that all predictions are qualitatively correct is important to the overall aim of utilizing the model to predict residual stress evolution, which will depend on the interplay amongst the different material aging responses. The DSC-focused calibration procedure generated the best all-around aging predictions for both materials, demonstrating material models that can qualitatively predict the whole host of different physical aging responses that have been measured. This step forward in predictive capability comes from an unanticipated source, utilization of calorimetry measurements to specify model parameters. The DSC-focused calibration technique performed better than compression-focused techniques that more heavily weigh measurements more closely related to the structural responses to be predicted. Indeed, the DSC-focused calibration procedure was only possible due to recent incorporation of the enthalpy and heat capacity features into SPEC that was newly verified during this L2 milestone. Fundamentally similar aspects of the two material model calibrations as well as parametric studies to assess sensitives of the aging predictions are discussed within the report. A perspective on the next steps to the overall goal of residual stress evolution predictions under stockpile conditions closes the report.

36 MATERIALS SCIENCE↗

DOE OSTI2022

6.26 Low Cost Basalt Fiber for Automotive Applications

Vehicle lightweighting is an essential component to the automotive industry to improve fuel economy of internal combustion engine (ICE) vehicles to meet ever improving emission standards and to improve the range of electric vehicles (EV). Composite materials offer high specific modulus and specific strength, which makes them appealing for these light weighting efforts. Sheet molding compounds (SMC) are particularly interesting from an automotive perspective because of the relatively low cost and high volume of producing SMC parts. Traditionally, composite materials for automotive application are glass fiber reinforced because of the attractive price - performance ratio, but basalt fibers are a cost and recycling competitive reinforcement alternative in this market. The aim of this project was to examine the feasibility of utilizing basalt fiber for automotive applications. More specifically, an effort was made to examine different fiber sizings on basalt fiber combined with vinyl-ester (VE) resin, and their performance as part of an SMC process. In addition to offering vehicle lightweighting with fiber reinforced polymer composites, basalt fiber is a fully recyclable material and thus supports the IACMI technical goal of: Demonstrate that the technology is capable at a sufficient scale for >80% recyclability or reuse of fiber reinforced polymer composites in five years into useful components with projected cost and quality at commercial scale competitive with virgin materials on a pathway to 95% recyclability or reuse starting in ten years. Three different fiber sizings were applied to a continuous roving of basalt fiber and compared to a traditional Electrical/Chemical Resistance (E-CR) glass fiber that is typically used in these types of applications. Fiber tows were examined for Loss on Ignition percentage (LOI%), Tex, and tow strength. Some sizings clearly outperformed others, and the ability to process these fibers on a pilot scale SMC line was demonstrated. A test plan for the manufacturing and mechanical testing of SMC panels was developed. This work continues outside the time frame allocated for this project. When this work is completed, it will be added to this report and posted as Appendix C. Glass fiber reinforced SMC materials have already proven feasible as a light weighting method for traditionally steel parts like the Volkswagen (VW) Atlas lift-gate (Figure 1); this project team is seeking the feasibility of basalt fiber as a drop-in replacement for glass fiber reinforced SMC. Sizing development for basalt fibers has proven that the mechanical properties are better than E-glass and closer to S-glass, which makes it an interesting material for SMC applications. Better mechanical properties translate to less material needed to achieve load case requirement for target applications. The business case has already been demonstrated for 100,000 parts per year of glass fiber reinforced SMC Atlas lift-gates compared to traditional steel manufacturing processes. Reduced overhead and assembly costs are offset by glass fiber SMC higher cost per kg beyond 100,000 parts per year, which is still a relatively low volume for the automotive industry. For basalt fiber reinforced SMC to become feasible for automotive applications, the price-performance ratio has to be precisely determined. Based on the mechanical performance it is possible to establish a range of applications and technical solutions in which the potential of basalt SMC can be utilized, while the price of the material can be used to compile the business case for such applications. Based on these business cases and the sustainability indicators, glass fiber reinforcement (or other) materials can be directly substituted. Volkswagen’s commitment to reducing carbon emissions cannot be understated. Basalt fiber shows promise of reducing the carbon footprint in SMC materials, especially if sizing optimizations can be made with thermoplastic based SMC. To fully realize the value of basalt fiber reinforced materials, a lifecycle cost analysis should be performed on basalt’s production and recycling, and then compared against E-glass. From this assessment, a true judgement can be made on the commercialization potential of this material. Figure 1. Example of Fiber Reinforced Polymer Composite Liftgate As a conclusion, we can state that Mafic basalt fiber is not a direct replacement for E-glass or E-CR glass based on price, but should be considered a technical solution when E-glass does not provide adequate performance in a composite design and S-glass, aramid and carbon fibers are too costly. Mafic basalt fiber can be placed on the high-performance fiber spectrum next to S-glass for performance but at one third the price. It should be considered for more technically challenging structural designs wherein the performance can demonstrate 20-25% performance enhancement over E-glass to elicit more strength or a weight reduction. Both Michelman and Mafic produce thermoplastic sizings which, in combination with Nylon and polypropylene resin and fibers, can further advance high speed composite implementations while maintaining an eco-friendly manufacturing process.

36 MATERIALS SCIENCE↗