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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A Feasibility Study on Use of an Accelerometer to Measure the Dynamic Forces in Turning

Metal cutting is a highly dynamic process that generates continuously varying forces. Measurement of these forces is essential to characterizing a cutting process and to fully utilize the machine tool. A force dynamometer is often used to measure these varying forces; however, it is limited by the natural frequency of the sensor and can sometimes be hard to set up on a machine. Therefore, this study aims to estimate the dynamic component of the cutting force using an accelerometer placed directly below the cutting edge. The placement of the sensor helps achieving better signal to noise ratio (S/N). The cutting tool is modelled as a single degree of freedom (SDOF) system relative to the workpiece and dynamic loads are experimentally simulated on it. The measured acceleration is numerically integrated to obtain velocity and deflection, which along with the natural frequency (ω n ) and damping ratio (ζ), is used to predict the dynamic load using the system equation. The dynamic forces tested over a wide range of frequencies, show good agreement with the data from simultaneous dynamometer measurement and the force estimated using the proposed method. The study shows the feasibility of this method in a real cutting scenario and the capability to apply it to a multi DOF system. One major limitation is the inability to capture the static or quasi-static component of the cutting force.

Cutting vibrations↗
DOE OSTI2021

Using Ionic Liquid Additive to Enhance Lubricating Performance for Low-Viscosity Engine Oil

Energy efficient lubricants are essential for sustainable transportation, and the trend is to develop and implement lower viscosity lubricants with more effective additives. Ionic liquids (ILs) have been reported as candidate additives with superior friction and wear reducing capabilities. Unlike most literature relying on bench-scale testing of simple oil–IL blends, this study produced low-viscosity (SAE 0W-12) fully formulated engine oils using a phosphonium-organophosphate IL as an antiwear additive and evaluated them in both bench-scale tribological testing and full-scale fired engine dynamometer testing. The experimental formulation containing a combination of ZDDP and IL outperformed the formulations using either ZDDP or IL alone, as well as a commercial SAE 0W-20 engine oil in terms of mitigating boundary friction, wear, and contact fatigue-induced micropitting. Furthermore, racing engine dynamometer tests demonstrated 3–4 °C lower oil temperature, 4–5 ft-lbs higher horsepower output, and up to 9.9% better fuel economy for the IL-containing SAE 0W-12 experimental oil compared with selected commercial SAE 5W-30 and 0W-20 engine oils.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Evaluating Efficiency and Security of Connected and Autonomous Vehicle Applications

Evaluating efficiency and security of Connected and Autonomous Vehicles (CAVs) requires an environment that can support applications and measurements under real-world conditions. This work introduces our implementation and evaluation of a Connected and Autonomous Vehicle Research Environment (CAVRE). We implement and evaluate an existing CAV application called Cooperative Adaptive Cruise Control (CACC) using physical Vehicle-to-Vehicle (V2V) communications between a virtual agent and a real autonomous vehicle operating on a steerable dynamometer. CAVRE allows the follower to autonomously control longitudinal behavior on the dynamometer in order to maintain a steady following time gap from the leader. The effects of a wireless jamming attack on CACC and fuel efficiency is also evaluated. By executing attacks in a controlled environment, we learn how compromised communications can degrade CAV applications. We show that jamming V2V communications can impact CACC’s string stability and decrease fuel efficiency by more than 50%.

Taylor, Curtis↗
DOE OSTI2026

Testing and Expertise for Marine Energy (TEAMER) Program Support (CRADA Final Report)

Virginia Tech (VT) had previously developed a 50 kW AC to DC power converter that is specifically designed to improve the performance and efficiency of wave energy converters (WECs). Through this CRADA, NLR will test the VT power converter via a coupled dynamometer and power electronics test platform. The NLR test platform will be comprised of (1) a rotary dynamometer that will drive a VT provided gearbox and generator, (2) one or more DC regenerative power supplies that provide input power to and take power from the VT supplied power electronics, and (3) a data acquisition system for measurement. NLR will work with VT to develop a test plan, set up the test platform and integrate the test article, perform the testing, and assist in the data analysis.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Safety Compliance Verification of Fuel Cell Electric Vehicle Exhaust

NREL has been developing compliance verification tools for allowable hydrogen levels prescribed by the Global Technical Regulation Number 13 (GTR-13) for hydrogen fuel cell electric vehicles (FCEVs). As per GTR-13, FCEV exhaust is to remain below 4 vol% H2 over a 3-second moving average and shall not at any time exceed 8 vol% H2 and that this requirement is to be verified with an analyzer that has a response time of less than 300 ms. To be enforceable, a means to verify regulatory requirements must exist. In response to this need, NREL developed a prototype analyzer that meets the GTR metrological requirements for FCEV exhaust analysis. The analyzer was tested on a commercial fuel cell electric vehicle (FCEV) under simulated driving conditions using a chassis dynamometer at the Emissions Research and Measurement Section of Environment and Climate Change Canada and FCEV exhaust was successfully profiled. Although the prototype FCEV Exhaust Analyzer met the metrological requirements of GTR-13, the stability of the hydrogen sensor was adversely impacted by condensed water in the sample gas. FCEV exhaust is at an elevated temperature and nearly saturated with water vapor. Furthermore, condensed water is present in the form of droplets. Condensed water in the sample gas can collect on the hydrogen sensing element, which would not only block access of hydrogen to the sensor but can also permanently damage the sensor. In the past year, the design of the gas sampling system was modified to mitigate against the transport of liquid water to the sensing element. Laboratory testing confirmed the effectiveness of the modified sampling system water removal strategy while maintaining the measurement range and response time required by GTR-13. Testing of the upgraded analyzer design on an FCEV operating on a chassis dynamometer is scheduled for the summer of 2021.

DIRECT ENERGY CONVERSION,HYDROGEN↗
DOE OSTI2022

Experimental driving performance evaluation of battery-powered medium and heavy duty all-electric vehicles

As the push to reduce air pollutants and carbon dioxide for global warming continues, there is increasing interest in the development and deployment of battery electric vehicles for heavy-duty applications as one of the critical and challenging steps of a broader effort to fully electrify the transportation sector. This study evaluated and quantified the energy consumption rates and energy regeneration rates for three heavy-duty battery electric vehicles (a step van, a yard tractor, and a class 8 truck) using driving cycle tests with a heavy-duty vehicle chassis dynamometer. Information in this area is currently very limited, and yet it is critical to understanding how effective heavy-duty battery electric vehicles will be for a wide range of applications as the electrification of the heavy-duty vehicle market continues to expand. Energy consumption rates ranged from 0.37 and 2.71 kWh/km for most vehicle/cycle combinations. On a diesel liter energy-equivalent basis, the heavy-duty vehicles had approximately 3 to 6 times better energy consumption rates compared to comparable diesel vehicles, with weight normalized energy consumption rates also comparing favorably to the current and future greenhouse gas/fuel economy standards for equivalent diesel vehicles. Based on battery capacities ranging from 80 to 215 kWh, the vehicle ranges varied from 38.18 km to 171.2 km, with ranges of 115.9 km to 171.2 km for most types of driving and lower ranges of 38.18 to 42.20 km for sustained grade cycles. Overall, the advantage of improved energy consumption rates coupled with improvements that can be expected for battery technology and vehicle range, provide promise for expanded use of heavy-duty vehicles going into the future.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

A Deterministic Multivariate Clustering Method for Drive Cycle Generation from In-Use Vehicle Data

Accurately characterizing vehicle drive cycles plays a fundamental role in assessing the performance of new vehicle technologies. Repeatable, short duration representative drive cycles facilitate more informed decision making, resulting in improved test procedures and more successful vehicle designs. With continued growth in the deployment of onboard telematics systems employing global positioning systems (GPS), large scale, low cost collection of real-world vehicle drive cycle data has become a reality. As a result of these technological advances, researchers, designers, and engineers are no longer constrained by lack of operating data when developing and optimizing technology, but rather by resources available for testing and simulation. Experimental testing is expensive and time consuming, therefore the need exists for a fast and accurate means of generating representative cycles from large volumes of real-world driving data. This paper explores the development and initial validation of a method of generating representative drive cycles from large collections of real-world vehicle data using a deterministic multivariate clustering approach. Starting with theory and diving into the methodology behind representative cycle generation, the paper aims to also present graphical and tabular results of initial validation via vehicle simulation and chassis dynamometer testing. Additional topics for further research and areas for ongoing development will also be presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗
DOE OSTI2020

Two-phase operation of a Terry steam turbine using air and water mixtures as working fluids

Terry steam turbines are employed in the safety systems of many nuclear Boiling Water Reactors to drive pumps and provide cooling water to the nuclear reactor core. While the turbine efficiency is low, the more important feature is high reliability under off-normal conditions. An important aspect of reliability is the ability to function with two-phase steam-water injection into the turbine, as most likely occurred in the Fukushima Dai-ichi nuclear accidents. This study investigates the characteristics of a Terry turbine during air-water injection with gas mass fractions ranging from 1 (dry gas) to 0.05 (wet gas), to better understand the Terry turbine’s true operational capabilities and provide justification for extended Terry turbine use for reactor safety. Other parameters investigated are the inlet pressure, the exhaust backpressure and the turbine’s rotational speed. The turbine performance is presented in terms of dynamometer loading and pump performance change as functions of the gas mass fraction.

42 ENGINEERING↗
DOE OSTI2025

Effects of ambient temperature on electric vehicle range considering battery Performance, powertrain Efficiency, and HVAC load

Here, this study investigates the impact of ambient temperature on the range of electric vehicles (EVs) by analyzing its effects on usable battery energy (UBE), heating, ventilation, and air conditioning (HVAC) energy consumption, and powertrain energy losses. Chassis dynamometer tests within a thermal chamber were conducted under various temperature conditions to investigate these impacts. The results indicate that lower temperatures lead to a decrease in UBE for lithium-ion batteries in EVs. At −18 °C, the UBE exhibited reductions of 4---8 % compared to the UBE at 22 °C. Battery thermal management strategies significantly affected the UBE loss, with different strategies resulting in distinct UBE reductions. HVAC energy consumption, especially for interior heating, proved to be the most dominant variable affecting EV driving range. Larger discrepancies between the HVAC target temperature (22 °C) and the ambient temperature increased HVAC energy usage. The type of HVAC system also influenced energy consumption, where EVs equipped with heat pumps demonstrated lower energy consumption for heating compared to those relying solely on resistance heaters. Ambient temperature also influenced motor energy consumption due to increased frictions, powertrain losses and tire rolling resistance at lower temperatures; consequently, regenerative braking energy decreased in cold conditions. Combining these effects influenced the overall energy consumption and driving range of EVs. At −18 °C, the driving range saw a substantial decrease of up to 60 % compared to 22 °C, while a slight decrease was observed at 35 °C.

Ambient Temperature↗
DOE OSTI2023

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Correlation of Surface Acoustic Wave (SAW) force myography sensor output with elbow joint torque

Accurate assessment of skeletal muscle forces and net joint torque is essential for preventing fatigue-related injuries, optimizing physical training, and monitoring disease progression in neuromuscular conditions. However, existing joint torque evaluation techniques are hindered by limited portability and high operational costs, confining their use to controlled laboratory or clinical settings. Despite substantial advances in wearable joint torque estimation systems, ongoing challenges such as power constraints, bulky wired setups, and susceptibility to environmental or motion artifacts underscore the urgent need for truly batteryless, wireless solutions deployable in real-world settings. This paper proposes a novel surface acoustic wave (SAW)-based force myography (FMG) system for noninvasive measurement of joint torque, validated against a gold-standard electromechanical dynamometer. The approach uses a single SAW sensor embedded in an armband to detect volumetric biceps brachii changes, with a second-order polynomial mapping sensor output and elbow angle to torque. Seven participants were tested in both isometric (15°–90°) and isokinetic (10°/s and 20°/s) supinated elbow flexion tasks. Under isometric conditions, subject-specific calibration achieved a normalized root-mean-square error (NRMSE) of 13.6% ± 6.0% and R 2 = 0.834 ± 0.180, while a group-level model yielded 14.4% ± 6.8% and 0.808 ± 0.208, respectively. For isokinetic trials, the group model produced an NRMSE of 24.1% ± 6.6% at 10°/s and 24.9% ± 08.9% at 20°/s, highlighting the feasibility of using a single-sensor SAW-FMG setup across different speeds. Because SAW devices support wireless, battery-free operation, the proposed system offers a pathway to portable, real-time monitoring for sports medicine, rehabilitation, and clinical diagnostics.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Oil miscible phosphonium-phosphate ionic liquid as novel antiwear and antipitting additive for low-viscosity rear axle lubricants

Here we explored the feasibility of using a phosphonium phosphate ionic liquid as a candidate anti-wear and anti-pitting additive for rear axle lubricant. This particular IL was first added to a VHVI8 base oil at 2–3% concentration and demonstrated effective surface protection for wear and micro-cracking under rolling-sliding contacts. The promising results directed to a step further to produce a series of IL-containing low-viscosity (about a half of SAE 75W-90) fully formulated gear oils. Selected IL-containing experimental oils showed superior mitigation of rolling contact fatigue to a commercial SAE 75W-90 gear oil in bench-scale rolling-sliding tests. Full-scale hub dynamometer tests were then conducted and demonstrated more than 3% power output and torque generation for an IL-containing low-viscosity gear oil benchmarked against commercial baselines.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Model Based Validation of Intelligent Powertrain Strategies for Connected and Automated Vehicles

Systems incorporating Vehicle to Everything (V2X) and conventional cellular based communication in vehicles can significantly help improve energy consumption via a combination of intelligent powertrain control strategies, smarter routing algorithms and driving in such a way as to minimize fuel economy and the emission of carbon dioxide, known as "eco-driving." In projects led by the Southwest Research Institute (SwRI), large-scale traffic simulations are created to model real-world scenarios with dynamic behavior that is reactive to imposed changes. Coupled with high fidelity powertrain models, the closed loop framework enables research and development of such Connected and Automated Vehicle (CAV) enabled technologies at scale. This paper will discuss a traffic system simulation environment that was built based on the High Street urban corridor in Columbus, Ohio. Eco-driving strategies were tested at scale on a variety of powertrain platforms – internal combustion engines, hybrid electric and fully electric vehicles. Furthermore, the paper will focus on hybrid electric powertrain modeling along with details on how the powertrain model was leveraged to develop a sophisticated clustering scheme to help down-select speed traces from large scale simulation studies for validation on vehicle dynamometer. Nominal energy consumption improvement around 12% was observed with good match between simulation studies and vehicle testing.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Sequence Impedance Measurement of Utility-Scale Wind Turbines and Inverters – Reference Frame, Frequency Coupling, and MIMO/SISO Forms

Sequence impedance responses with or without considering frequency coupling in both MIMO and SISO forms are increasingly used for the stability analysis of three-phase power electronic systems; however, many aspects of sequence impedance measurement are not fully explored. It is not clear if the sequence impedance has a reference frame similar to the dq impedance. If so, the role of the grid voltage angle estimation in aligning the sequence impedance reference frame has not been discussed. Additionally, existing methods for measuring the sequence impedance with frequency coupling are complicated, are not feasible for large wind turbines and inverters, and provide the sequence impedance responses in only either MIMO or SISO form. This paper presents a sequence impedance measurement method that considers the frequency coupling, performs reference frame alignment, demonstrates the impact of the grid voltage angle estimation, and obtains the sequence impedance response in both MIMO and SISO forms. This paper demonstrates the proposed method and practical problems associated with the sequence impedance measurement of utility-scale wind turbines and inverters on a 1.9-MW Type III wind turbine and a 2.2-MVA inverter using an impedance measurement system built around a 7-MW/13.8-kV grid simulator and a 5-MW dynamometer.

17 WIND ENERGY↗
DOE OSTI2022

A Novel Anatomic Reconstruction for Posterior Tibialis Tendon in Treatment of Flexible Adult‐Acquired Flatfoot Deformity

Objective To present a novel approach for the anatomic reconstruction of the posterior tibialis tendon (PTT) in restoring plantar insertions and evaluate its efficiency in treating flexible adult‐acquired flatfoot deformity (AAFD) caused by PTT dysfunction. Methods For AAFD treatment, a novel PTT reconstruction method was presented. The current study involved 16 patients, including three men, and 13 women, from August 2017 to July 2019. The mean age was 43.2 ± 15.1 years (21–64 years). The innovative PTT repair method was used on all patients. The treatment involved performing a traditional Flexor Digitorum Longus (FDL) transfer in the navicular tuberosity and suturing the plantar insertions to FDL as tension was applied to tighten the plantar structures of the foot. The results were retrospectively analyzed. The clinical outcome was assessed using the pain visual analogue scale (VAS), the satisfaction VAS, and the American Orthopedic Foot and Ankle Society ankle–hindfoot scale (AOFAS‐AH). Isokinetic testing was performed using a dynamometer at 60°/s and 120°/s for inversion/eversion and plantarflexion/dorsiflexion, respectively, to determine the mean peak torque. Radiographic measurements were employed to assess the outcomes. Results Bone surgeries combined with the modified anatomic PTT reconstruction were performed on patients with medializing calcaneal osteotomy in 12 (75%) patients and subtalar joint fusion in four (25%) patients. The branch linking to the plantar insertions was detected in every case, with an average width of 3.5 ± 0.8 mm (3.1–4.3 mm). All patients were followed up for the mean of 16.8 ± 1.8 months (range, 15–20 months). The average postoperative functional scores, including pain VAS, satisfaction VAS, total AOFAS‐AH, and all AOFAS‐AH sub‐scales, steadily improved during the follow‐up. In the last follow‐up, isokinetic testing revealed no loss of plantarflexion strength ( p = 0.350 and 0.098) and significant improvement in the inversion strength ( p = 0.007 and 0.008) in the operated ankles at 60°/s and 120°/s. Radiographic outcomes, particularly the talar head uncovering, improved significantly after more than a year ( p < 0.001 for all). Conclusions The novel technique for PTT reconstruction in restoring the plantar insertions serves as an effective procedure in treating AAFD caused by PTT dysfunction in terms of delivering a consistent improvement in ankle inversion strength, medial longitudinal arch restoring, and satisfactory clinical outcomes.

Hu, Yong↗
DOE OSTI2021

Comparison of Rotary and Linear Cutting Methodology in Determining Specific Cutting Energy of Granite

Abstract Single polycrystalline diamond compact (PDC) cutting is a practical technique to understand the rock–tool interactions in drag-bit-type geothermal drilling operations. This paper introduces a rotary cutting method to determine specific cutting energy (SCE) and compares it with the conventional linear cutting method. In this work, granite is selected to represent hard rock formations in geothermal drilling. Cutting tests are conducted on a Computer Numerical Control (CNC) machine with a realistic cutting speed of 12.7 m/min and several chip loads ranging from 0.08 to 0.25 mm. The cutting force is measured using a dynamometer and then converted to specific cutting energy (SCE). The results show that the rotary method produces an inverse relationship between SCE and chip load, whereas the linear method shows the opposite. As a result, the produced SCE by the rotary method tends to be lower than that of the linear method at a higher chip load at and over 0.16 mm. The difference may be attributed to the cutting configuration and associated force components.

Engineering↗
DOE OSTI2022

Evaluation of dynamic testing of full-scale wind turbine drivetrains with hardware-in-the-loop

Dynamometer testing of full-scale wind turbine drivetrains involves subjecting integrated components to extreme static loads, fatigue loads, or dynamic loads to replicate field conditions. This paper provides a detailed evaluation of the uncertainty and errors in applied loads and measured responses, and their magnitude relative to established repeatability bounds for a drivetrain subjected to static and dynamic loads on the 7.5 MW test bench at the Clemson University Wind Turbine Drivetrain Testing Facility. An ideal drivetrain simulation model is utilized to isolate the influence of load tracking errors on test article responses. It is shown that the test article response variations are mainly driven by run out and clearances inherent to the drivetrain. For the dynamic profiles, the load tracking errors are within acceptable limits. Furthermore, a frequency analysis is used to show that the test bench controller tracking performance is acceptable for profiles with frequency content up to 1.5 Hz.

17 WIND ENERGY↗