Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Michigan”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Hydroxylpyromorphite, a mineral important to lead remediation: Modern description and characterization

Abstract Hydroxylpyromorphite, Pb5(PO4)3(OH), has been documented in the literature as a synthetic and naturally occurring phase for some time but has not previously been formally described as a mineral. It is fully described here for the first time using crystals collected underground in the Copps mine, Gogebic County, Michigan. Hydroxylpyromorphite occurs as aggregates of randomly oriented hexagonal prisms, primarily between about 20–35 μm in length and 6–10 μm in diameter. The mineral is colorless and translucent with vitreous luster and white streak. The Mohs hardness is ~3½–4; the tenacity is brittle, the fracture is irregular, and indistinct cleavage was observed on {001}. Electron microprobe analyses provided the empirical formula Pb4.97(PO4)3(OH0.69F0.33Cl0.06)Σ1.08. The calculated density using the measured composition is 7.32 g/cm3. Powder X-ray diffraction data for the type material is compared to data previously reported for hydroxylpyromorphite from the talc mine at Rabenwald, Austria, and from Whytes Cleuch, Wanlockhead, Scotland. Hydroxylpyromorphite is hexagonal, P63/m, at 100 K, a = 9.7872(14), c = 7.3070(10) Å, V = 606.16(19) Å3, and Z = 2. The structure [R1 = 0.0181 for 494 F>4σ(F) reflections] reveals that hydroxylpyromorphite adopts a column anion arrangement distinct from other members of the apatite supergroup due to the presence of fluorine and steric constraints imposed by stereoactive lone-pair electrons of Pb2+ cations. The F– anion sites are displaced slightly from hydroxyl oxygen anions, which allows for stronger hydrogen-bonding interactions that may in turn stabilize the observed column-anion arrangement and overall structure. Our modern characterization of hydroxylpyromorphite provides deeper understanding to a mineral useful for remediation of lead-contaminated water.

Geochemistry & Geophysics↗
DOE OSTI2025

Data-Driven Energy Resilience Assessment and Enhancement in Urban Communities: A Case Study in Detroit

This paper presents a data-driven framework for assessing and enhancing energy resilience in urban communities. The resilience assessment is based on two datasets: 1) annual aggregated power outage data and 2) 15-minute interval outage data. High-impact, low-probability (HILP) events are identified within these datasets to evaluate community resilience under extreme conditions. To enhance resilience, an optimization framework utilizing mixed integer linear programming is developed to determine the optimal sizing and placement of solar photovoltaic (PV) systems and battery energy storage systems (BESS). This method offers a cost-effective and practical solution for improving energy resilience in vulnerable communities. Furthermore, a case study of the City of Detroit in Michigan demonstrates the effectiveness of the framework through simulation and validation.

Energy resilience assessment↗
DOE OSTI2020

Rosen Scholar

Dr. Tim Chupp is a professor of physics, applied physics, and biomedical engineering from the University of Michigan. As Rosen Scholar he will work with the Subatomic Physics group’s Neutron Team to develop the LANL RoomTemperature Neutron Electric Dipole Moment (nEDM) experiment that will used at LANSCE's world-leading Ultracold Neutron Facility. The electric dipole moment is the electrical stretching of neutrons or atoms along their spin axis.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

High BMEP and High Efficiency Micro-Pilot Ignition Natural Gas Engine (Final Project Report)

The project objectives were to develop demonstrate a high-efficiency high-output natural gas diesel micro-pilot stoichiometric engine operating with diesel pilot contribution of less than 5% on a medium duty engine. The program’s outcomes achieve in a partnership between Michigan Technological University and Westport Power Inc. were very successful. The engine platform was a 6.7L I6 engine with a compression ratio of 15:1 and achieved 24 bar BMEP and 41% brake thermal efficiency at lambda. Simulation and modeling with an improved turbocharger and combustion chamber improvements demonstrated a clear path to 43% BTE. The operational stoichiometric range was from 5 to 24 bar with minimal throttling. Diesel contribution over the cycle was 4.6%. The results achieved in this program are well above the best in-class baseline natural gas spark ignition engines of 19.5 bar BMEP and 40% BTE.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Women in Environmental Science

Despite the prominent role that women have traditionally played in environmental activism and initiatives to promote environmental justice, women’s representation in most environmental science fields remains low. The first environmental laws in the U.S., established in the 60’s and 70’s, were propelled by movements evolved out of male dominated scientific professions, mainly engineering. To this day, environmental fields are still perceived as not open to women. Yet the field being so broad, it offers many opportunities for women scientists to contribute to the advancement of science and technology needed to address the most pressing environmental issues. To this end, the Society for Industrial Microbiology and Biotechonology organized a session at its 2019 General Meeting entitled Women in Environmental Science that showcased the work of women leading efforts in environmental fields. The session was convened by Dr. Gemma Reguera (Michigan State University) and Dr. Arpita Bose (Washington University in St. Louis) and included 4 additional speakers whose work spans basic and applied environmental research yet impacts discovery-driven science, technology development, science policy and communication, in addition to environmental advocacy and stewardship. The talks highlighted the career path of women-led teams whose research and professional activities are contributing to the development of “biobased solutions to DOE mission challenges in energy and environment”.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Evaporation Sub-model Development for Volume of Fluid (eVOF) Method Applicable to Spray-Wall Interaction Including Film Characteristics with Validation at High Pressure and Temperature Conditions (Final Report)

Internal combustion engines have seen a great evolution over the last several decades through application of high pressure direct injection, multiple injections, and other technologies to reduced fuel consumption, NOx, and PM. Although combustion systems with advanced injection strategies have been studied extensively, there exists a significant fundamental knowledge gap on the fuel-spray interactions with the piston surface and chamber walls. Advanced computational codes validated with experimental techniques have to be developed for accurate representation of the drop impingement, fuel film formation, and vaporization. Current engine CFD spray models utilize a Lagrangian framework for modeling which lacks critical considerations of the physics pertaining to these interactions and thus requiring extensive parameterization, tuning and validation. The team from Michigan Technological University, University of Massachusetts Dartmouth, and Argonne National Laboratory is composed of experts in sprays, combustion, engines and CFD with a wide spectrum of knowledge including specific expertise in the area under consideration. In the proposed work, a VOF modeling approach has been adopted for the spray-wall interaction, film formation and spreading, and vaporization. With the inclusion of a vaporization submodel, a more predictive and accurate simulation of the spray-film was performed without extensive need of parameterization and tuning. Extensive experimentation of the spray-wall interaction under the range of conditions matching the thermodynamic and surface temperatures that occur in diesel and gasoline engines were conducted to validate the SWI submodels and for development of the evaporation sub-model, which has been implemented in the Converge software.

42 ENGINEERING↗
DOE OSTI2020

Evaporation Submodel Development for Volume of Fluid (eVOF) Method Applicable to Spray-Wall Interaction Including Film Characteristics with Validation at High Pressure and Temperature Conditions

Internal combustion engines have seen a great evolution over the last several decades through application of high pressure direct injection, multiple injections, and other technologies to reduced fuel consumption, NOx, and PM. Although combustion systems with advanced injection strategies have been studied extensively, there exists a significant fundamental knowledge gap on the fuel-spray interactions with the piston surface and chamber walls. Advanced computational codes validated with experimental techniques have to be developed for accurate representation of the drop impingement, fuel film formation, and vaporization. Current engine CFD (Computational Fluid Dynamics) spray models utilize a Lagrangian framework for modeling which lacks critical considerations of the physics pertaining to these interactions and thus requiring extensive parameterization, tuning and validation. The team from Michigan Technological University, University of Massachusetts Dartmouth, and Argonne National Laboratory is composed of experts in sprays, combustion, engines and CFD with a wide spectrum of knowledge including specific expertise in the area under consideration. In the proposed work, a VOF (Volume of Fluid) modeling approach has been adopted for the spray-wall interaction, film formation and spreading, and vaporization. With the inclusion of a vaporization submodel, a more predictive and accurate simulation of the spray-film was performed without extensive need of parameterization and tuning. Extensive experimentation of the spray-wall interaction under the range of conditions matching the thermodynamic and surface temperatures that occur in diesel and gasoline engines were conducted to validate the SWI submodels and for development of the evaporation submodel, which has been implemented in the flow solver.

42 ENGINEERING↗
DOE OSTI2020

Separate Effects Validation for Subcooled Boiling in CTF

In 2010, the U.S. Department of Energy created its first Energy Innovation Hub, which is focused on developing high-fidelity and high-resolution modeling and simulation (M&S) tools for modeling of light water reactors (LWRs). This hub, the Consortium for Advanced Simulation of LWRs (CASL), has developed an LWR simulation tool called the Virtual Environment for Reactor Applications (VERA). The multi-physics capability of VERA is achieved through the coupling of single-physics codes, including CTF (the CASL version of Coolant Boiling in Rod Arrays— Three Field (COBRA-TF)), Michigan Parallel Characteristics Transport (MPACT), BISON, and Materials Performance and Optimization (MPO) Advanced Model for Boron Analysis (MAMBA). As part of its M&S efforts, CASL has identified various challenge problems, including Crud Induced Power Shift (CIPS), Crud-Induced Localized Corrosion (CILC), Pellet-Cladding Interaction (PCI), and Departure from Nucleate Boiling (DNB). This work addresses CASL milestone L2:VVI.P19.03, which focuses on uncertainty quantification of crud, which is relevant to both CIPS and CILC. This is achieved through an analysis and separate effects validation of the thermal hydraulic phenomenon known as subcooled boiling. As part of this work, various sources of experimental data are examined and compared to different options for empirical modeling of subcooled boiling. Through this analysis, a complete understanding of the underlying models and their implementation details are understood. A subset of these data are incorporated into a separate effects validation study of CTF. The Westinghouse Advanced Loop Tester (WALT) and Rohsenow experiments are modeled, and it is shown that the newly-implemented Gorenflo correlation is more accurate than the existing Chen and Thom correlations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Cost of saving natural gas through efficiency programs funded by utility customers: 2012–2017

This study estimates the cost of saving a therm of natural gas from energy efficiency programs funded by utility customers during the period 2012 to 2017. Berkeley Lab researchers compiled and analyzed efficiency program data reported by investor-owned utilities and other program administrators in a dozen states representative of the four U.S. Census regions — Arkansas, California, Connecticut, Iowa, Massachusetts, Michigan, Minnesota, New Jersey, New York, Oklahoma, Rhode Island and Utah. Depending on the year, the dataset accounts for about 50 percent to 70 percent of annual national spending on natural gas efficiency programs. The estimated cost of saving natural gas during the study period is $0.40 per therm. The analysis also includes estimates of the program administrator cost of saved energy for three core sectors for natural gas: commercial and industrial, residential, and low-income households. It aggregates these sectors to provide regional and national values. Our metrics include savings-weighted averages, unweighted medians, and interquartile ranges (25th and 75th percentiles) of the levelized program administrator cost of saving gas, in constant 2017 dollars. In addition, the study analyzes cost trends during the study period, finding that average program costs trended downward. The U.S. Department of Energy’s Building Technologies Office supported this work.

03 NATURAL GAS↗
DOE OSTI2020

Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions: Vehicle Modeling Final Report

The Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions (GEFORCE) project was proposed in response to the U.S. Department of Energy’s Funding Opportunity Announcement 0991 by a team made up of the members of the Coordinating Research Council (CRC) and the research staff at Oak Ridge National Laboratory (ORNL.) The project focused on investigating the potential benefits that might be attained through synergistic use of specific engine technology together with fuels formulated to represent potential directions that high-octane fuels of the future might progress. A stated objective in the DOE FOA was to demonstrate a 25% reduction in petroleum consumption through optimization of the engine technologies together with a suitable fuel. An advanced engine was constructed and used with a matrix of research fuels to investigate potential avenues for efficiency improvement. The engine incorporated technologies expected to become mainstream for boosted engines in the next 10 to 20 years. These included increased compression ratio, a two-stage turbocharger, and cooled external exhaust gas recirculation (EGR). The fuel matrix was designed to investigate impacts from research octane number (RON), volumetric ethanol content, and the final boiling point of the fuel. The engine calibration was optimized for each fuel individually and data collected to enable vehicle system modelling that projected energy consumption, fuel economy, tailpipe CO₂ emissions, and impact on petroleum consumption for an industry-average mid-size sedan. The engine calibration and data collection were carried out at IAV in Michigan and is the subject of a separate report. IAV provided the engine data to Oak Ridge National Laboratory to support the vehicle modelling portion of the project. The vehicle modelling results show the following trends: Ethanol content does have a consistently strong influence on the fuel economy results for all cycles and all fuels. Among the fuels of a nominal RON level, increasing ethanol content consistently lowers fuel economy, with the 30% ethanol fuels always providing the lowest fuel economy for a given RON level. However, in some cases the energy consumption improvement allows the 30% ethanol fuels to match the fuel economy of the ethanol-free fuel P. These observations underscore the importance of both engine efficiency and fuel volumetric energy content on vehicle fuel economy.; There was no consistent trend in the projected energy consumption results for differences in fuel T90 for all fuels and cycles. Fuel economy projections did show a consistent trend, with the higher T90 fuel providing slightly greater fuel economy when compared to the low T90 fuel of the same ethanol content. The observed trends were consistent with differences in the heating value of the fuels.; The 102-RON fuels provided reduced energy consumption and greater fuel economy for the advanced engine on all drive cycles. The engine compression ratio of 11.5 was higher than would typically be used in a turbocharged engine when 92-RON fuel use is expected. Hence, the engine experiences more efficiency degradation from knock avoidance when using the 92-RON fuels. This degradation causes the fuel economy results for the 92-RON fuels to be lower than those for the 102-RON fuels.; Fuels E and F (92-RON, 30% ethanol) are projected to achieve 10% or greater reduction in petroleum consumption, with fuels K (102-RON, 30% ethanol) and O (97 RON, 30% ethanol) achieving greater than a 20% reduction. Fuel L (102-RON, 30% ethanol) achieves greater than 25% reduction, meeting the petroleum reduction target of the project. All of the fuels that achieve 10% or greater reduction in petroleum consumption are 30% ethanol blends.; Increasing final boiling point increased fuel economy at fixed ethanol content when the 102-RON fuels were used. This trend is a result of differences in the volumetric energy content of the fuels and the projected energy consumption values for the fuels. In the case of the 102-RON fuels, increasing final boiling point also resulted in an increase in the energy content of the fuel. There was not a consistent trend between the energy content and final boiling point for the 92-RON fuels at fixed ethanol content.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Energy Impact of Connected and Automated Vehicle Technologies. Final report

The overarching goal of this project is to understand the potential impact of connected and automated vehicles. The goal was achieved through data collection, model development, algorithm designs, simulations, and limited field tests. The main outcomes from this project include: (1) we collected energy consumption and GPS data from 500 vehicles over one year, with a total mileage of 8 million miles; (2) Based on the collected data and other datasets collected at the University of Michigan, we developed a calibrated Ann Arbor model in Polaris (model developed by ANL), and the fuel economy accuracy was found to be around 3.9% by comparison with field collected data; (3) An open-source SUMO model of Ann Arbor was developed; (4) Eco-Routing algorithms in Ann Arbor using the SUMO model shows 6% fuel saving potential; (5) Experiments conducted at the Mcity test facility shows that human drivers roughly follow the Eco-driving suggestions roughly 70% of the time; (6) Based in the Ann Arbor travel patterns, we found that each shared automated vehicle can replace around 4 individually owned vehicles; and (7) Adaptive Traffic Signal Control Algorithm developed through this project has been validated both in simulations and preliminary test results. For connected and automated vehicles, on average the performance is 13% delay reduction, and 10% fuel reduction. While connected and automated vehicles are in their early stage of deployment, the results from this project confirm that there is significant potential for energy saving if the technologies are developed and used properly. The three main technologies studied in this project include eco-routing, shared autonomous rides, and adaptive traffic signal controls. The data collected and model developed through the project can be used to study many other connected and automated vehicle technologies.

02 PETROLEUM↗
DOE OSTI2020

Ultra-Light Hybrid Composite Door Design, Manufacturing and Demonstration

New Corporate Average Fuel Economy regulations require improved fuel efficiency of the future vehicle fleet. Weight reduction is key to achieving these targets. Replacing metallic body and chassis components with carbon fiber-reinforced composites offers the most weight reduction potential at up to 70%. Introduction of the BMW i3 and i8 in 2014 required mass production processes to meet 20,000+ units per year. Preforming with High Pressure Resin Transfer Molding has been implemented and meets rate, cost, and performance requirements. We will advance these technologies to develop an ultra-light driver’s side door for the vehicle with production rates of 40,000 units annually per plant in Detroit, Michigan. This project sought to employ a comprehensive systems approach for designing, manufacturing, and demonstrating an ultra-light hybrid composite automotive door. Composite structural components are integrated with other functional systems to reduce part count and full-system weight by a minimum of 42.5%. The approach will be demonstrated on a driver’s- side front door and will consider all fit, functional, safety, and cost requirements. These concepts will be evaluated using structural and crash simulations and linked to a manufacturing feasibility study, resulting in producible designs of an integrated door system. A cost model will evaluate part of the cost for the various designs and will ensure the cost target of less than $5 per pound of weight saved is met. Hybrid composites consisting of carbon, glass, and metal components will be included in our trade-off studies to satisfy these cost and performance goals.

02 PETROLEUM↗
DOE OSTI2020

Evaluation of a Combined Raffinate Waste Stream for Mo-99 Production

Niowave, Inc., based in Lansing, Michigan, intends to produce Mo-99 from the fission of low enriched uranium (LEU) targets. In FY20, SRNL was tasked to provide technical assistance in identifying the primary waste raffinate present in Niowave’s commercial scale system and evaluating methods for disposal. Due to limited information on Niowave’s complete flowsheet and isotope recovery plans, a combined raffinate stream including the entire radionuclide inventory from the irradiated fuel was used for this evaluation. Results of the evaluation indicated the majority of the waste generated can be expected to be Class A; however radioisotopes such as Pu-239, Cs-137, Sr-90, and some of the shorter lived (< 5 year half-life) may challenge Niowave’s ability to meet the waste acceptance criteria for land burial. With appropriate waste management strategies, it is probable that Niowave’s waste could meet Class C requirements for all constituents, with the possible exception of Pu-239. More detailed information of Niowave’s processes are needed to form a more accurate understanding required to execute and effective, economic, and feasible waste management strategy.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

LaserNetUS. Final report

In this proposal we have formed a consortium in response to a request from the DoE Office of Fusion Energy Sciences to establish a national network of Petawatt-class laser systems to act as domestic user facilities that can enable a broad range of frontier scientific research. This new entity is called LaserNet US. The network formed here is directly responsive to recommendations made in a recently released National Academy of Sciences Report with regard to US strategy for high intensity laser research, “Opportunities in Intense Ultrafast Lasers: Reaching for the Brightest Light”. As detailed in this report, the research in this area has the potential to transform science in a number of research fields and to open up new areas of fundamental research. High field science was initiated in the US in the 1990’s, and subsequently Europe and Asia have embraced this research field, investing more than a billion dollars in this area over the past several years. Our network includes five academic and two national lab-based high intensity laser facilities. These facilities are distributed geographically throughout the US and the network provides access to complementary facilities which have unique world-class laser and experimental capabilities. LaserNet US will make these existing Petawatt-class laser facilities available to users from around the country who until now have not had regular access to such machines. Consequently, the network, which will develop over time, will also become a key element in driving forward national research in high field and high energy density plasma science. In particular, the University of Michigan provides access to the Hercules laser facility and the T-cubed laser facility for collaborative experiments as part of the first year operation. In the second year - to begin in summer 2019 - the experiments will be chosen via proposal submission and review by an outside panel formed by DOE.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Midwest EVOLVE (Midwest Electric Vehicle Opportunities: Learning, eVents, Experience)

The Midwest Electric Vehicle Opportunities: Learning, eVents, Experience (Midwest EVOLVE) project was a 45 month, seven-state effort to introduce electric vehicles to the public, workplaces, corporate fleets and auto dealership staff. Midwest EVOLVE projects were planned and completed in the following states: Illinois, Indiana, Michigan, Minnesota, North Dakota, Ohio, and Wisconsin. The project was coordinated by the American Lung Association of the Upper Midwest (ALAUM), dba Twin Cities Clean Cities Coalition (TC4).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Life Cycle Analysis of Greenhouse Gas Emissions for the Niagaran Reef Complex CO 2 -EOR Operations

A greenhouse gas emissions life cycle analysis (LCA) was completed for 22 years of carbon dioxide-enhanced oil recovery (CO 2 -EOR) operations at the Niagaran reef complex in the northern Michigan Basin based on research by the Midwest Regional Carbon Sequestration Partnership (MRCSP). The objective of the greenhouse gas LCA was to account for the total greenhouse gas emissions generated through the CO 2 -EOR process..

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Enhanced Recovery Opportunities in the Appalachian Basin

The Midwest Regional Carbon Sequestration Partnership (MRCSP) has incorporated the work of geologic research teams (Geoteams) in its regional characterization, project planning and carbon dioxide (CO2) injection implementation work since the partnership was established by the U.S. Department of Energy (DOE) in 2003. Over this 16-year period, the cohort of Geoteams has grown from five to ten states and has contributed to the characterization of geologic sequestration opportunities, refinement of reservoir and seal data, and supported injection efforts through both predictive and post-injection assessments. The regional characterization work conducted by the Geoteams during the MRCSP Phase III project period (2010 – 2019) focused on the following tasks: (1) refinement of geologic seals/reservoir systems; (2) assessment of Atlantic Coastal Plain and offshore opportunities; (3) expanded assessments of oil and gas fields, particularly as they relate to enhanced recovery opportunities; (4) regional support for implementation of carbon capture utilization and storage (CCUS) in the partnership area; and (5) communication and data sharing. The findings of this work are summarized in the final report entitled Final Report of Geologic Carbon Capture Utilization and Storage Opportunities in the form of a state-by-state presentation for the MRCSP Region. In addition to the capstone deliverable mentioned above, the Geoteams have also prepared a series of topical reports to elaborate on specific geologic intervals and/or geographic areas of study completed during the Phase III project period. Specifically, these topical reports address: (1) the Atlantic Coastal Plain and adjacent offshore; (2) Cambro-Ordovician reservoirs/seals in the region; (3) enhanced oil and gas recovery opportunities in the Appalachian Basin; and (4) enhanced oil recovery (EOR) in the Michigan Basin. The remainder of this topical report presents our findings relative to enhanced recovery opportunities in the Appalachian Basin.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Reduction of CO 2 Emissions Through Lightweight Body Panels (Project Final Report)

Lightweight construction is an integral part of Volkswagen’s overall strategy of reducing CO 2 emissions. Due to its low cost, steel is the most commonly used material for automotive exterior body panels today. Unfortunately, steel has a high density, resulting in a relatively low specific strength. Glass fiber based sheet molding compounds (SMC) provide high properties in combination with lower density. The high specific strength of SMC offers an enormous lightweight potential. To unlock the full potential of SMC materials in combination with cutting edge manufacturing processes, Volkswagen Group of America worked together with IACMI (Institute for Advanced Composites Manufacturing Innovation) and the academic partners: University of Tennessee Knoxville, Purdue University and Michigan State University; as well as the industry partners: Ashland, IDI, Owens Corning and Continental Structural Plastics. Leveraging the expertise of all project partners, reaching over the entire supply chain the project demonstrated the potential of these materials. This report will highlight the major steps in the development process on the way to technology readiness for SMC using the example of the Volkswagen Atlas Liftgate. Over the 36-month period of the project, the work focused on three R&D areas: material development, design and simulation, and development of the manufacturing process. Material selection included alternative fibers and resin systems, and accounted for material availability, properties, and cost-efficiency. The work undertaken in the field of design and simulation has pushed the envelope of short fiber reinforced thermoset molding compound process simulation. Design iterations were virtually tested, while the final design was used to validate the simulation software against physical parts. Manufacturing development used cutting-edge technology, while experts along the supply chain were working together to ensure the best possible results. In the final stage of the project, liftgates were molded, trimmed, bonded, painted and assembled before exhaustive testing. The result is an e-coat (electrophoretic dip coating) capable Class-A SMC liftgate, which is ready for high-volume production, and can be used as a technology demonstrator. The prototypes manufactured in the scope of this work have exhibited a mass reduction for the Volkswagen Atlas liftgate of up to 35% compared to the series production steel version, without a degradation of the functionalities.

36 MATERIALS SCIENCE↗