Prototyping Energy Efficient Thermo-Magnetic and Induction Hardening for Heat Treat and Net Shape Forming Applications
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01 COAL, LIGNITE, AND PEAT↗
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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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Machining Elimination through Application of Thread Forming Fasteners in Net-Shaped Cast Holes
The ultimate objective of this work was to eliminate approximately 30% of the machining performed in typical automotive engine and transmission plants by using thread forming fasteners in as-cast holes of aluminum and magnesium cast components. The primary issues at the source of engineers reluctance to implementing thread forming fasteners in lightweight castings are: • Little proof of consistency of clamp load vs. input torque in either aluminum or magnesium castings. • No known data to understand the effect on consistency of clamp load as casting dies wear. The clamp load consistency concern is founded in the fact that a portion of the input torque used to create clamp load is also used to create threads. The torque used for thread forming may not be consistent due to variations in casting material, hole size and shape due to tooling wear and process variation (thermal and mechanical). There is little data available to understand the magnitude of this concern or to form the basis of potential solutions if the range of clamp load variation is very high (> +/- 30%). The range of variation that can be expected in as-cast hole size and shape over the full life cycle of a high pressure die casting die was established in previous work completed by Pacific Northwest National Laboratory, (PNNL). This established range of variation was captured in a set of 12 cast bosses by designing core pins at the size and draft angles identified in the sited previous work. The cast bosses were cut into nuts that could be used in the Ford Fastener Laboratory test-cell to measure clamp load when a thread forming fastener was driven into a cast nut. There were two sets of experiments run. First, a series of cast aluminum nuts were made reflecting the range of shape and size variations to be expected over the life cycle of a die casting die. Taptite thread forming fasteners, (a widely used thread forming fastener suitable for aluminum applications), were driven into the various cored, as-cast nuts at a constant input torque and resulting clamp loads were recorded continuously. The clamp load data was used to determine the range of clamp loads to be expected. The bolts were driven to failure. The clamp load corresponding to the target input of 18.5 Nm was recorded for each fastener. In a like fashion, a second set of experiments were run with cast magnesium nuts and ALtracs thread forming fasteners, (a widely used thread forming fastener suitable for magnesium applications). Again all clamp loads were recorded and analyzed similarly to the Taptites in aluminum cast nuts. Results from previous work performed on the same test cell for a Battelle project using standard M8 bolts into standard M8 nuts were included as a comparator for a standard bolt and nut application. The results for the thread forming fasteners in aluminum cast holes were well within industry expectations of +/- 30% for out of the box and robustness range testing. The results for the dry and lubed extreme conditions were only slightly higher than industry expectations at +/- 35.6%. However, when compared to the actual Battelle results (+/- 40%) for a standard bolt and nut the tread forming fasteners performed slightly better. The results for the thread forming fasteners in magnesium cast holes were all well within industry expectations of +/- 30% for all three conditions. The robustness range (.05mm larger and smaller holes than the expected wear pattern of a die casting die at full life cycle) results also fell within the industry expectations for standard threaded fasteners. These results were very encouraging. It was concluded that this work showed that clamp load variation with thread forming fasteners is consistent with industry expectations for standard steel bolts and nuts at +/- 30%. There does not appear to be any significant increase in clamp load variation due to the application of thread forming fasteners in as-cast holes of aluminum or magnesium over the effective life of a die casting mold. The fully implemented potential benefit of thread forming fasteners in as-cast holes of aluminum and magnesium is estimated to be 6 trillion Btu per year for North America. Economic benefit is estimated to be nearly $800 million per year. Environmental benefits and quality improvements will also result from full implementation of this technology.
36 MATERIALS SCIENCE↗
Weighting and Bayes Nets for Rollup of Surveillance Metrics
The LANL IKE team proposes that the surveillance metrics for several data stream that are used to detect the same failure mode be weighted. Similarly, the failure mode metrics are weighted to obtain a subsystem metric.
97 MATHEMATICS AND COMPUTING↗
Prototyping Energy Efficient Thermo-Magnetic & Induction Hardening for Heat Treat & Net Shape Forming Applications
Within this project, Eaton undertook the task of bringing about significant impact with respect to sustainability. One of the major goals for the Department of Energy is to achieve energy savings with a corresponding reduction in carbon foot print. The use of a coupled induction heat treatment with high magnetic field heat treatment makes possible not only improved performance alloys, but with faster processing times and lower processing energy, as well. With this technology, substitution of lower cost alloys for more exotic alloys became a possibility; microstructure could be tailored for improved magnetic properties or wear resistance or mechanical performance, as needed. A prototype commercial unit has been developed to conduct processing of materials. Testing of this equipment has been conducted and results demonstrate the feasibility for industrial commercialization.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Near Net Shape Manufacturing of New, Low Cost Titanium Powders for Industry
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Peter, William H↗
Low Cost Electrochromic Film on Plastic for Net-Zero Energy Buildings
Over 4 Quads of energy are lost through windows annually. Passive coatings reduce wasted energy, but energy lost through windows would remain over 2 Quads with complete replacement of Low-E glass. Active control of transmitted light and solar heating with electrochromic (EC) windows can transform the efficiency of energy use within buildings, thereby reducing energy footprints and corresponding greenhouse emissions. High production, integration, and distribution cost limits adoption of current EC products. ITN aimed to utilize its proven heritage of efficiently transitioning technologies from rigid to flexible substrates employing roll-to-roll manufacturing to capture the emerging EC window market opportunity. The project focused on three main efforts (1) Transition Small Scale Prototypes To Limited 0.5 Meter Wide, Web Coater Production, (2) Satisfy Market Driven EC Performance Metrics on Plastic Substrates, and (3) Product Development and Commercialization. The overall goal was to substantially reduce investor risk to motivate private investment in a production facility to further transition and scale this promising technology. A 0.5 meter roll-to-roll web coater was designed, constructed, and commissioned at ITN to support EC development effort. With this tool, we were able to establish the feasibility of roll-to-roll production of EC devices. Individually layers were continuously produced at lengths up to 3 meters with good uniformity, both down web and cross web. Solid state devices were produced, and device performance was being enhanced through hardware modifications underway at the close of the project. When deployed in composite device structures, we were able to verify that individual layers were able to achieve a transmission range of 3-70% transmission average over the visible portion of the spectrum. Initial development of intelligent process controls led to verification of a 2-state controller employed during deposition of the electrochromic layer. The project also successfully increased device performance in line with market needs. Improved device materials provided increased transmission range to a 5-65% transmission over the visible spectrum and faster switching times for both small area batch parts and large area composite materials. We were able to demonstrate durable cycling over 10,000-20,000 cycles in a variety of architectures including suspended films in an IGU and films laminated to glass tested in open air representative of retrofit applications. Robust packaging techniques were identified and samples proved durable even in 40C and 100% relative humidity outside the IGU environment.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
The Role of Occupant Behavior in Achieving Net Zero Energy: A Demonstration Project at Fort Carson
This study, sponsored by the U.S. General Services Administration’s Office of Federal High-Performance Green Buildings, aimed to understand the potential for institutional and behavioral change to enhance the performance of buildings, through a demonstration project with the Department of Defense in five green buildings on the Fort Carson, Colorado, Army base. To approach this study, the research team identified specific occupant behaviors that had the potential to save energy in each building, defined strategies that might effectively support behavior change, and implemented a coordinated set of actions during a three-month intervention.
Army↗
Controls of Net Ecosystem Exchange at an Old Field, a Pine Plantation, & a Hardwood Forest under Identical Climatic & Edaphic Conditions (Final Report)
The project yielded papers on fluxes (energy, water and carbon dioxide)between each ecosystem and the atmosphere, and explained the temporal dynamics of fluxes based on intrinsic (physiology, canopy leaf area and structure) and extrinsic (atmospheric and edaphic conditions). Comparisons between any two of the ecosystems, and among all three followed, attributing differences in behavior to different patterns of phenology and differential sensitivities to soil and atmospheric humidity. Finally, data from one-to-three of the ecosystems (incorporated into FluxNet data archive) were used in syntheses across AmeriFlux sites and even more broadly across FluxNet sites.
54 ENVIRONMENTAL SCIENCES↗
Financial impacts of net-metered PV on utilities and ratepayers: A scoping study of two prototypical U.S. utilities
Deployment of customer-sited photovoltaics (PV) in the United States has expanded rapidly in recent years, driven in part by public policies premised on a range of societal benefits that PV may provide. With the success of these efforts, heated debates have surfaced in a number of U.S. states about the impacts of customer-sited PV on utility shareholders and ratepayers, and such debates will likely become only more pronounced and widespread as solar costs continue to decline and deployment accelerates. To inform these discussions, we performed a scoping analysis to quantify the financial impacts of customer-sited PV on utility shareholders and ratepayers and to assess the potential efficacy of various options for mitigating those impacts.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
EcoVillage: A Net Zero Energy Ready Community
CARB is working with the EcoVillage co-housing community in Ithaca, New York, on their third neighborhood called the Third Residential EcoVillage Experience (TREE). This community scale project consists of 40 housing units --15 apartments and 25 single family residences. The community is pursuing certifications for DOE Zero Energy Ready Home, U.S. Green Building Council Leadership in Energy and Environmental Design Gold, and ENERGY STAR for the entire project. Additionally, seven of the 25 homes, along with the four-story apartment building and community center, are being constructed to the Passive House (PH) design standard.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
EcoVillage: A Net Zero Energy Ready Community
CARB is working with the EcoVillage co-housing community in Ithaca, New York, on their third neighborhood called the Third Residential EcoVillage Experience (TREE). This community scale project consists of 40 housing units --15 apartments and 25 single family residences. The community is pursuing certifications for DOE Zero Energy Ready Home, U.S. Green Building Council Leadership in Energy and Environmental Design Gold, and ENERGY STAR for the entire project. Additionally, seven of the 25 homes, along with the four-story apartment building and community center, are being constructed to the Passive House (PH) design standard.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Achieving a Net Zero Energy Retrofit – in a humid, temperate climate – lessons from the University of Hawai’i at Mānoa
The University of Hawai’i at Mānoa (UHM) partnered with the US Department of Energy (DOE) and the Hawai`i Clean Energy Initiative to develop and implement solutions to retrofit exiting buildings to reduce energy consumption by at least 30% as part of DOE’s Commercial Building Partnerships (CBP) Program1. Kuykendall Hall, located on the UHM campus in Honolulu, was the focus of a CBP analysis and design collaboration among the University of Hawai’i, their consultants, and Lawrence Berkeley National Laboratory (LBNL). Kuykendall Hall consists of two 1960s-era wings – a four-story wing containing classrooms, and a seven-story tower containing offices – with a total floor area of approximately 76,000 square feet (ft²).
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
LANL: Net Zero Campus Using Modular Construction
Since its creation, Los Alamos National Laboratory has been a mission driven facility. One goal, of many, is to enable mission delivery through next-generation facilities, infrastructure, and operational excellence. That goal is fostered through the creation of a modern, environmentally responsible workplace. With this drive towards environmental stewardship, there has been an increase in the not only the design of high performing sustainable buildings, but in the use of sustainable construction practices as well. To maintain the current environment, projects have begun to use modular construction. While the practice may offer a multitude of benefits, the high cost of building energy consumption remains. This study stands as an attempt to offer a solution to that problem. With the future creation of a 10 Mega-Watt Photovoltaic System as well as the shift towards modular construction, it may be feasible to generate a Zero Energy Campus whose energy consumption zeros out and environmental footprint remains minimal.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Net Metering Expansion on the Winnebago Tribe of Nebraska Reservation (Final Technical Report)
The Winnebago Tribe of Nebraska, through their affiliated economic development entity Ho-Chunk, Inc; their affiliated non-profit Ho-Chunk Community Development Corporation; and an additional project partner Nebraska Renewable Energy Systems conducted a community scale renewable energy project on their reservation in Nebraska. Over the two-year project period, we installed PV Solar systems on ten tribally owned commercial/retail/office facilities, which included both six roof mounted and four pole mount installations. The project was undertaken as a part of the Tribe’s broader initiative to increase renewable energy production on the reservation, reduce the Tribe’s financial obligations for purchasing energy, and lessen our reliance upon outside sources of energy to meet our basic needs. The project enabled us to formalize and strengthen community collaborations and build our capacity to pursue additional renewable energy opportunities that will enhance our energy sovereignty.
14 SOLAR ENERGY↗
Interpretable Deep Learning for the Earth System with Fractal Nets
Focal Area 3: Explainable AI Our confidence in the projections made by Earth System Models (ESMs) depends on understanding them to be, in some important respects, faithful representations of the Earth system. Here we present an “explainable Artificial Intelligence (AI)” method that allows us to uncover the dynamical structure of the observed and modeled Earth system, discover hidden links across wide spatiotemporal scales, target model development efforts at poorly-represented dynamics, and optimize observed or modeled data collection to maximize predictive information. Science Challenge: Dynamical system science for the Earth system poses unique challenges given the large degree of internal climate variability. Thus, tools that help us understand how ESMs succeed and fail at representing these dynamics are crucial, particularly in relation to the observed system. Furthermore, the computational and memory constraints on ESM data output motivate in situ analysis of ESM dynamics, including automatic detection of dynamical shifts. Also, of key importance are procedures that leverage ESMs to optimize observational campaigns for improving process representation, reducing structural uncertainty and improving model skill.
54 ENVIRONMENTAL SCIENCES↗
Efficient and Zero Net Energy-Ready Plug Loads
Plug loads are the devices plugged into common electrical outlets. Modern buildings contain hundreds of these devices which, together, are responsible for at least 25 percent of the energy use in California buildings. Energy consumed by plug loads is increasing because the “Internet of Things” is, to a great extent, the “Internet of Plug Loads.” This project developed technologies that will reduce the energy use of plug loads. Two crosscutting strategies were investigated in detail: (1) technologies to reduce standby power use to near zero, and (2) methods to increase the use of direct current (DC) as a power source. Two new approaches to reduce standby to near zero were developed and have potential applicability to a wide range of devices. Prototype DC appliances were developed to demonstrate energy savings by bypassing power supplies and avoiding other losses. Networks of DC-powered devices can save even more energy and provide other benefits, such as resiliency during power outages. A unique category of energy-using devices was identified that provide life safety, health, and security to building occupants. Their installation or use is dictated by building codes, health providers, insurance companies, and other entities—none of whom would ordinarily prioritize energy efficiency. In the case of ground fault circuit interrupts (GFCIs), savings of 80 percent appear possible, simply by adopting the most efficient designs. Home medical equipment, particularly oxygen concentrators, are a rising category of energy use where significant savings are possible. This report also reviews the codes, standards, and other policies that affect energy use of plug loads.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Beyond the building: NET Academy unveils innovative training center [News brief]
The news article describes the ribbon-cutting ceremony for the New Employee Training center at Los Alamos National Laboratory (LANL).
99 GENERAL AND MISCELLANEOUS↗
Effective Kitchen Ventilation for Healthy Zero Net Energy Homes with Natural Gas
Past studies indicate that kitchen ventilation that minimally complies with California’s Residential Building Code is inadequate at controlling combustion pollutants from natural gas burners and particulate matter produced during cooking. Effectiveness is further limited by misperceptions that kitchen ventilation is infrequently needed. This project developed the technical basis for updating kitchen ventilation requirements to protect health in new California homes, especially in smaller homes common among low-income renters. Tasks included (1) a field study of ventilation equipment performance and indoor air quality in 23 low-income apartments at four sites; (2) analysis of range hood use related to cooking time and household parameters using data from 54 houses and 17 low-income apartments; (3)a measurement-based study to quantify performance of over-the-range microwave ovens with integrated exhaust fans;and (4) pollutant exposure simulations to inform capture efficiency standards.The field study found operational deficiencies with mechanical ventilation systems in a substantial fraction of low-income apartments that affected performance, resulting in higher exposures to pollutants generated indoors. Using gas cooking burners produced high short-term and weekly time-averaged nitrogen dioxide in apartments.Range hoods were used more frequently with cooking in houses (36percent) than apartments (28percent); use increased with overall cooking frequency in a home and with duration of cooktop but not oven events; actual use was correlated to, but lower than,self-reported use;and use was more frequent in houses when cooking generated any fine particulate matter (PM2.5)or when high PM2.5resulted from cooking in apartments. Performance of over-the-range microwaves with integrated exhaust fans was similar to that of range hoods of comparable price. Simulation analysis found that performance standards need to be updated to ensure that kitchen exhaust ventilation adequately protects for substantial cooking in new California residences.
03 NATURAL GAS↗