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Door assembly with collapsible carrier and water shield

A door assembly for a motor vehicle comprised of an outer door panel and an inner door panel interconnected to define a door panel structure having an internal door cavity. A collapsible carrier module is configured to be oriented in a collapsed arrangement to facilitate installation into the door cavity through an opening in the inner door panel. The collapsible carrier module can be moved from its collapsed arrangement into an expanded arrangement upon installation within the door cavity to facilitate subsequent mounting to the door panel structure. The collapsible carrier module includes a barrier configured to close off the opening in the inner panel.

Fortin, Raymond Edward↗

Demo 5: RapidClave Technology Demonstrations – Round II (Task 2)

The purpose of this project task was to make automotive composite part manufacturing more cost competitive for low volume production and thereby drive composite application innovation. The strategy was to incorporate low-cost preforming, snap cure resins, and RapidClave® processing to create an alternative to conventional automotive composite manufacturing based on SMC. The program used RapidClave® technology from Globe Machine Manufacturing, fast-curing (“snap cure”) epoxy resins from Hexion, and conformable/stretchable glass fiber reinforcement mats produced by Owens Corning for rapid preforming. O’Gara Armoring retrofits vehicles to meet special security needs, such as larger doors to facilitate easier entry into the vehicle. O’Gara has a variety of custom vehicles in need of custom doors that require affordable tooling to produce approximately 100 ship sets/year. The project focused on a composite door panel application provided by O’Gara that is currently made by manual chopped fiber spray-up processing. UDRI reverse-engineered the current composite door panel and created tooling for use in the RapidClave®. UDRI designed an improved composite door using MultiMat fiberglass reinforcement from Owens Corning. UDRI made snap cure resin films from Hexion resin. Finally, UDRI conducted molding trials to compare autoclave processing with RapidClave® processing. The technical goals of the project were to reduce tooling cost by 50% as compared to SMC compression molding and to reduce cycle time by 50% compared to current manual spray-up process. The approach to reduce tool costs is based on use of single sided tooling for use at 100 psi, as compared to matched metal SMC tooling. An added benefit realized from the program is that the Owens Corning mat provided more uniform thickness and improved performance. Tensile and flexural strengths and moduli were increased by at least 50%. This task also demonstrated a 75% decrease in cycle time. O’Gara is evaluating the technology demonstrated in this project for some of their current production. Additionally, there are new products O’Gara is pursuing which require higher production rates than their current products. O’Gara has identified these new products as good candidates for the RapidClave® technology. The cost advantages demonstrated by this project would then lead to significant economic development. In conclusion, this task successfully combined the RapidClave® technology from Globe with a snap cure epoxy resin film system from Hexion and preform material from Owens Corning. Further research is needed to better map the technical limits such as cycle time of these technologies. Additionally, the technology should be extended in terms of size and shape to include large parts outside of automotive applications, such as a small aircraft fuselage.

36 MATERIALS SCIENCE↗

USAMP Low-Cost Mg Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $\$5.50$/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between $\$4.26$ to $\$6.60$/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗

Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $5.50/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between 4.26 USD to 6.60 USD/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

36 MATERIALS SCIENCE↗

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.

99 GENERAL AND MISCELLANEOUS↗

High Velocity Joining of Multi-material Stacks Containing 3rd Generation Advanced High-Strength Stainless Steel and Aluminum Extrusion and Casting (Abstract)

Advanced lightweight materials, including multi-phase steels, aluminum extrusions and aluminum castings, have increasingly replaced mild steel to meet original equipment manufacturer (OEM) demand for increased fuel economy and crash-safety requirements. Third Generation (Gen 3) AHSS provides a superior combination of strength and ductility for crash energy management components in the vehicle body-in-white (BIW). Aluminum extrusions are widely used for bumper, door rocker panel, cradle and battery frame applications. Aluminum castings are increasingly being used in electric vehicles to provide part consolidation, weight saving and increased driving range. Rocker panels are, for example, an important component of the battery electric vehicle (BEV) body structure. The rocker panel serves several purposes, including structural support, crash resistance, protection for the vehicle's underbody and battery tray, and contributing to the overall aesthetics. In order to reduce weight, rocker panels are usually constructed using outer panels consisting of 3rd generation advanced high strength steels (AHSS) and an inner multicell aluminum extrusion structure for energy absorption which protects the batteries in a crash event. It is well known, however, that these material combinations provide significant challenges for joining and are susceptible to liquid metal embrittlement and loss of strength. The overall goal is to find a solution that addresses these challenges in order to produce multi-material vehicle components with reduced weight and minimal galvanic and recyclability issues. The approach being proposed here is to utilize a novel high velocity (HiVe) riveting and clinching technique recently demonstrated by Pacific Northwest National Laboratory (PNNL) to join (2T/3T) sheets of aluminum alloys and steel. This process will not only address the aforementioned challenges but also help significantly reduce the joining cycle time. This work will also demonstrate use of HiVe assemblies to be retrofitted to existing body-shop robots thus having minimal impact to existing body shop operations.

36 MATERIALS SCIENCE↗

LightMat Seedling Project: Enabling the Development of High Strength Magnesium Alloy Sheet for Light-Weighting Applications

It is well known that a 10% reduction in vehicle weight can result in a 6-8% fuel economy improvement in gasoline/diesel vehicles. Replacing steel and aluminum with magnesium can result in weight savings between 25 and 75% and hence magnesium alloys have been considered for multiple body-in-white components to reduce the weight of the glider. For example, magnesium sheet has been considered for decklid inner panels, rear seatback panels, roof panels, and door inners.

36 MATERIALS SCIENCE↗

Vertical high-pressure rinse machine

A high-pressured rinsing system comprises a base including a liquid reservoir, a rotation motor housing including a rotation motor adapted to rotate a spray wand attached, and extending vertically upward from, the rotation motor housing and base, a linear rail support frame attached the base and including a vertical motor and associated linear rail attached thereto, a cavity mounting plate attached to the linear rail, wherein vertical movement of the linear rail causes vertical movement of the cavity mounting plate over the base; and at least one door and a plurality of side panels mounting to an enclosure support frame, wherein the enclosure support frame is mounted and secured to the linear rail support frame and base to create an enclosure around the spray wand and linear rail.

Ring, Timothy J.↗

Automatic Segmentation of Building Envelope Point Cloud Data Using Machine Learning

About 50% of buildings in the US were constructed before energy codes were introduced. Modular overclad panel retrofits, in which a new envelope is constructed over the existing building, are a promising solution given that it minimizes occupant disruption and shortens construction time at the jobsite. Current state-of-the-art retrofit panel layout and dimensioning consists of three steps: 1) 3D point cloud data generation of the building envelope using commonly available surveying equipment, 2) manual segmentation of 3D point cloud data by a trained professional to identify and dimension window openings, door openings, and other architectural features, and 3) modular panel layout optimization and dimensioning by an architect or engineer. Among these steps, the second one remains the most difficult and costly because it is very labor-intensive. We propose a methodology to automatically label 3D point cloud data to reduce the time and expense spent in manual segmentation. Machine learning methods were employed to classify the point cloud data into distinct groups, each of which corresponds to different features of the building envelope. After classification, a segmentation algorithm was developed to perform boundary detection and separate the components of the façade. Finally, the algorithm returns the relative positions and dimensions of the features in the building envelope. The measurements obtained with the proposed automated method were compared against the actual dimensions to determine the overall algorithm accuracy. The proposed algorithm can then be used to reduce manual efforts for 3D point cloud labeling before modular panel layout optimization is performed.

Maldonado Puente, Bryan↗

Advanced Zonal Infiltration Measurement Method for Multifamily Buildings: A Novel Test Procedure to Determine Air Leakage Through External and Internal Surfaces

Measuring air infiltration through the external building envelope as well as between adjacent zones within a building is important since air leakage is related to increased energy use and poor indoor air quality (IAQ). State of the art methods can determine both leakages, however it can be both time consuming and labor intensive as it requires running both guarded and compartmentalization tests. This paper presents our work on developing a simplified testing procedure to determine power law flow equation leakage parameters of both external and internal boundaries of tested zones. The proposed Zonal Multipoint Pressure Test (ZMPT) method modulates airflow in the zone using a variable airflow measurement panel (mounted in either a window or the door), and solving the mass balance equations for the leakage parameters. ZMPT results were compared to conventional test results and found to correlate to within +/-7%.

Jayarathne, Tharanga↗

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Deep Point Cloud Building Envelope Segmentation (DeeP-CuBES) using Deep Learning

Building Information Modeling (BIM) plays an important role in building design and construction, particularly for achieving energy-efficient retrofits. Building envelope retrofits using panelized prefabricated system, such as those popularized by the Energiesprong program, need accurate as-built dimensions of facade features (windows, doors, etc.) to achieve the desired thermal and air tightness. Traditionally, building surveying is done manually, resulting in a time-consuming and labor-intensive process. Recently, 3D point clouds from terrestrial LiDAR have been used to automate the generation of as-built dimensions of existing buildings. However, automated BIM using LiDAR relies on solving the point cloud semantic segmentation (PCSS) problem. In this work, we propose a robust pipeline for solving the PCSS problem using deep neural networks, focusing on overcoming challenges posed by imbalanced datasets and complex architectural features. We introduce the first high-density, labeled, and validated building envelope point cloud dataset derived from multiple building scans, specifically curated to tackle challenges in facade-level segmentation. Results from the trained neural networks show that advanced attention-based architectures and incorporating radiometry (light intensity and RGB) features significantly boost segmentation accuracy for windows and doors.

Selvakumar, Balaji [ORNL]↗

High Energy Physics Network Requirements Review (Final Report, July-October 2020)

Throughout 2020, ESnet and the Office of High Energy Physics (HEP) of the DOE SC organized an ESnet requirements review of HEP-supported activities. Preparation for this event included identification of key stakeholders: program and facility management, research groups, technology providers, and a number of external observers. These individuals were asked to prepare formal case study documents about their relationship to the HEP program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward. A series of pre-planning meetings better prepared case study authors for this task, along with guidance on how the review would proceed in a virtual fashion.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Blast Effects on Buildings (Final Report)

Lawrence Livermore National Laboratory (LLNL) has conservatively reduced the explosive safety standards suggested by the Small Quantities in Research Laboratories (SQRL) program testing by 60%. For this reason, further research into the detailed effects of small amounts of explosives in typically constructed rooms is needed in order to improve their factor of safety. The team was tasked with designing an experiment to investigate the effect of different variables on drywall under explosive blasts. In order to meet this objective, the team conducted a comprehensive literature review to gain an understanding of industry-standard construction practices and review previous tests conducted by the Army corp of engineers. Since the team used PBXN-5 rather than C4, as in SQRL, an initial shot was conducted to compare damage levels. From those results and the physical constraints of the testing chamber, the team redesigned multiple single-panel drywall frames to capture the entirety of the incurred damage. Proposed designs were narrowed down using a decision matrix. From the study of previous tests and literature review, variables were chosen that the team hypothesized to have an impact on drywall strength. The variables that were tested were chosen from the results of that work and specific variables the sponsor was interested in, and they were paint, humidity/moisture content, and explosive positioning relative to the studs. Detailed plans were made for each variable according to what conditions the team wanted to investigate. For humidity, this involved testing low, ambient, and high conditions by treating the panels in a chamber. Preliminary shots were performed to test the structural integrity of the frame and streamline the test diagnostics which involved a high-speed camera placed behind the drywall, outside of the chamber, and a pressure probe placed behind the drywall, inside the chamber. Once the instrumentation, diagnostics, and frame design were finalized, a quantitative damage criteria matrix was created to categorize the results of the main shot series. In conjunction with evidence from the high-speed video, the achieved damage levels indicate that high moisture content drywall is better able to withstand explosive blasts. Larger stud damage and lower drywall damage occurred when the explosive was located directly in front of a stud. Paint had no noticeable impact on strength. Ultimately, the team conducted a total of 17 tests, leaving the door open for future in-depth research into the impact of humidity.

36 MATERIALS SCIENCE↗

Safer Foundation Solar Demands Skill Collaborative

The milestones and accomplishments achieved in Safer’s Solar Demands Skill Training program required a collective effort of stakeholders. The ability to achieve the desired results and impact lives of the population we serve works best when collaborating with community stakeholders such as community-based organizations, faith-based organizations, community activists, local law enforcement, community residents, employers, and elected and appointed officials. We are working harder than ever to place clients in-demand careers and high-growth industry sectors. Our employer engagement with high growth sectors continues to increase, we have been able to deepen our relationships in this space by providing in demand stackable credential training. Launched our initiative in the green job space by partnering with organizations like ComEd, the Department of Energy, community-based organizations, faith-based organizations, and manufacturers that helped to train clients in the green jobs and renewable energy space. By the end of the year, we will have completed our tenth cohort of photovoltaic solar installation training. The training has been used as a foundation for solar panel installers to acquire new skills in in the green jobs career pathways, such as sales and customer service. It has also served as a pipeline to union-level trade positions through the skills participants obtained through partnership engagement. Safer Foundation's policy and advocacy team plays a major role in expanding opportunities for people with records to over one hundred occupations, including the trades. This reform has allowed many to secure living wage employment, reducing the high recidivism rate within Illinois. Safer continues to build our social enterprise with Reconstructive Technology Partners (RTP). RTP is introducing people with records to the construction trades such as solar, carpentry and electrical through residential remodeling of homes on smaller construction projects. Understanding the need to have a greater community presence, outreach was extended to a boots on the ground model, including, but not limited to door-to-door engagement, DE-EE0008571 Safer Foundation Page 4 of 29 local radio broadcasting and print ads in local newspapers. We continue to seek innovative ways to increase Safer Foundations' presence in the renewable energy space. Outreach efforts gave us an opportunity to share critical reentry information and opportunities about our PV installer program. Giving us reach with local and national audiences alike. We launched a systematic approach to improving client data and client tracking through an evidence-based practices initiative. That implemented an agency wide cross-functional data management system. The system supported our goal of reviewing, evaluating, and making recommendations to improve operational processes, program delivery, information sharing, and more. Played a significant part in the success of the solar program. Finally, economists around the nation agree that there is a significant labor shortage. The shortage directly threatens our ability to sustain our economic growth; if employers do not have access to the workers they need, it can lead to a shutdown in the economic recovery. The demand for Safer Foundation services is more important and impactful than ever. We will continue to build upon our 50 years of experience to address the challenges ahead and serve more people in a better way. We are confident we will accomplish beautiful things that benefit everyone involved because together, we are powerful.

14 SOLAR ENERGY↗

Using Cosmic Ray Muons to Assess Geological Characteristics in the Subsurface

Cosmic rays are energetic nuclei and elementary particles that originate from stars and intergalactic events. The interaction of these particles with the upper atmosphere produces a wide range of secondary particles that reach the surface of the earth, of which muons are the most prominent. With enough energy, muons can travel up to a few kilometers beneath the surface of the earth before being stopped completely. The terrestrial muon flux profile and associated zenith angle can be utilized to determine geological characteristics of a location (e.g., rock overburden and density) without having to use conventional methods such as boreholes. This work uses a low-power plastic scintillator-based muon detection system as a prototype for this non-destructive geological assay methodology. Four custom designed 102 cm x 51 cm x 5 cm plastic scintillation panels are used to realize two orthogonal detection planes. Optical photons from each scintillation panel are read using OnSemi J-Series 4x4 silicon photomultiplier (SiPM) arrays in conjunction with preamplifiers. Simultaneous triggers between detectors from two planes indicate a coincidence event which is recorded using the QuarkNet data acquisition system (DAQ) from Fermi National Accelerator Laboratory. A custom detector holder was designed to securely mount the detection system and rotate the panels along the zenith to collect data at variable angles. In order to quantify the systematic uncertainties associated with the detector, such as energy depositions and angular resolution of the detector design, a Monte Carlo (MC) simulation using Geant4 is being developed. Cosmic ray flux prediction will be included in the project by adding the CORSIKA MC code to the simulation toolchain. Simulated and experimental data will drive the development and validation of a reconstruction algorithm that, upon completion, is expected to predict average overburden and rock density. Extended detector exposure to muons can be used as a means to understand changes in the surrounding environment like rock porosity. On the experimental front, muons will initially be measured at the surface, establishing the baseline flux. This is followed by recording the muon flux at variable depths and zenith angles, where the data will be used by the reconstruction algorithm to predict the overburden. The result will be benchmarked against geological surveys. The measured flux data will also be used to benchmark independent and established models. Successful proof-of-concept demonstration of this technology can open doors for long term non-invasive geological monitoring. The detector design, experimental methodology, and the benchmarking efforts are detailed in this work.

Gadey, Harish Reddy↗