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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

A System-Level Cost Modeling Framework for Design for Remanufacturing: A Case Study of an Agricultural Machine Transmission

Remanufacturing offers significant environmental and economic benefits by restoring end-of-life products to as-new conditions. Although extensive research has been conducted on the topic, the adoption of remanufacturing practices remains limited across various industries. A primary barrier to broader implementation is the substantial upfront investment required, which necessitates reliable cost modeling to justify potential future savings. Most existing models treat components independently and ignore inter-component dependencies. We develop a probabilistic, system-level cost modeling framework that integrates reliability, reusability, and a dependency matrix to capture cascading effects across components over multiple life cycles. Our model identifies those critical components that maximize remanufacturing benefits across a product's many lives. A toy example and an industry case study (John Deere PowrQuad transmission subassembly) illustrate how design alternatives affect cumulative cost. Using a Monte Carlo simulation (MCS) to perform life cycle cost analysis on the system with different design changes, we show the normalized average cost savings after three remanufacturing cycles. Accounting for dependencies meaningfully alters cost projections and ignoring them underestimates accumulated cost by up to 20% in our examples. Furthermore, the results of our study confirm that accounting for component interdependencies is necessary to produce cost estimates that meet industry standards.

Life Cycle Analysis and Design↗
DOE OSTI2023

Reman Co-Design: A Combined Design and Remanufacturing Optimization Framework for the Sustainable Design of High-Value Components

Remanufacturing is a process that returns end-of-life equipment to as-new conditions and offers numerous environmental and economic benefits. To fully capitalize on remanufacturing, its synergistic interactions with design must be fully realized and addressed during the design stage. Although this fact is widely recognized in the literature, most of the current studies focus primarily either on the design or remanufacturing aspects of design for remanufacturing (DfRem). In an effort to offer a more integrated DfRem approach than those reported in the literature, we propose a new combined design and remanufacturing optimization (reman co-design) framework that takes a holistic approach by leveraging the intricate interplay between design and remanufacturing. Here, the aim of this formulation is to identify the optimal decisions that maximize the benefits of remanufacturing throughout the entire lifespan of a product. To showcase the utility of the new formulation, we are using a case study of a hydraulic manifold, (re)manufactured by John Deere. Using this industry example, we compare the results of reman co-design to the ones from a decoupled remanufacturing design approach. Results reveal that remanufacturing benefits are better realized and improved upon when using the developed reman co-design approach.

design for X↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Energy I-Corps Annual Report 2022

The U.S. Department of Energy Office of Technology Transitions is pleased to provide an update on the Energy I-Corps program. Now in its eighth year, Energy I-Corps addresses critical gaps in workforce development for our National Lab researchers. It provides meaningful real-world opportunities for the application of commercialization and entrepreneurial skills to DOE technologies. As of November 2022, 191 teams from 12 National Labs have participated in Energy I-Corps over the course of 15 cohorts and the pilot. Since its inception, Energy I-Corps participants have learned from more than 180 industry mentors and conducted over 13,600 discovery interviews with companies like: EPRI, Shell, Ford, World Bank, Breakthrough Energy, John Deere, Siemens Gamesa, Chevron, Eaton, Samsung, Lowes, Johns Manville, LEGO, U.S. Army, Trane, Tesla, GM, Dow Chemical, 3M, Whirlpool, GE, Home Depot, and Amazon. Over 20 teams have launched new businesses based on their Energy I-Corps technology. Post Energy I-Corps, technologies have attracted over $140M in post-program funding and executed over 75 licenses.

cohort↗
DOE OSTI2026

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Thermal Management for Planar Package Power Electronics (CRADA Final Report)

The National Renewable Energy Laboratory (NREL) and John Deere Electronic Solutions (JDES) collaborated to develop and evaluate computer models and simulations related to the thermal performance of semiconductor device packaging for an inverter of an off-road vehicle ("Semiconductor Packaging"). The objective of the research was for NREL and JDES to develop a two or three-dimensional computer-aided design model of the Semiconductor Packaging ("Computer Model") for thermal performance evaluation in a simulation. The project developed computer models of a Semiconductor Package of silicon-carbide semiconductor devices with appropriate thermal dissipation via one or more of the following thermal features: a double-sided planar cooling configuration, an air-cooled configuration, a liquid-cooled configuration for off-road inverter applications in a relevant simulated operating environment. It is noted that surface area and prototype product embodiment consisting of air-cooled and liquid-cooled configurations may and may not be in direct contact with power semiconductor chips. The idea was to explore and develop packaging and thermal management technology for power semiconductors that was most effective in the performance yet had least burden in overall product cost for a given application.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗
DOE OSTI2023

Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE)

Raytheon Technologies Research Center (RTRC) is the central research and development (R&D) organization for RTX, and has extensive expertise in the design, modeling and analysis of high-performance electrical machines and thermal management for all its business units. The proposing team consists of researchers from RTRC and John Deere (JD), will be referred as “Team”. Each organization a has long track record of successful R&D of materials, manufacturing, components, and systems for energy efficiency applications. Motor power density and efficiency are limited by fundamental physical trade-offs between electromagnetics, thermal management, and structural design considerations. The team is proposing to utilize novel technologies and multi-physics design methods to develop a Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE), demonstrating an 8X improvement in power density.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

PowerAmerica (Final Technical Report)

The U.S. Department of Energy’s Advanced Manufacturing Office (predecessor to AMMTO) established PowerAmerica in December 2014 to develop and accelerate the adoption of wide bandgap (WBG) semiconductor chips and power electronics in manufacturing. The objective was to spark early commercialization of energy efficient products; educate and train the workforce; create high-tech jobs; and nurture the growth of the U.S. WBG semiconductor manufacturing industry. PowerAmerica isled by North Carolina State University by way of a five-year, $140M cooperative agreement with DoE. This private-public partnership with DoE includes member companies ranging from startups and small-medium enterprises to large system integrators, world-class universities, and national labs. The WBG power electronic ecosystem formed by our diverse membership is focused on using advanced manufacturing to 1) lower the cost of silicon carbide and gallium nitride semiconductor devices to be comparable to silicon devices; 2) demonstrate the system benefits and energy efficiency advantages of WBG semiconductor power electronics through system demonstrations that validate their effectiveness; and 3) build an education pipeline for a skilled workforce to meet the future demand for emerging WBG semiconductor markets — and enhance U.S. economic competitiveness globally. PowerAmerica was initially funded in six budget periods, each lasting 12 to 18 months. By the end of Budget Period 6 (August 2023), PowerAmerica had achieved its major objectives in technology development, semiconductor device cost reduction, ecosystem growth and engagement, and education and workforce development. Through strategic foundry investments, we helped to establish the first U.S. SiC foundry (X-FAB) and supported a lab (Microchip) to start SiC volume production. We’ve helped bring together companies from different parts of the supply chain, resulting in several successful new partnerships and business relationships. Through projects with some of the largest manufacturers of energy-intensive equipment in the U.S. — John Deere, GE, United Technologies, Raytheon, Carrier, Toshiba, and others — we have successfully demonstrated the energy and system benefits of WBG technology. We have also harnessed the unique capabilities and facilities of national labs — the Naval Research Laboratory, National Renewable Energy Laboratory, and Argonne National Laboratory — to help solve challenging technical problems for industry. Thanks to our many webinars, tutorials, annual events, and presence at major energy and electronics conferences around the world, the PowerAmerica name has become synonymous with WBG technology advancement. The commercial interest in WBG technology is higher than ever; companies and governments around the world have announced hundreds of millions of dollarsin future investment to build capacity — and compete with silicon in many markets and applications. We have trained hundreds of engineering students, from universities across the U.S., through hands-on projects and WBG coursework. Working professionals have also benefited through the years from our many targeted short courses, tutorials, and technical webinars. In short, PowerAmerica has made great strides in each of our key objectives, and the organization has been operating without government or NC State

14 SOLAR ENERGY↗
DOE OSTI2025

A Design for Remanufacturing Framework Incorporating Identification, Evaluation, and Validation: A Case Study of Hydraulic Manifold

In recent years, academic researchers and engineers in the industry have widely recognized the necessity of integrating remanufacturing considerations into product design iterations to advance sustainability objectives. Acknowledging the importance of design for remanufacturing (DfRem), efforts were made to develop tools and guidelines that could be implemented in practice. However, such methods largely rely upon experiential insights and qualitative assessments, leaving a gap in the ability to quantitatively assess the economic and environmental impacts of design choices. To bridge this gap, we investigate existing efforts and present a framework for DfRem that integrates established design and remanufacturing practices into a cohesive workflow with quantitative assessments. To demonstrate its efficacy for making practical design changes for remanufacturing, we apply the framework to a hydraulic manifold in a transmission system for heavy-duty tractors. Through this industry-relevant case study, we focus on showcasing the practical utility of our framework. Based on the identified design modifications from remanufacturability analysis, we estimate the reductions in life cycle costs, energy consumption, and emissions. Afterward, the modifications are tested using physical experiments with plans for integration into future iterations of the hydraulic manifold design and production. Here, we anticipate this framework can illustrate the process of remanufacturing that ensures improvements in sustainability while maintaining performance and reliability standards.

design for X↗
DOE OSTI2020

Holistic Thermal Management

This presentation, part of the 2019 Applied Power Electronics Conference (APEC), discusses holistic thermal management.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2023

Land-use history, fire regime, and large-mammal herbivory affect deer-preferred plant diversity in longleaf pine woodlands

Since ecological systems often experience multiple disturbances, understanding changes in important ecological interactions, such as plant-herbivore interactions, may require studies capable of disentangling the unique and interactive effects of multiple forms of disturbance. For example, understanding how mammalian herbivores affect plant communities may require understanding how widespread past disturbances, such as agricultural land use, interact with contemporary disturbances, such as prescribed fire. Here, we tested if past agricultural land use and contemporary fire regime modified the effects of mammalian herbivory on focal plant communities by measuring the richness of plant species preferred by deer at 26 longleaf pine woodlands containing paired open and large-mammal exclusion plots. Land-use history significantly affected the community composition of deer-preferred species, and focal species were 8.19 times more likely to be present in post-agricultural sites than non-agricultural sites. Large-mammal herbivory only affected plant species richness in woodlands with low fire frequencies wherein focal species were on average 2.23 times more likely to be present in exclusion plots than open plots. These results suggest that past and present disturbances can mediate contemporary plant-animal interactions and may explain spatial patterns in the intensity of large-mammal herbivory. Our findings also suggest that common management practices, such as use of prescribed burns, may indirectly promote plant species richness by reducing deer herbivory.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Co-occurrence of native white-tailed deer and invasive wild pigs: Evidence for competition?

Understanding whether invasive and native species compete for shared resources where they co-occur is essential for mitigating the negative impacts of invasive species on native ecosystems. Here, we examined how the presence and density of an invasive species, wild pigs (Sus scrofa), affect native white-tailed deer (Odocoileus virginianus; hereafter, deer) on the Savannah River Site, SC, USA. We examined potential changes in deer areas of use, temporal overlap, and occupancy to evaluate the effects of wild pig occurrence and density on deer space use, diel activity, and co-occurrence with wild pigs across 9 months during 2018 and 2019. Wild pig density had the strongest effect on deer space use in high- and moderate-use areas. Declines in deer space use in response to wild pig density were most pronounced in March and October 2018 and April 2019 for females, while male space use declined in response to wild pig density in October and December 2018. Both species were largely nocturnal with high overlap in diel activity across months. Deer occupancy responses to wild pig density varied across months, with negative responses in May and October 2018 and positive responses in July 2018 and April 2019. Deer and wild pigs co-occurred at 30%–59% of camera stations across months, with broadscale co-occurrence patterns being unaffected by changes in shared cover or wild pig occurrence. Overall, our results suggest that deer make fine-scale behavioral adjustments to avoid wild pigs, providing evidence that competition is likely occurring even where wild pig density is relatively low. Such fine-scale behavioral plasticity in deer appears to mitigate the costs of competition with wild pigs and may be a mechanism enabling long-term co-existence of deer and wild pigs. Our study provides novel insight on the complexities of spatiotemporal relationships between invasive wild pigs and native deer and suggests that the negative effects of interactions between deer and wild pigs may be more pronounced when deer life history needs are particularly demanding. In areas where eradication of invasive wild pigs may be impossible, maintaining low wild pig densities may help mitigate, but may not eliminate, the negative effects of wild pigs on deer.

resource partitioning↗
DOE OSTI2023

White-tailed deer responses to acoustic predator cues are contingent upon past land use and contemporary fire regime

Prey can assess the immediate risk of predation by detecting cues of predator presence, and it is expected that prey should invest in costly antipredator behaviors when a cue of predator presence is detected. Features of the habitat in which the cue is detected, such as vegetative concealment, serve as indirect cues of risk and can mediate how prey respond to direct cues of predator presence. Past agricultural land use and contemporary fire regimes are common disturbances that may modify prey perceptions of risk and could, therefore, alter prey responses to direct cues of predator presence. Here we examined whether the overlap of these two disturbances affected white-tailed deer (Odocoileus virginianus) responses to cues of predator presence by measuring deer vigilance and foraging bout duration in response to coyote (Canis latrans) vocalizations across 20 woodlands that varied in past land use and contemporary fire regime. Frequent fire regimes consistently increased deer visibility to predators across both land-use history contexts. Deer exhibited no behavioral response to the predator cue in habitats containing infrequent fire regimes or agricultural legacies. Deer responded to the cue in frequently burned woodlands without agricultural legacies through increased vigilance and time spent at a foraging location. These findings reveal that land-use legacies and contemporary fire regimes can mediate how prey respond to direct cues of risk. They also suggest that prey may balance the uncertainty associated with cues of predation risk with the urgency of responding to a potential attack by being vigilant and remaining in place.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Assessing springtime vertebrate prey of sympatric mesopredators in the southeastern United States using metabarcoding analysis

Coyotes (Canis latrans) colonized the eastern United States over the last century and formed a 3-species predator guild with bobcats (Lynx rufus) and gray foxes (Urocyon cinereoargenteus) across much of the southeastern United States. Diets among the three species vary along with respective impacts on game species such as white-tailed deer (Odocoileus virginianus) and wild turkeys (Meleagris gallopavo). To determine predation impacts on vertebrate prey and dietary overlap in consumption of prey items, we assessed diets of coyote, bobcat, and gray fox during spring, coinciding with white-tailed deer fawning and wild turkey nesting and brood rearing. We sampled across three sites along the Savannah River in South Carolina from mid-May through mid-June of 2020–2021. We collected 180 scat samples along 295.9 kilometers (71.1–122.4 km/site) of unpaved secondary roads and used DNA metabarcoding to determine vertebrate diet items. We identified predator species of scat using DNA metabarcoding and species-specific mtDNA fragment analysis (153 were coyote, 20 bobcat, and seven gray fox). Overall, we found evidence that two species, coyote and bobcat, consumed deer while all three consumed turkeys. Frequency of deer in the diet varied across sites for coyotes from 62–86% and wild turkey was present with a frequency of occurrence of 9% for coyotes, 5% for bobcats, and 14% for gray fox. Vertebrate diet specialization was evident across predator species with high frequency of deer in coyote diets, rabbits and small mammals in bobcat diets, and herpetofauna in gray fox diets. During deer fawning and wild turkey nesting and brood rearing, dietary overlap appears to be mediated by disparate selection of prey items, which reduced competition among coyotes, bobcats, and gray foxes. Use of DNA metabarcoding may augment our understanding of dietary preferences within this predator guild by providing increased resolution of diet composition among important game species.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Deer Vigilance and Movement Behavior Are Affected by Edge Density and Connectivity

ABSTRACT Animal behavior is an important component of individual, population, and community responses to anthropogenic habitat alteration. For example, antipredator behavior (e.g., vigilance) and animal movement behavior may both be important behavioral responses to the increased density of habitat edges and changes in patch connectivity that characterize highly modified habitats. Importantly, edge density and connectivity might interact, and this interaction is likely to mediate animal behavior: linear, edge‐rich landscape features often provide structural connectivity between patches, but the functional connectedness of patches for animal use could depend upon how edge density modifies animal vigilance and movement. Using remote cameras in large‐scale experimental landscapes that manipulate edge density (high‐ vs. low‐density edges) and patch connectivity (isolated or connected patches), we examined the effects of edge density and connectivity on the antipredator behavior and movement behavior of white‐tailed deer ( Odocoileus virginianus ). Deer vigilance was 1.38 times greater near high‐density edges compared to low‐density edges, regardless of whether patches were connected or isolated. Deer were also more likely to move parallel to connected high‐density edges than all other edge types, suggesting that connectivity promotes movement along high‐density edges. These results suggest that increases in edge density that accompany human fragmentation of existing habitats may give rise to large‐scale changes in the antipredator behavior of deer. These results also suggest that conservation strategies that simultaneously manipulate edge density and connectivity (i.e., habitat corridors) may have multiple effects on different aspects of deer behavior: linear habitat corridors were areas of high vigilance, but also areas where deer movement behavior implied increased movement along the habitat edge.

Bartel, Savannah L. [University of Wisconsin‐Madis↗
DOE OSTI2021

Past agricultural land use affects multiple facets of ungulate antipredator behavior

Antipredator behavior affects prey fitness, prey demography, and the strength of ecological interactions. Although predator-prey interactions increasingly occur in habitats that experience multiple forms of human-generated disturbance, it is unclear how different forms of disturbance might affect antipredator behavior. Fire is a contemporary disturbance that has dramatic effects on terrestrial habitats. Such habitats may have also experienced past disturbances, like agricultural land use, that leave lasting legacies on habitat structure (e.g., overstory and understory composition). It is unclear how these past and present disturbances affect the use of different antipredator behaviors, like temporal avoidance and vigilance. We examined whether variation in disturbance regimes generates differences in ungulate antipredator behavior by using cameras to measure white-tailed deer vigilance and activity time across 24 longleaf pine woodlands that vary in past land use and contemporary fire regime. Regardless of land-use history, woodlands with high fire frequencies had 4 times less vegetation cover than low-fire woodlands, generating riskier habitats for deer; however, deer responded to fire with different antipredator strategies depending on land-use history. In nonagricultural woodlands, fire affected deer activity time such that activity was nocturnal in low-fire woodlands and crepuscular in high-fire woodlands. In post-agricultural woodlands, fire affected vigilance and not activity time such that deer were more vigilant in high-fire woodlands than in low-fire woodlands. Furthermore, these results suggest that ungulate antipredator behavior may vary spatially depending on past land use and contemporary fire regime, and such disturbances may generate “landscapes of fear” that persist for decades after agricultural use.

60 APPLIED LIFE SCIENCES↗