Materials-Enabled High-Efficiency (MEHE) Heavy-Duty Diesel Engines Page: 5 of 8
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Abstract
The purpose of this Cooperative Research and Development Agreement (CRADA) between UT-
Battelle, Inc. and Caterpillar, Inc. was to improve diesel engine efficiency by incorporating
advanced materials to enable higher combustion pressures and temperatures necessary for
improved combustion. The project scope also included novel materials for use in advanced
components and designs associated with waste-heat recovery and other concepts for improved
thermal efficiency. Caterpillar initially provided ORNL with a 2004 Tier 2 C 15 ACERTTM diesel
engine (designed for on-highway use) and two 600 hp motoring dynamometers.
The first year of the CRADA effort was focused on establishing a heavy-duty experimental
engine research cell. First year activities included procuring, installing and commissioning the
cell infrastructure. Infrastructure components consisted of intake air handling system, water
tower, exhaust handling system, and cell air conditioning. Other necessary infrastructure items
included the fuel delivery system and bottled gas handling to support the analytical
instrumentation. The second year of the CRADA focused on commissioning the dynamometer
system to enable engine experimentation. In addition to the requirements associated with the
dynamometer controller, the electrical system needed a power factor correction system to
maintain continuity with the electrical grid. During the second year the engine was instrumented
and baseline operated to confirm performance and commission the dynamometer. The engine
performance was mapped and modeled according to requirements provided by Caterpillar. This
activity was further supported by a Work-for-Others project from Caterpillar to evaluate a
proprietary modeling system. A second Work-for-Others activity was performed to evaluate a
novel turbocharger design. This project was highly successful and may lead to new turbocharger
designs for Caterpillar heavy-duty diesel engines. During the third (and final) year of the
CRADA, a novel valve material was evaluated to assess high temperature performance and
durability. A series of prototype valves, composed of a unique nickel-alloy was placed in the
engine head. The engine was aggressively operated using a transient test cycle for 200 hours.
The valve recession was periodically measured to determine valve performance. Upon
completion of the test the valves were removed and returned to Caterpillar for additional
assessment.
Industrial in-kind support was available throughout the project period. Review of the status and
research results were carried out on a regular basis (meetings and telecons) which included
direction for future work activities. A significant portion of the industrial support was in the
form of information exchange and technical consultation.
1. Statement of Objectives
The following goals were pursued in this project:
1. Improve thermal and combustion efficiency by incorporating new materials as in-cylinder
components and assess engine response to novel material and component applications
2. Identify pathways to improving efficiency through the utilization of advanced materials
3. Characterize selected component and materials performance
4. Identify potential thermal exhaust management approaches3
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Kass, M. & Veliz, M. (Caterpillar, Inc.). Materials-Enabled High-Efficiency (MEHE) Heavy-Duty Diesel Engines, report, September 30, 2011; Oak Ridge, Tennessee. (https://digital.library.unt.edu/ark:/67531/metadc843807/m1/5/: accessed April 19, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.