8 Matching Results

Search Results

Advanced search parameters have been applied.

Materials-Enabled High-Efficiency (MEHE) Heavy-Duty Diesel Engines

Description: The purpose of this Cooperative Research and Development Agreement (CRADA) between UTBattelle, 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 C15 ACERT 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 ...
Date: September 30, 2011
Creator: Kass, M. & Veliz, M. (Caterpillar, Inc.)
Partner: UNT Libraries Government Documents Department

Production of Diesel Engine Turbocharger Turbine from Low Cost Titanium Powder

Description: Turbochargers in commercial turbo-diesel engines are multi-material systems where usually the compressor rotor is made of aluminum or titanium based material and the turbine rotor is made of either a nickel based superalloy or titanium, designed to operate under the harsh exhaust gas conditions. The use of cast titanium in the turbine section has been used by Cummins Turbo Technologies since 1997. Having the benefit of a lower mass than the superalloy based turbines; higher turbine speeds in a more compact design can be achieved with titanium. In an effort to improve the cost model, and develop an industrial supply of titanium componentry that is more stable than the traditional aerospace based supply chain, the Contractor has developed component manufacturing schemes that use economical Armstrong titanium and titanium alloy powders and MgR-HDH powders. Those manufacturing schemes can be applied to compressor and turbine rotor components for diesel engine applications with the potential of providing a reliable supply of titanium componentry with a cost and performance advantage over cast titanium.
Date: May 4, 2012
Creator: Muth, T. R. & Mayer, R. (Queen City Forging)
Partner: UNT Libraries Government Documents Department

Engine Materials Compatability with Alternative Fuels

Description: The compatibility of aluminum and aluminum alloys with synthetic fuel blends comprised of ethanol and reference fuel C (a 50/50 mix of toluene and iso-octane) was examined as a function of water content and temperature. Commercially pure wrought aluminum and several cast aluminum alloys were observed to be similarly susceptible to substantial corrosion in dry (< 50 ppm water) ethanol. Corrosion rates of all the aluminum materials examined were accelerated by increased temperature and ethanol content in the fuel mixture, but inhibited by increased water content. Pretreatments designed to stabilize passive films on aluminum increased the incubation time for onset of corrosion, suggesting film stability is a significant factor in the mechanism of corrosion.
Date: April 5, 2013
Creator: Pawel, Steve & Moore, D.
Partner: UNT Libraries Government Documents Department

Expanding Robust HCCI Operation with Advanced Valve and Fuel Control Technologies

Description: Delphi Automotive Systems and ORNL established this CRADA to advance the commercialization potential of the homogeneous charge compression ignition (HCCI) advanced combustion strategy for gasoline engine platforms. HCCI combustion has been shown by others to produce high diesel-like efficiency on a gasoline engine platform while simultaneously producing low NOX and particulate matter emissions. However, the commercialization barriers that face HCCI combustion are significant, with requirements for a more active engine control system, likely with next-cycle closed-loop feedback control, and with advanced valve train technologies to enable negative valve overlap conditions. In the partnership between Delphi and ORNL, each organization brought a unique and complementary set of skills to the project. Delphi has made a number of breakthroughs with production-intent valve train technologies and controls in recent years to make a part time production-intent HCCI engine plausible. ORNL has extensive knowledge and expertise with HCCI combustion, and also has a versatile research engine with hydraulic valve actuation (HVA) that is useful for guiding production of a cam-based HCCI system. Partnering these knowledge bases and capabilities was essential towards making progress to better understand HCCI combustion and the commercialization barriers that it faces. ORNL and Delphi maintained strong collaboration throughout the project. Meetings were held regularly, with additional reports, presentations, and meetings as necessary to maintain progress. Delphi provided guidance to ORNL regarding operational strategies to investigate on their single-cylinder research engine with HVA and data from their experimental multi-cylinder engine for modeling. ORNL provided single-cylinder engine data and modeling results.
Date: September 11, 2012
Creator: Szybist, J. P. & Confer, K.
Partner: UNT Libraries Government Documents Department

UV and EB Curable Binder Technology for Lithium Ion Batteries and UltraCapacitors

Description: the basic feasibility of using UV curing technology to produce Lithium ion battery electrodes at speeds over 200 feet per minute has been shown. A unique set of UV curable chemicals were discovered that were proven to be compatible with a Lithium ion battery environment with the adhesion qualities of PVDF.
Date: April 30, 2012
Creator: Voelker, Gary
Partner: UNT Libraries Government Documents Department

Advanced Sensor Technologies for Next-Generation Vehicles

Description: This report summarizes the development of automobile emissions sensors at Argonne National Laboratory. Three types of sensor technologies, i.e., ultrasound, microwave, and ion-mobility spectrometry (IMS), were evaluated for engine-out emissions monitoring. Two acoustic sensor technologies, i.e., surface acoustic wave and flexural plate wave, were evaluated for detection of hydrocarbons. The microwave technique involves a cavity design and measures the shifts in resonance frequency that are a result of the presence of trace organic compounds. The IMS technique was chosen for further development into a practical emissions sensor. An IMS sensor with a radioactive {sup 63}Ni ion source was initially developed and applied to measurement of hydrocarbons and NO{sub x} emissions. For practical applications, corona and spark discharge ion sources were later developed and applied to NO{sub x} emission measurement. The concentrations of NO{sub 2} in dry nitrogen and in a typical exhaust gas mixture are presented. The sensor response to moisture was evaluated, and a cooling method to control the moisture content in the gas stream was examined. Results show that the moisture effect can be reduced by using a thermoelectric cold plate. The design and performance of a laboratory prototype sensor are described.
Date: January 30, 2002
Creator: Sheen, S. H.; Chien, H. T.; Gopalsami, N.; Jendrzejczyk, A. & Raptis, A. C.
Partner: UNT Libraries Government Documents Department

Advanced Engine/Aftertreatment System R&D

Description: Navistar and ORNL established this CRADA to develop diesel engine aftertreatment configurations and control strategies that could meet emissions regulations while maintaining or improving vehicle efficiency. The early years of the project focused on reducing the fuel penalty associated with lean NOx trap (LNT, also known as NOx adsorber catalyst) regeneration and desulfation. While Navistar pursued engine-based (in-cylinder) approaches to LNT regeneration, complementary experiments at ORNL focused on in-exhaust fuel injection. ORNL developed a PC-based controller for transient electronic control of EGR valve position, intake throttle position, and actuation of fuel injectors in the exhaust system of a Navistar engine installed at Oak Ridge. Aftertreatment systems consisting of different diesel oxidation catalysts (DOCs) in conjunction with a diesel particle filter and LNT were evaluated under quasi-steady-state conditions. Hydrocarbon (HC) species were measured at multiple locations in the exhaust system with Gas chromatograph mass spectrometry (GC-MS) and Fourier transform infrared (FTIR) spectroscopy.
Date: September 30, 2011
Creator: Pihl, J.; West, B.; Toops, T.; Adelman, B. (Navistar, Inc.) & Derybowski, E. (Navistar, Inc.)
Partner: UNT Libraries Government Documents Department

Materials for High-Pressure Fuel Injection Systems

Description: The high-level goal of this multi-year effort was to facilitate the Advanced Combustion Engine goal of 20% improvement (compared to 2009 baseline) of commercial engine efficiency by 2015. A sub-goal is to increase the reliability of diesel fuel injectors by investigating modelbased scenarios that cannot be achieved by empirical, trial and error methodologies alone. During this three-year project, ORNL developed the methodology to evaluate origins and to record the initiation and propagation of fatigue cracks emanating from holes that were electrodischarge machined (EDM), the method used to form spray holes in fuel injector tips. Both x-ray and neutron-based methods for measuring residual stress at four different research facilities were evaluated to determine which, if any, was most applicable to the fuel injector tip geometry. Owing to the shape and small volumes of material involved in the sack area, residual stress data could only be obtained in the walls of the nozzle a few millimeters back from the tip, and there was a hint of only a small compressive stress. This result was consistent with prior studies by Caterpillar. Residual stress studies were suspended after the second year, reserving the possibility of pursuing this in the future, if and when methodology suitable for injector sacks becomes available. The smooth specimen fatigue behavior of current fuel injector steel materials was evaluated and displayed a dual mode initiation behavior. At high stresses, cracks started at machining flaws in the surface; however, below a critical threshold stress of approximately 800 MPa, cracks initiated in the bulk microstructure, below the surface. This suggests that for the next generation for high-pressure fuel injector nozzles, it becomes increasingly important to control the machining and finishing processes, especially if the stress in the tip approaches or exceeds that threshold level. Fatigue tests were also conducted using EDM notches ...
Date: September 30, 2011
Creator: Blau, P.; Shyam, A.; Hubbard, C.; Howe, J.; Trejo, R.; Yang, N. (Caterpillar, Inc. Technical Center) et al.
Partner: UNT Libraries Government Documents Department