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Electric vehicles (EVs) are becoming increasingly recognized as an effective solution in the battle against climate change and reducing greenhouse gas emissions. Lithium-ion batteries have become the standard for energy storage in the automobile industry, widely used in EVs due to their superior characteristics compared to other batteries. The growing popularity of the Vehicle-to-grid (V2G) concept can be attributed to its surplus energy storage capacity, positive environmental impact, and the reliability and stability of the power grid. However, the increased utilization of the battery through these integrations can result in faster degradation and the need for replacement. As batteries are one of the most expensive components of EVs, the decision to deploy an EV in V2G operations may be uncertain due to the concerns of battery degradation from the owner’s perspective.

Thermal barrier coatings (TBCs) have long been studied as a potential pathway to achieve higher thermal efficiency in spark ignition engines. Researchers have studied coatings with different thicknesses and thermophysical properties to counteract the volumetric efficiency penalty associated with TBCs in spark ignition. To achieve an efficiency benefit with minimal charge heating during the intake stroke, low thermal inertia coatings characterized by their larger temperature swings are required. To study the impact of low thermal inertia coatings in spark ignition, coatings were applied to the cylinder head, piston crown, intake and exhaust valve faces, and intake and exhaust valve backsides. Tier III EEE E10 certification gasoline was used to keep the experiments relevant to the present on-road vehicles. This study is aimed at analyzing durability of the coatings as well as efficiency and emissions improvements.

Rotary valve technology can provide increased flow area and higher discharge coefficients than conventional poppet valves for internal combustion engines. This increase in intake charging efficiency can improve the power density of four-stroke internal combustion engines, particularly at high engine speeds, where flow is choked through conventional poppet valves. In this work, the valvetrain of a light duty single cylinder spark ignition engine was replaced with a rotary valve train. The impact of this valvetrain conversion on performance and emissions was evaluated by comparing spark timing sweeps with lambda ranging from 0.8 to 1.1 at wide open throttle. The results indicated that the rotary valvetrain increased the amount of air trapped at intake valve closing and resulted in a significantly faster burn duration than the conventional valvetrain.

Catalytic converters, which are commonly used for after-treatment in SI engines, exhibit poor performance at lower temperatures. This is one of the main reasons that tailpipe emissions drastically increase during cold-start periods. Thermal inertia of turbocharger casing prolongs the catalyst warm-up time. Exhaust enthalpy management becomes crucial for a turbocharged direct injection spark ignition (DISI) engine during cold-start periods to quickly heat the catalyst and minimize cold-start emissions. Thermal barrier coatings (TBCs), because of their low thermal inertia, reach higher surface temperatures faster than metal walls, thereby blocking heat transfer and saving enthalpy for the catalyst. The TBCs applied on surfaces that exchange heat with exhaust gases can increase the enthalpy available for the catalyst warm-up.

Renewable fuels, such as the alcohols, ammonia, and hydrogen, have a high autoignition resistance. Therefore, to enable these fuels in compression ignition, some modifications to existing engine architectures is required, including increasing compression ratio, adding insulation, and/or using hot internal residuals. The opposed-piston two-stroke (OP2S) engine architecture is unique in that, unlike conventional four-stroke engines, the OP2S can control the amount of trapped residuals over a wide range through its scavenging process. As such, the OP2S engine architecture is well suited to achieve compression ignition of high autoignition resistance fuels. In this work, compression ignition with wet ethanol 80 (80% ethanol, 20% water by mass) on a 3-cylinder OP2S engine is experimentally demonstrated. A load sweep is performed from idle to nearly full load of the engine, with comparisons made to diesel at each operating condition.

Spark ignition knock is highly sensitive to changes in intake air temperature. Hot surface temperatures due to ceramic thermal barrier coatings increase knock propensity by elevating the incoming air temperature, thus mitigating the positive impacts of low heat transfer losses by requiring spark retard to avoid knock. Low thermal inertia coatings (i.e. Temperature swing coatings) have been proposed as a means of reducing or eliminating the open cycle charge heating penalty of traditional TBCs through a combination of low thermal conductivity and low volumetric heat capacity materials. However, in order to achieve a meaningful gain in efficiency, a significant fraction of the combustion chamber must be coated. In this study, a coated piston and intake and exhaust valves with coated combustion faces, backsides, and stems are installed in a single-cylinder research engine to evaluate the effect of high coated fractions of the combustion chamber in a knock-sensitive architecture.

Multi-material design is one of the trending methods for automakers to achieve lightweighting cost-efficiently and meet stringent regulations and fuel efficiency concerns. Motivated by this trend, the hybrid single-shot (HSS) process has been recently introduced to manufacture thermoset-thermoplastic composites in one single integrated operation. Although this integration is beneficial in terms of reducing the cycle time, production cost, and manufacturing limitations associated with such hybrid structures, it increases the process complexity due to the simultaneous filling, forming, curing, and bonding actions occurring during the process. To overcome this complexity and have a better understanding on the interaction of these physical events, a quick yet accurate simulation of the HSS process based on an experimentally calibrated numerical approach is presented here to elucidate the effect of different process settings on the final geometry of the hybrid part.

Diesel engine exhaust poses an ongoing threat to human health as well as to the environment. Automotive exhaust treatment systems have been developed over the years to reduce the large amount of diesel particulate matter (DPM) released to the atmosphere. Current systems can be categorized as selective catalytic reduction, catalytic converters, and diesel particulate filters. This study presents an emission system that focuses on the removal of exhaust particles using Brownian diffusion of DPM toward fog drops followed by cyclonic separation of DPM rich fog drops. The experimental system consisted of a 13.2 kW diesel engine, heat exchanger to cool the exhaust to saturation temperature, ultrasonic fogger, cyclone separator, and recovery of waste particulate. Representative emission tests have been performed at five different diesel engine speeds and corresponding crankshaft loads.

Compared to traditional materials, carbon fiber reinforced polymers (CRFPs) have allowed designers to design stiff, light-weight structures, but at the cost of increased complexity in the design process. In this paper, the automation and optimization of the composite design process and how it affects design space exploration are evaluated. Specifically investigated is the design process for CFRP sandwich structures using the third-party optimization software modeFRONTIER. For given surface geometry and load cases, the approach aims to explore the Pareto frontier for the minimization of mass while constraining stiffness parameters. In this approach, the problem is framed as a single integrated optimization problem. In each optimization iteration, this method updates the CAD geometry and discretization of plies across the structure before exporting the model for Finite Element Analysis (FEA).

Vehicle lightweighting has been a constant theme of research at numerous Original Equipment Manufacturers (OEM’s) as it provides one of the best opportunities for improving fuel efficiency. In this regard, the Department of Energy (DOE) Vehicle Technology Office set a challenge to lightweight a fully assembled driver’s side front door by at least 42.5% with the cost constraint of a maximum $5 increase for every pound saved. A baseline door of an OEM’s 2014 mid-size SUV was selected, and an integrated design, analysis, and optimization approach was implemented to meet this goal. The ultra-lightweight door design had to meet or exceed the fit & function and mechanical performance (static and dynamic) of the baseline door while being suitable for mass production. The design strategy involved parts consolidation, and multi-material distribution to enable mass reduction without compromising the fit and functional requirements.

The US Code of Federal Regulations (CFR) Title 40 Part 1065 and 1066 require gravimetric determination of automobile Particulate Matter (PM) collected onto filter media from the diluted exhaust. PM is traditionally collected under simulated driving conditions in a laboratory from a full flow Constant Volume Sampler (CVS) system, where the total engine exhaust is diluted by HEPA filtered air. This conventional sampling and measurement practice is facing challenges in accurately quantifying PM at the upcoming 2025-2028 CARB LEVIII 1 mg/mi PM emissions standards. On the other hand, sampling a large amount of PM emitted from large size high power engines introduces additional challenges. Applying flow weighting, adjusting the Dilution Ratio (DR) and Filter Face Velocity (FFV) are proposed options to overcome these challenges.

The ever-growing concern to reduce the impact of transportation systems on environment has pushed automotive industry towards fuel-efficient and sustainable solutions. While several approaches have been used to improve fuel efficiency, the light-weighting of automobile components has proven broadly effective. A substantial effort is devoted to lightweighting body-in-white which contributes ~35% of total weight of vehicle. Closure systems, however, have been often overlooked. Closure systems are extremely important as they account for ~ 50% of structural mass and have a very diverse range of requirements, including crash safety, durability, strength, fit, finish, NVH, and weather sealing. To this end, a carbon fiber-reinforced thermoplastic composite door is being designed for an OEM’s mid-size SUV, that enables 42.5% weight reduction. In this work, several novel composite door assembly designs were developed by using an integrated design, analysis and optimization approach.

In-cylinder surface temperature is of heightened importance for Homogeneous Charge Compression Ignition (HCCI) combustion since the combustion mechanism is thermo-kinetically driven. Thermal Barrier Coatings (TBCs) selectively manipulate the in-cylinder surface temperature, providing an avenue for improving thermal and combustion efficiency. A surface temperature swing during combustion/expansion reduces heat transfer losses, leading to more complete combustion and reduced emissions. At the same time, achieving a highly dynamic response sidesteps preheating of charge during intake and eliminates the volumetric efficiency penalty. The magnitude and temporal profile of the dynamic surface temperature swing is affected by the TBC material properties, thickness, morphology, engine speed, and heat flux from the combustion process. This study follows prior work of authors with Yttria Stabilized Zirconia, which systematically engineered coatings for HCCI combustion.

Spark-assisted compression ignition (SACI) leverages flame propagation to trigger autoignition in a controlled manner. The autoignition event is highly sensitive to several parameters, and thus, achieving SACI in production demands a high tolerance to variations in conditions. Limited research is available to quantify the combustion response of SACI to these variations. A simulation study is performed to establish trends, limits, and control implications for SACI combustion over a wide range of conditions. The operating space was evaluated with a detailed chemical kinetics model. Key findings were synthesized from these results and applied to a 1-D engine model. This model identified performance characteristics and potential actuator positions for a production-viable SACI engine. This study shows charge preparation is critical and can extend the low-load limit by strengthening flame propagation and the high-load limit by reducing ringing intensity.

Tensile behavior of advanced high strength steel (AHSS) grades with strengths up to 980 MPa has been extensively studied. However, limited data is found in literature on the tensile behavior of steels with tensile strengths of the order of 1180 MPa, especially at nominal strain rates up to 500/s. This paper examines tensile flow behavior to fracture of four different 1180 MPa grade steels at strain rates of 0.005/s, 0.5/s, 5/s, 50/s and 500/s using an experimental methodology that combines a servo-hydraulic tester and high speed digital image correlation. Even though the strength increase with the strain rate is consistent between the four different materials, the total elongation increase with the strain rate varies widely. Some insights as to why this occurs from examination of the steel microstructure and variation of retained austenite with strain are offered.

An experimental study was conducted on a Ricardo Hydra single-cylinder light-duty diesel research engine. Start of Injection (SOI) timing sweeps from -350 deg aTDC to -210 deg aTDC were performed on a total number of five pistons including two baseline metal pistons and three coated pistons to investigate the effects of thick thermal barrier coatings (TBCs) on the efficiency and emissions of low-temperature combustion (LTC). A fuel with a high latent heat of vaporization, wet ethanol, was chosen to eliminate the undesired effects of thick TBCs on volumetric efficiency. Additionally, the higher surface temperatures of the TBCs can be used to help vaporize the high heat of vaporization fuel and avoid excessive wall wetting. A specialized injector with a 60° included angle was used to target the fuel spray at the surface of the coated piston.

Automotive and truck manufacturers are introducing electric propulsion systems into their ground vehicles to reduce fossil fuel consumption and harmful tailpipe emissions. The mobility shift to electric motors requires a compact thermal management system that can accommodate heat dissipation demands with minimum energy consumption in a confined space. An innovative cooling system design, emphasizing passive cooling methods coupled with a small liquid system, using a thermal bus architecture has been explored. The laboratory experiment features an emulated electric motor interfaced to a thermal cradle and multiple heat rejection pathways to evaluate the transfer of generated heat to the ambient surroundings. The thermal response of passive (e.g., carbon fiber, high thermal conductivity material, thermosyphon) and active cooling systems are investigated for two operating scenarios.

Capacitance sensing is the technology that detects the presence of nearby objects by measuring the change in capacitance. A change in capacitance is triggered either by a change in dielectric constant, area of overlap or distance of separation between the electrodes of the capacitor. It is a technology that finds wide use in applications such as touch screens, proximity sensing etc. Drawing motivation from such applications, this paper investigates how capacitive sensing can be employed to detect the presence and posture of occupants inside vehicles. Compared to existing solutions, the proposed approach is low-cost, easy to deploy and highly efficient. The sensing system consists of a capacitance-sensing mat that is embedded with copper foils and an associated sensing circuitry. Inside the mat the foils are arranged in rows and columns to form several touch-nodes across the surface of the mat.

Fuel efficiency improvement in automobiles has been a topic of great interest over the past few years, especially with the introduction of the new CAFE 2025 standards. Although there are multiple ways of improving the fuel efficiency of an automobile, lightweighting is one of the most common approaches taken by many automotive manufacturers. Lightweighting is even more significant in electric vehicles as it directly affects the range of the vehicle. Amidst this context of lightweighting, the use of composite materials as alternatives to metals has been proven in the past to help achieve substantial weight reduction. The focus of using composites for weight reduction has however been typically limited to major structural components, such as BiW and closures, due to high material costs. Secondary structural components which contribute approximately 30% of the vehicle weight are usually neglected by these weight reduction studies.

Adiabatic heating during plastic straining can slow the diffusionless shear transformation of austenite to martensite in steels that exhibit transformation induced plasticity (TRIP). However, the extent to which the transformation is affected over a strain rate range of relevance to automotive stamping and vehicle impact events is unclear for most third-generation advanced high strength TRIP steels. In this study, an 1180MPa minimum tensile strength TRIP steel with carbide-free bainite is evaluated by measuring the variation of retained austenite volume fraction (RAVF) in fractured tensile specimens with position and strain. This requires a combination of servo-hydraulic load frame instrumented with high speed stereo digital image correlation for measurement of strains and ex-situ synchrotron x-ray diffraction for determination of RAVF in fractured tensile specimens.