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Over several years, a fuel economy test measurement technique has been developed to highlight the magnitude of benefits expected in real world applications of different heavy-duty vehicle (HDV) engine oils in an operating vehicle. This method provides discriminatory results using an alternative to the widely used gravimetric fuel measurement methodology of Brake Specific Fuel Consumption (BSFC), in order to measure gains of <2% in a more repeatable manner. For the results to prove meaningful to the wider commercial audience, such as vehicle operators, original equipment manufacturers and oil providers, the systemic test vehicle operating conditions need to closely represent on-road conditions experienced on a daily basis by long haul, heavy duty diesel vehicles. This paper describes the parameters, necessary measures and methodologies required to record real world data and create representative proving ground test cycles.

Neutron diffraction is a powerful tool that can be used to identify the phases present and to measure the spacing of the atomic planes in a material. Thus, the residual stresses can be determined within a component and/or the phases present. New intercritically austempered irons rely on the unique properties of the austenite phase present in their microstructures. If these materials are to see widespread use, methods to verify the quality (behavior consistency) of these materials and to provide guidance for further optimization will be needed. Neutron diffraction studies were performed at the second generation neutron residual stress facility (NRSF2) at the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory on a variety of intercritically austempered irons. For similar materials, such as TRIP steels, the strengthening mechanism involves the transformation of metastable austenite to martensite during deformation.

The Friction Stir Spot Welding (FSSW) process is a derivative of the friction stir welding (FSW) process, without lateral movement of the tool during the welding process. It has been applied in the production of aluminum joining for various Mazda and Toyota vehicles. Most of the applications and published studies were concentrated in aluminum sheet in the range of 1.0 to 1.5 mm, suitable for non-structural automotive closure applications. The objective of this study is to study the feasibility of FSSW process for automotive structural aluminum joining, up to 3 mm in thickness, for potentially replacement of self-piercing rivets (SPR) process. Joining thicker aluminum with FSSW tooling with a typical smooth concave shoulder and threaded probing pin, requires long process time, which would not be appropriate in mass-production automotive body construction. In this paper, an innovative FSSW tool with grooved shoulder was developed.

We report experimental observations of cyclic combustion variability during the transition between propagating flame combustion and homogeneous charge compression ignition (HCCI) in a single-cylinder, stoichiometrically fueled, spark-assisted gasoline engine. The level of internal EGR was controlled with variable valve actuation (VVA), and HCCI combustion was achieved at high levels of internal EGR using the VVA system. Spark-ignition was used for conventional combustion and was optionally available during HCCI. The transition region between purely propagating combustion and HCCI was mapped at multiple engine speeds and loads by incrementally adjusting the internal EGR level and capturing data for 2800 sequential cycles. These measurements revealed a complex sequence of high COV, cyclic combustion variations when operating between the propagating flame and HCCI limits.

Forty-nine plant-wide energy efficiency assessments have been undertaken under sponsorship of the U.S. Department of Energy's Industrial Technologies Program. Plant-wide assessments are comprehensive, systematic investigations of plant energy efficiency, including plant utility systems and process operations. Assessments in industrial facilities have highlighted opportunities for implementing best practices in industrial energy management, including the adoption of new, energy-efficient technologies and process and equipment improvements. Total annual savings opportunities of $201 million have been identified from the 40 completed assessments. Many of the participating industrial plants have implemented efficiency-improvement projects and already have realized total cost savings of more than $81 million annually. This paper provides an overview of the assessment efforts undertaken and presents a summary of the major energy and cost savings identified to date.

This study describes the use of Quantitative Structure Activity Relationships (QSAR) to develop predictive models for non-acidic Lubricity agents. The work demonstrates the importance of separating certain chemical families to give better and more robust equations rather than grouping a whole data set together. These models can then be used as important tools in further development work by predicting activities of new compounds before actual synthesis/testing.

Microstructures and failure mechanisms of spot friction welds (SFW) in aluminum 5754 lap-shear specimens were investigated. In order to study the effect of tool geometry on the joint strength of spot friction welds, a concave tool and a flat tool were used. In order to understand the effect of tool penetration depth on the joint strength, spot friction welds were prepared with two different penetration depths for each tool. The results indicated that the concave tool produced slightly higher joint strength than the flat tool. The joint strength did not change for the two depths for the flat tool whereas the joint strength slightly increases as the penetration depth increases for the concave tool. The experimental results show that the failure mechanism is necking and shearing for the spot friction welds made by both tools. The failure was initiated and fractured through the upper sheet under the shoulder indentation near the crack tip.

Oak Ridge National Laboratory's (ORNL) computer code PMM_IDT (Permanent Magnet Motor Interactive Design Tool) was used to study the sensitivity to changes in design parameters at constant power output and scaling laws for similar designs with different rated power outputs. The base design used was a radial-gap motor with 30 kW of net output characteristic of the PNGV “Series” vehicles. Sensitivity parameters studied were active length, magnet and air gap thicknesses, and number of magnets. Power output variation approaches considered were active length, stator external diameter, and rotor external diameter. The impact on efficiency, cost, weight, specific power, cooling requirements, drive current and voltage requirements, and demagnetization margins are presented. Common constraints in this study are: Hollow rotor, trapezoidal back emf - 212 V maximum - and double layer winding leading to an even number of turns per slot

The HTML (High Temperature Materials Laboratory) is a U.S. Department of Energy User Facility, offering opportunities for in-depth characterization of advanced materials, specializing in high-temperature-capable structural ceramics. Available are electron microscopy for micro-structural and microchemical analysis, equipment for measurement of the thermophysical and mechanical properties of ceramics to elevated temperatures, X-ray and neutron diffraction for structure and residual stress analysis, and high speed grinding machines with capability for measurement of component shape, tolerances, surface finish, and friction and wear properties. This presentation will focus on structural materials characterization, illustrated with examples of work performed on heat engine materials such as silicon nitride, industrial refractories, metal-and ceramic-matrix composites, and structural alloys.

Multigrade automotive lubricants contain polymeric viscosity modifiers which enable the oil to provide adequate hydrodynamic lubrication at high temperatures and good starting/pumping performance at low temperatures. Under operating conditions in engines, transmissions and gear boxes, polymeric additives undergo both temporary and permanent viscosity loss. The former is caused by flow orientation and the latter by molecular chain scission. Whatever the mechanism, original equipment manufacturers are interested in maintaining a minimum level of hydrodynamic viscosity from oil change to oil change. This is often expressed as a “stay-in-grade” requirement. Commercial viscosity modifiers (VM) span a wide range of chemistries and molecular architectures.

All automotive gear oils must satisfy a series of standard industry or Original Equipment Manufacturer (OEM) tests. These usually include bench, axle dynamometer, and field tests. However, product development testing must extend beyond satisfying standard test protocols. This is especially true as increased emphasis is placed on extending oil drain intervals and increasing equipment life in the face of greater performance demands through new heavy-duty vehicle designs. End-users ultimately benefit from extended oil drain intervals and increased equipment life. However, the effort to achieve both initiatives will prove successful only through careful development and selection of the proper performance additives and base fluids. Also, a broad focus must be maintained to satisfy all lubricant requirements. These requirements build on a solid base of standard features and include new features that stretch the current envelope of gear oil performance.

Increased awareness of preserving the environment has motivated the development of a wide variety of environmentally compatible products. Such products include environmentally compatible lubricants. Sale and use of these types of lubricants illustrates diligence by the lubricant manufacturer, original equipment manufacturer (OEM), and the consumer in contributing to a cleaner environment. The use of this type of lubricant could enhance the image of the lubricant manufacturer and vendor as well as the equipment manufacturer who employs such a fluid. To base such a lubricant on a vegetable oil creates a product environmentally friendly by its farming origin and its ability to readily biodegrade if released. No machinery is so uniquely suited to using vegetable oil based lubricants as agricultural equipment. Since this equipment is particularly close to the environment, the lubricant can easily come in contact with the soil, ground water, and crops.

A new field test procedure for evaluation of the sludge formation tendencies of lubricants has been developed. The procedure has the benefits of short running time, reduced variability, and dramatic separation of API SF vs API SG oils. This paper discusses development of the operational procedure and evaluation of four lubricants, including commercial-type API SF and API SG oils as well as experimental future oils. Significantly improved sludge ratings were obtained with an experimental API SG oil. The sludge formation process was studied using infrared spectroscopy, TAN, dielectric measurements, viscosity, quasielastic light scattering particle size, and transmission electron microscopy techniques. These analyses show production of contaminants which form insoluble particles that build up and precipitate out of suspension as sludge. Certain drain analyses can be used as tools for predicting field sludge deposition time.