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The U.S. Environmental Protection Agency (EPA) contracted with FEV, Inc. to estimate the per-vehicle cost of employing selected advanced efficiency-improving technologies in light-duty motor vehicles. The development of transparent, reliable cost analyses that are accessible to all interested stakeholders has played a crucial role in establishing feasible and cost effective standards to improve fuel economy and reduce greenhouse gas (GHG) emissions. The FEV team, together with engineering staff from EPA's National Vehicle and Fuel Emissions Laboratory, and FEV's subcontractor, Munro & Associates, developed a robust costing methodology based on tearing down, to the piece part level, relevant systems, sub-systems, and assemblies from vehicles ?with and without? the technologies being evaluated.

Biofuel usage is increasingly expanding thanks to its significant contribution to a well-to-wheel (WTW) reduction of greenhouse gas (GHG) emissions. In addition, stringent emission standards make mandatory the use of Diesel Particulate Filter (DPF) for the particulate emissions control. The different physical properties and chemical composition of biofuels impact the overall engine behaviour. In particular, the PM emissions and the related DPF regeneration strategy are clearly affected by biofuel usage due mainly to its higher oxygen content and lower low heating value (LHV). More specifically, the PM emissions and the related DPF regeneration strategy are clearly affected by biofuel usage due mainly to its higher oxygen content and lower low heating value, respectively. The particle emissions, in fact, are lower mainly because of the higher oxygen content. Subsequently less frequent regenerations are required.

All internal combustion piston engines emit solid nanoparticles. Some are soot particles resulting from incomplete combustion of fuels, or lube oil. Some particles are metal compounds, most probably metal oxides. A major source of metal compound particles is engine abrasion. The lube oil transports these abraded particles into the combustion zone. There they are partially vaporized and ultrafine oxide particles formed through nucleation [1]. Other sources are the metallic additives to the lube oil, metallic additives in the fuel, and debris from the catalytic coatings in the exhaust-gas emission control devices. The formation process results in extremely fine particles, typically smaller than 50 nm. Thus they intrude through the alveolar membranes directly into the human organism. The consequent health risk necessitates a careful investigation of these emissions and effective curtailment.

A 2007 Cummins ISL 8.9L direct-injection common rail diesel engine rated at 272 kW (365 hp) was used to load the filter to 2.2 g/L and passively oxidize particulate matter (PM) within a 2007 OEM aftertreatment system consisting of a diesel oxidation catalyst (DOC) and catalyzed particulate filter (CPF). Having a better understanding of the passive NO2 oxidation kinetics of PM within the CPF allows for reducing the frequency of active regenerations (hydrocarbon injection) and the associated fuel penalties. Being able to model the passive oxidation of accumulated PM in the CPF is critical to creating accurate state estimation strategies. The MTU 1-D CPF model will be used to simulate data collected from this study to examine differences in the PM oxidation kinetics when soy methyl ester (SME) biodiesel is used as the source of fuel for the engine.

In order to extend the CAI operation range in 4-stroke mode and maximize the benefit of low fuel consumption and emissions in CAI mode, 2-stroke CAI combustion is revived operating in a GDI engine with poppet valves, where the conventional crankcase scavenging is replaced by boosted scavenging. The CAI combustion is achieved through the inherence of the 2-Stroke operation, which is retaining residual gas. A set of flexible hydraulic valve train was installed on the engine to vary the residual gas fraction under the boosting condition. The effects of spark timing, intake pressure and short-circuiting on 2-stroke CAI combustion and its emissions are investigated and discussed in this paper. Results show the engine could be controlled to achieve CAI operation over a wide range of engine speed and load in the 2-stroke mode because of the flexibility of the electro-hydraulic valvetrain system. Presenter Yan Zhang, Brunel University

High-load HCCI combustion has recently been demonstrated with conventional gasoline using intake pressure boosting. The key is to control the high combustion heat release rates (HRR) by using combustion timing retard and mixture stratification. However, at naturally aspirated and moderately boosted conditions, these techniques did not work well due to the low autoignition reactivity of conventional gasoline at these conditions. This work studies a low-octane distillate fuel with similar volatility to gasoline, termed Hydrobate, for its potential in HCCI engine combustion at naturally aspirated and low-range boosted conditions. The HCCI combustion with fully premixed and partially stratified charges was examined at intake pressures (Pin) from 100 to 180 kPa and constant intake temperature (60�C) and engine speed (1200 rpm).

This paper presents the first results of an experimental study into a hybrid combustion concept for next-generation heavy-duty diesel engines. In this hybrid concept, at low load operating conditions, the engine is run in Pre-mixed Charge Compression Ignition (PCCI) mode, whereas at high load conventional CI combustion is applied. This study was done with standard diesel fuel on a flexible multi-cylinder heavy-duty test platform. This platform is based on a 12.9 liter, 390 kW heavy-duty diesel engine that is equipped with a combination of a supercharger, a two-stage turbocharging system and low-pressure and high-pressure EGR circuitry. Furthermore, Variable Valve Actuation (VVA) hardware is installed to have sufficient control authority. Dedicated pistons, injector nozzles and VVA cam were selected to enable PCCI combustion for a late DI injection strategy, free of wall-wetting problems.

This paper reports results of an experimental investigation performed on a commercial diesel engine supplied with fuel blends having low cetane number to attain a simultaneous reduction in NOx and smoke emissions. Blends of 20% and 40% of n-butanol in conventional diesel fuel have been tested, comparing engine performance and emissions to diesel ones. Taking advantage of the fuel blend higher resistance to auto ignition, it was possible to extend the range in which a premixed combustion is achieved. This allowed to match the goal of a significant reduction in emissions without important penalties in fuel consumption. The experimental activity was carried on a turbocharged, water cooled, 4 cylinder common rail DI diesel engine. The engine equipment included an exhaust gas recirculation system controlled by an external driver, a piezo-quartz pressure transducer to detect the in-cylinder pressure signal and a current probe to acquire the energizing current to the injector.

Four-way, integrated, diesel emission control systems that combine selective catalytic reduction for NOx control with a continuously regenerating trap to remove diesel particulate matter were evaluated under real-world, on-road conditions. Tests were conducted using a semi-tractor with an emissions year 2000, 6-cylinder, 12 L, Volvo engine rated at 287 kW at 1800 rpm and 1964 N-m. The emission control system was certified for retrofit application on-highway trucks, model years 1994 through 2002, with 4-stroke, 186-373 kW (250-500 hp) heavy-duty diesel engines without exhaust gas recirculation. The evaluations were unique because the mobile laboratory platform enabled evaluation under real-world exhaust plume dilution conditions as opposed to laboratory dilution conditions. Real-time plume measurements for NOx, particle number concentration and size distribution were made and emission control performance was evaluated on-road.

The combination of advanced combustion with advanced selective catalytic reduction (SCR) catalyst formulations was studied in the work presented here to determine the impact of the unique hydrocarbon (HC) emissions from premixed charge compression ignition (PCCI) combustion on SCR performance. Catalyst core samples cut from full size commercial Fe- and Cu-zeolite SCR catalysts were exposed to a slipstream of raw engine exhaust from a 1.9-liter 4-cylinder diesel engine operating in conventional and PCCI combustion modes. The zeolites which form the basis of these catalysts are different with the Cu-based catalyst made on a chabazite zeolite which las smaller pore structures relative to the Fe-based catalyst. Subsequent to exposure, bench flow reactor characterization of performance and hydrocarbon release and oxidation enabled evaluation of overall impacts from the engine exhaust.

Manganese oxides show high catalytic activity for CO and HC oxidation without including platinum group metals (PGM). However, there are issues with both thermal stability and resistance to sulfur poisoning. We have studied perovskite-type YMnO3 (YMO) with the aim of simultaneously achieving both activity and durability. This paper describes the oxidation activity of PGM-free Ag/i-YMO, which is silver supported on improved-YMO (i-YMO). The Ag/i-YMO was obtained by the following two methods. First, Mn4+ ratio and specific surface area of YMO were increased by optimizing composition and preparation method. Second, the optimum amount of silver was supported on i-YMO. In model gas tests and engine bench tests, the Ag/i-YMO catalyst showed the same level of activity as that of the conventional Pt/?-Al2O3 (Pt = 3.0 g/L). In addition, there was no degradation with respect to either heat treatment (700°C, 90 h, air) or sulfur treatment (600°C to 200°C, total 60 h, 30 ppm SO2).

This paper presents a new concept for a 100% plastic prototype automotive door panel. This concept has the potential of providing a weight reduction of up to 40% compared to conventional steel door panels, but with equivalent performance (static strength). This innovative technology can be used for a variety of exterior automotive parts. The concept includes a composite sandwich panel combination of GFRP (glass fiber reinforced polymer), and LACTIF®, which is expanded beads foam made from PLA (polylactic acid) and developed by JSP Corporation. This GFRP+LACTIF® composite design offers the following characteristics: Excellent environmental resistance Strong adhesion Equivalent static strength (vs. conventional door panels) Design flexibility This concept also offers an alternative to conventional steel door panel systems by using unsaturated polyester material of plant origin as part of the GFRP composite.

TERBAN® hydrogenated nitrile rubber (HNBR) is a specialty elastomer used in demanding engineering applications such as the automotive, heavy duty, and industrial markets. It has excellent combination of heat, oil and abrasion resistance in addition to its high mechanical strength, very good dynamic and sealing properties. This paper will present data on aging HNBR for five thousand hours in an aggressive and un-stabilized B30A biodiesel fuel blend (70% ULSD, 30% SME, and an aggressive additive package) and explore the effect of HNBR polymer properties and vulcanizate composition on the performance in such fuel blends. Presenter Victor Nasreddine

The need for light-weighting of automotive structures has spurred on a tremendous amount of interest in and development of low cost carbon fiber composite materials and manufacturing. This presentation provides a description of the commercial carbon fiber concept compared to traditional aerospace and specialty carbon fiber products. A specific update is presented on the development and commercialization of new low cost carbon fiber based on lignin / PAN precursor technology. The second focus of the presentation is on carbon fiber composite manufacturing processes, including carbon SMC, RTM, prepregs, and thermoplastic processes. Advantages and disadvantages of these processes are discussed, especially related to low cost manufacturing. Presenter George Husman, Zoltek Companies Inc.

Composite bearings of PTFE as the base material have been widely used for automotive parts. However, in recent years, due to downsizing, faster sliding speeds, and tendency to increase the bearing load with high performance, particularly for boundary lubrication conditions, the PTFE-based composite bearing is often worn, making it difficult to apply to some applications. A high strength polymer was selected as an alternative to PTFE base material, and the mechanical properties and performance in a start-stop test, reciprocating sliding test and seizure test were evaluated. Focusing on the characteristics of high strength, by applying a PEEK resin, in each evaluation, it was confirmed that superior performance was achieved compared with a conventional PTFE based composite bearing. Presenter Yohei Takada, Daido Metal Co., Ltd.

Exatec� PC glazing technology team, has developed advanced weathering and abrasion resistant coatings technology that can be applied to protect polycarbonate. It is of particular interest to quantify and understand the factors that determine the surface abrasion performance of coated PC in rear window and backlight applications that have a wiper system. In the present study we describe Exatec's lab scale wiper testing equipment and test protocols. We also describe adaptation of optical imaging system to measure contrast and nano-profiling using nano-indenter, as post wiper surface characterization methods. These methods are more sensitive to fine scratches on glazing surface than standard haze measurement and mechanical profilometry. Three coating systems were investigated; Siloxane wetcoat (A), Siloxane wetcoat (B), and Siloxane wetcoat (B) plus plasma coat (Exatec� E900 coating). The performance comparisons were made using all these surface characterization methods.

The copper-rotor induction-motor made its debut in automotive electric traction in 1990 in GM's Impact EV. Since then, this motor architecture has covered millions of miles on other vehicle platforms which will soon include Toyota's RAV4-EV. With the industry's attention focused on cost-effective alternatives to permanent-magnet traction motors, the induction motor has returned to the spotlight. This talk will overview where the copper-rotor induction-motor is today, how the technology has evolved since the days of the GM Impact, the state-of-play in its mass-manufacturing processes and today's major supply-chain players. Presenter Malcolm Burwell, International Copper Association Inc.

For internal combustion engines and industrial machinery, it is well recognized that the most cost-effective way of reducing energy consumption and extending service life is through lubricant development. This presentation summarizes our recent R&D achievements on developing a new class of candidate lubricants or oil additives ionic liquids (ILs). Features of ILs making them attractive for lubrication include high thermal stability, low vapor pressure, non-flammability, and intrinsic high polarity. When used as neat lubricants, selected ILs demonstrated lower friction under elastohydrodynamic lubrication and less wear at boundary lubrication benchmarked against fully-formulated engine oils in our bench tests. More encouragingly, a group of non-corrosive, oil-miscible ILs has recently been developed and demonstrated multiple additive functionalities including anti-wear and friction modifier when blended into hydrocarbon base oils.

This presentation will cover an overview of challenges and key discussion points for advanced electric motor and drive testing . Voiko will visit some examples of how D&V approaches these issues and also some suggestions for how the industry can view these intriguing problems as opportunities. The presentation will also delve into current testing developments that involve resolver, load bank and power measurement devices by highlighting solutions in the market today. There will also be a cursory look into the future of electric motor testing and what we can expect in the near term. Presenter Voiko Loukanov, D&V Electronics Limited

Trans Tech recently debuted the all-electric eTrans school bus providing a total zero emission school bus. The presentation will demonstrate Smith Electric Vehicles and their history with electric vehicles. The presentation will help ensure that everybody has an idea of what the electric school bus will do and to dispel any rumors about the vehicle. Presenter Brian S. Barrington, Trans Tech. Bus