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Industries related to automotive manufacturing and its supply chain play a key role in leaving a carbon footprint during an automobile's life cycle. Per the report from Lawrence Berkeley National Laboratory (LBNL) in March, 2008 [1], “motor vehicle industry in the U.S. spends about $3.6 billion on energy annually.” The proposed research will focus on energy savings opportunities in automotive manufacturing and its supplier network. The US Department of Energy (DOE) funds 24 Industrial Assessment Centers (IAC) throughout the U.S. that conduct energy assessments at many of these facilities. The results of these assessments are summarized in a database maintained by Rutgers University which acts as the central management body for all the IACs. This research will present key concepts summarized from this database.

Automotive industries in the US and around the world have enormous impact on the economy of each country. Not just the major vehicle manufacturer, but all the other companies in the supply chain are equally important. This was evident with the earthquake and Tsunami that happened in March 2011. Because of the massive destruction at suppliers' facilities, the automakers in the US and other countries struggled to get the necessary parts and supplies. This created a ripple effect throughout the world and led to the closure of several automakers' facilities for a long time. Thus, the automotive supply chains are as important as the main automotive manufacturing facilities. Since these suppliers produce a lot of parts and supplies, the corresponding energy usage is also significant. The current research is focused on compressed air and process heating system analysis at one of the automotive parts manufacturer in Mexico.

In the case of advanced light weight material applications, the design of such components, in many cases, are based on applied surface tractions These surface loads can be caused by various means. When wind effects are present these tractions can be due to pressure, suction or drag. In the case of underwater applications, hydrostatic pressure and friction caused by moving against water current needs to be considered in the design. These are some of the traction load applications, a design engineer has to deal with in his advanced material applications. In contrast to the conventional materials, the modern structures made of highly directional dependent material properties, respond the applied loads and environment in an unpredicted way, so that, a detail analysis and design is always necessary. Hence in the present study a higher-order shear deformation formulation is developed to calculate the distribution of stresses accurately in angle-ply laminated shells of revolution.

The need to assess the effect of exhaust gas emissions from heavy duty vehicles (buses and trucks) on emission inventories is urgent. Exhaust gas emissions measured during the fuel economy measurement test procedures that are used in different countries sometimes do not represent the in-use vehicle emissions. Since both local and imported vehicles are running on the roads, it is thought that studying the testing cycles of the major vehicle manufacturer countries is worthy. Standard vehicle testing cycles on chassis dynamometer from the United States, Canada, European Community Market, and Japan1 are considered in this study. Each of the tested cycles is categorized as either actual or synthesized cycle and its representativness of the observed driving patterns is investigated. A total of fourteen parameters are chosen to characterize any given driving cycle and the cycles under investigation were compared using these parameters.

The emissions reduction benefits of Fischer-Tropsch (FT) diesel fuel have been shown in several recent published studies in both engine testing and in-use vehicle testing. FT diesel fuel shows significant advantages in reducing regulated engine emissions over conventional diesel fuel primarily to: its zero sulfur specification, implying reduced particulate matter (PM) emissions, its relatively lower aromaticity, and its relatively high cetane rating. However, the actual effect of FT diesel formulation on the in-cylinder combustion characteristics of unmodified modern heavy-duty diesel engines is not well documented. As a result, a Navistar T444E (V8, 7.3 liter) engine, instrumented for in-cylinder pressure measurement, was installed on an engine dynamometer and subjected to steady-state emissions measurement using both conventional Federal low sulfur pump diesel and a natural gas-derived FT fuel.

Heavy duty tractor-trailers under freeway operations consume about 65% of the total engine shaft energy to overcome aerodynamic drag force. Vehicles are exposed to on-road crosswinds which cause change in pressure distribution with a relative wind speed and yaw angle. The objective of this study was to analyze the drag losses as a function of on-road wind conditions, on-road vehicle position and trajectory. Using coefficient of drag (CD) data available from a study conducted at NASA Ames, Geographical Information Systems model, time-varying weather data and road data, a generic model was built to identify the yaw angles and the relative magnitude of wind speed on a given route over a given time period. A region-based analysis was conducted for a study on interstate trucking operation by employing I-79 running through West Virginia as a case study by initiating a run starting at 12am, 03/03/2012 out to 12am, 03/05/2012.

Natural gas (NG) is an alternative fuel for spark-ignition engines. In addition to its cleaner combustion, recent breakthroughs in drilling technologies increased its availability and lowered its cost. NG consists of mostly methane, but it also contains heavier hydrocarbons and inert diluents, the levels of which vary substantially with geographical source, time of the year and treatments applied during production or transportation. To investigate the effects of NG composition on engine performance and emissions, a 3D CFD model of a heavy-duty diesel engine retrofitted to NG spark ignition simulated lean-combustion engine operation at low speed and medium load conditions. The work investigated three NG blends with similar lower heating value (i.e., similar energy density) but different Methane Number (MN). The results indicated that a lower MN increased flame propagation speed and thus increased in-cylinder pressure and indicated mean effective pressure.