Materials Technology - Overvie · 2015 Accomplishments Highlights Energy Materials ... Matured plasma oxidation technology reduces ... such as collision welding by vaporizing foil

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VEHICLE TECHNOLOGIES OFFICE

Materials Technology -OverviewJune 6, 2016

Felix Wu (Presenter)

Jerry GibbsCarol SchutteWill Joost Sara Ollila

22 | Vehicle Technologies Program

Outline

Vehicle Performance Metrics Why Lightweight Materials and Propulsion Materials? Materials Technology Program Portfolio Light- and Heavy-Duty Vehicle Roadmaps

Technology gaps Opportunities & Challenges

2015 Accomplishments Highlights Energy Materials Network Summary


Performance Metrics

Sub-Program Sub-Program Goal Baseline Metric (year)

Target Metric(year)

Battery Technology R&D

Developing the technologies necessary to reduce modeled high-volume battery costs. $289/kWh (2015) $125/kWh (2022)

Electric Drive Technologies R&D

Develop components and systems to reduce the modeled high-volume cost of electric drive systems.

$12/kW ($660/system)(2015)

$8/kW ($440/system)(2022)

Advanced CombustionEngine R&D

Increase light-duty engine efficiency to improve gasoline/diesel passenger car and light-truck fuel economy.

2009 35%/50% (2020)

Advanced CombustionEngine R&D

Increase heavy-duty engine efficiency to improve commercial vehicle fuel economy. 2009 30% (2020)

Materials Technology

Weight reduction for light-duty vehicles including body, chassis, and interior.

2012 30% (2022)

Fuel and Lubricant Technologies

Demonstrate fuel properties that enable an increase in the operating range of advanced combustion regimes to 90 percent coverage of non-idling portions of the city (UDDS) and highway (HWFET) light-duty Federal drive cycles.

2010 90% (2020)

4

Powertrain - 25%

Body Structure - 25% Glazing - 3%

Closures - 8%

Interiors -14%

Chassis & Suspension - 21%Other - 4%

Electrical, Fluids, etc.

Typical Weight DistributionBody Structures, Chassis, And Powertrain Provide Significant Opportunities

Materials Lightweighting: Broad Application

2015 Chevrolet Impala

Increasing Focus


Vehicle Weight Reduction

10

20

30

40

50

60

50% 100% 150% 200%

Fuel

Eco

nom

y (m

pg)

Percent of Baseline Vehicle Mass

Conventional ICE Hybrid/Electric Vehicles

86.0

88.0

90.0

92.0

94.0

96.0

98.0

100.0

94% 96% 98% 100%

Frei

ght E

ffici

ency

(Ton

-mile

s/ga

llon)

Percent of Baseline Vehicle Mass Without Cargo

Fixed Load Added Load

NREL 2011Ricardo Inc., 2009

6-8% improvement in fuel economy for 10%

reduction in weight

13% improvement in freight efficiency for 6%

reduction in weight

Commercial/Heavy Duty

10

20

30

40

50

60

50% 100% 150% 200%

Percent of Baseline Vehicle MassNREL 2011

Improvement in range, battery cost, and/or

efficiency


Materials Technology Portfolio

Lightweight Materials Propulsion Materials

Properties and Manufacturing

Multi-Material Enabling

Modeling & Computational Materials Science

Lightweight Materials Propulsion Materials

FY15 Budget $28.5 M $7.1 M

FY16 Budget $21.6 M $5.3 M

Integrated Computational Materials Engineering (ICME)

Engine Materials, Cast Al & Fe High Temp Alloys

Materials Technology

Exhaust System Materials, Low Temp Catalysts


Lightweight Materials Program

Light- and Heavy-Duty Vehicle Roadmaps

Properties and Manufacturing Multi-Material Enabling Modeling and Simulation

Demonstration, Validation, and Analysis

Reduce cost:– Raw materials.– Processing.

Improve:– Performance.– Manufacturability.

Enable structural jointsbetween dissimilarmaterials.

Prevent corrosion incomplex materialsystems.

Develop NDEtechniques.

Accurately predictbehavior.

Tools to optimizecomplex processesefficiently.

ICME: Developing newmaterials andprocesses.

8

Material Critical ChallengesCarbon-FiberComposites

Low-Cost Fibers

High-Volume Mfg.

Predictive Modeling

Recycling Joining/ NDE & Life monitoring

Aluminum Feedstock Cost Manufacturing Improved Alloys

Recycling

Magnesium Feedstock Cost Corrosion Protection

Improved Alloys

Manufacturing Recycling

Advanced High-StrengthSteels

Manufactur-ability

Wt. Reduction Concepts

Alloy Development

Multi-materialSystems

Joining Corrosion Body Structure Design

New Assembly Operations

NDE & Life monitoring

Glazings Low-Cost Lightweight Matls.

Noise, Structure Models Simulations

Noise ReductionTechniques

UV and IR Blockers

Metal-MatrixComposites

Feedstock Cost Compositing Methods

Powder Handling

Compaction Machining & Forming

Titanium Low-Cost Extraction

Low-Cost Production

Forming & Machining

Low-Cost PM Alloy Development

Incr

easi

ng Im

pact

on

Redu

cing

Veh

icle

Mas

s

Increasing Severity of Challenge

Material Technology Roadmap Significant Opportunities & Challenges

Futu

re F

ocus

P

rimar

y F

ocus


Properties and Manufacturing

Magnesium Alloys Aluminum Alloys

China, 80%

U.S., 7%

Russia, 4%

Others, 9%

When it “works” 40-70% weight reductionCost (~$3-10/lb-saved)Otherwise

– Lack of domestic supply,unstable pricing.

– Challenging corrosionbehavior.

– Inadequate strength,stiffness, and ductility.

– Difficult to modeldeformation behavior.

When it “works” 25-55% weight reductionCost (~$2-8/lb-saved)Otherwise

– Insufficient strength inconventional automotive alloys.

– Limited room temperatureformability in conventionalautomotive alloys.

– Difficult to join/integrate toincumbent steel structures.

Carbon Fiber CompositesWhen it “works” 30-65% weight reduction

Cost (~$5-15/lb-saved)Otherwise – High cost of carbon fiber

(processing, input material).– Joining techniques not easily

implemented for vehicles.– Difficult to efficiently model

across many relevant length scales.

Advanced High Strength Steel15-25% weight reduction– Inadequate structure/properties

understanding to propose steelswith 3GAHSS properties.

– Insufficient post-processingtechnology/understanding.

– What other relevant propertiesshould be considered? Hydrogenembrittlement, local fracture, etc.

Choi et. al., Acta Mat. 57 (2009) 2592-2604


Total Vehicle Weight Reduction Potential

0

200

400

600

800

1000

1200

1400

1600

Today's Tech Adv. Steel Al Alloys Mg Alloys CF Composite

Wei

ght (

kg)

Body and Structure Chassis Powertrain HVAC and Electrical Other

~19%~30%

~37%~37%


HAZ property deterioration. Limited weld fatigue strength. Tool wear, tool load, infrastructure.

Mg Si Cu Zn5182 4.0 - 5.0 < 0.2 < 0.15 < 0.256111 0.5 - 1.0 0.6 - 1.1 0.5 - 0.9 < 0.157075 2.1 - 2.9 < 0.4 1.2 - 2.0 5.1 - 6.1

Multi-Material Enabling


Carbon Fiber Composites

Corrosion (galvanicand general).

Difficulty Joining:– Mg-Mg.– Mg-X.– Riveted Joints.

Questionablecompatibility withexisting paint/coatingsystems.

HAZ property deterioration. Difficulty joining mixed

grades:– Joint integrity.– Joint formability.

Difficulty recycling mixedgrades.

Corrosion and environmental degradation. Some difficulty joining. Questions regarding non-destructive evaluation.

AHSS


General lack of understandingon structures, phases, anddeformation mechanisms toachieve 3GAHSS properties.

Very complicated structures,phases, and deformationmechanisms likely.

Modeling and Computational Materials Science


Carbon Fiber Composites Insufficient capability in modeling relationships

between physical properties, mechanicalproperties, and ultimately behavior.

Lack of validated, public databases of CFCmaterial properties.

Inadequate processing-structure predictivetools.

AHSS

Q. Ma et al. Scripta Mat. 64(2011) 813–816

P.E. Krajewski et al. Acta Mat. 58 (2010) 1074–1086

N.I. Medvedeva et al. Phys. Rev. B 81 (2010) 012105

Complicateddeformation in HCP Mgalloys.

– Highly anisotropicplastic response.

– Profuse twinning. Few established design

rules for anisotropy.– Substantial gaps in basic

metallurgical data.

Basic metallurgicalmodels are wellestablished.

Substantialfundamental data isavailable.

Useful predictivemodels establishedfor some conditions.

Truly predictive,multi-scale modelsare still lacking.


Propulsion Materials Program

Light- and Heavy-Duty Vehicle Roadmaps,U.S. DRIVE Low-Temp Catalyst Workshop Report

Engine Materials Exhaust System MaterialsIntegrated Computational Materials

Engineering

Demonstration, Validation, and Analysis

Improve Engine Efficiency: Improved Materials:

– Strength.– Durability.– Operating

Temperature.– Manufacturability.– Lower Cost.

Low-Cost High-TempAlloys for ExhaustManifolds, TurbochargerHousings and Turbines.

Low-Temp CatalystMaterials and ceramicsubstrates.

New materials andprocesses using multi-scale modeling.

Modeling to createtailored materials.

Predict behavior. Optimizing complex

processes.

Accelerated Tech to Market Transition


Internal Combustion Engine (ICE) Materials

The Propulsion Materials’ cast alloy development program for engine applications.

Combines first principlescomputational materialsdesign, advancedcharacterization, andexperimental validation.

Results in new alloys andexpanded ICMEcapabilities.


Exhaust System Materials, Low-Temp Catalysts

http://www.pnnl.gov/main/publications/external/technical_Reports/PNNL-22815.pdf

The PropulsionMaterials’ low-temperature catalystdevelopment effort isguided by: USCARAdvanced after-treatment WorkshopReport.

All materialsdevelopment andvalidation activitiesreside in the areasoutlined in red bridgingmaterials fundamentalsand applied R&D.

Future Automotive after-treatment Solutions: The 150°C Challenge Workshop Report


Atoms to Engines: ORNL Provides Unique Capabilities to Industry

ORNL provided: High Temperature Materials Laboratory (HTML)

Materials Characterization. JEOL Aberration Corrected Electron Microscope

(ACEM). FEI 200X TALOS Scanning Transmission Electron

Microscope (STEM). LEAP4000XHR Atom Probe. The Titan Supercomputer. Spallation Neutron Source (SNS).Brookhaven National Laboratory Provided: National Synchrotron Light Source (NSLS)

Synchrotron Diffraction.

Results to date: >25% improvement in strength with >300°C performance.A low-cost, easy casting, high-performance AL alloy designed to enable next generation high-efficiency automotive engines with rapid technology to market transition potential.

Objective: 300°C capable AL alloy with 25% improvement in high-temperature strength. Must conform to existing production methods.


AdvancedCombustion

Models

Materials Target Setting with Linked ACE Models & ICME

Temperature and pressureBoundary conditions

Finite Element BaselineDesign Constraints

Prioritized Components

andMaterialPropertyTargetsEfficiency

improvement potential

Identify and prioritize the material improvements needed to enable high efficiency combustion systems, and quantify the benefits.


2015 Accomplishments

Matured plasma oxidation technology reduces energy use by 75% and increases throughput by a factor of 3, decreasing the cost to manufacture oxidized carbon fiber precursor. Ultimately, has potential to reduce carbon fiber cost by 20%. 4M Industrial Oxidation has announced commercialization of this technology due to the demonstrated scalability, robustness, and low variability of this process.

Oak Ridge National LaboratoryVirgin Precursor Oxidized Fiber



Demonstrated technical feasibility of breakthrough joining techniques such as collision welding by vaporizing foil actuator by successfully welding more than 14 dissimilar metal combinations consisting of magnesium, steel, and aluminum alloys. Laser assisted adhesive joining of CFRP to Al, another breakthrough technique, showed a 40% increase in lap shear strength as compared to a non-laser assisted baseline.

Ohio State University and Oak Ridge National Laboratory



Completed and validated a magnesium intensive demonstration structure for under-hood applications; investigated a wide range of processing, joining, corrosion protection, design, and testing procedures for magnesium intensive structures and validated modeling methodologies to the automotive lightweighting community.

USAMP led with large supplier, national lab, and university team



Developed and demonstrated new high-strength, exceptional ductility advanced steel with >1,200 MPa tensile strength and >30% elongation to failure, while simultaneously building an initial integrated computational modeling framework to predict properties of advanced steels.

USAMP led with large supplier, national lab, and university team



Completed detailed characterization of diffusion kinetics, microsegregation, and phase transformations of magnesium alloys processed at a wide range of cooling rates. Produced new data and insight essential for development of next-generation high performance magnesium alloys and began distributing this data to the broader materials community through established materials data repositories.

Ohio State University, University of Michigan (2 projects)

Microsegregation as a function of location in die cast AM70 Mg (experimental)

Impurity diffusivities in Mg (calculated from experiment)


MGI - Framework

New Material Innovations for Clean Energy 2X Faster and 2X Cheaper

Predictive Simulation

Across Scales

Synthesis & Characterization

Rapid Screening

End Use Performance

Process Scalability

Process Control

Real-time Characterization

Reliability Validation

Data Management & Informatics

Coordinated resource network with a suite of capabilities for advanced materials R&D

In Support of the Materials Genome Initiative (MGI)


Summary

Weight reduction and lightweight materials are important elements ofAutomotive OEM’s sustainability strategy.

Broader usage of new lightweight materials is delivering mass reduction, butsafety requirements and additional customer features are adding weight.

Manufacturers need lead time to overcome lightweight material cost, supplyand infrastructure issues.

New materials such as advanced high strength steel, aluminum, magnesium,and carbon fiber composites offer future opportunities but each faces theirown unique challenges.

Multi-material Vehicles enable the design & optimization of all materialsolutions to deliver lightweighting.

Utilizes Integrated Computational Materials Engineering (ICME) to target andaddress materials for high efficiency Internal Combustion Engines, powertrainmaterials interactions with new fuel compositions.

The Lightweight Materials Multi-Lab Consortium (LightMat) creates anenduring industry-DOE laboratory ecosystem to increase the U.S.competitiveness in manufacturing and reduce the time from development todeployment of advanced materials by 50% within five years.


Contact Information

Felix Wu (Supervisor)

– [email protected]

Jerry Gibbs (Propulsion Materials)


Carol Schutte (Lightweight Materials)


Will Joost (Lightweight Materials)


Sarah Ollila (Lightweight Materials)


Materials Technology - Overvie · 2015 Accomplishments Highlights Energy Materials ... Matured plasma oxidation technology reduces ... such as collision welding by vaporizing foil

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