U.S. Department of Energy Propulsion Materials FY 2013 Progress Report CONTENTS INTRODUCTION ....................................................................................................................................... 1 Project 18516 – Materials for H1ybrid and Electric Drive Systems ...................................................... 4 Agreement 19201 – Non-Rare Earth Magnetic Materials ............................................................................ 4 Agreement 23278 – Low-Cost Direct-Bonded Aluminum Substrates ....................................................... 11 Agreement 23279 – Improved Organics for Power Electronics and Electric Motors................................. 18 Agreement 23726 – Novel Manufacturing Technologies for High-Power Induction and Permanent Magnet Electric Motors (General Motors CRADA) ...................................................... 22 Agreement 26461 – Enabling Materials for High-Temperature Power Electronics ................................... 30 Project 18518 – Materials for High-Efficiency Engines ........................................................................ 32 Agreement 8697 – NOx Sensor Development ............................................................................................ 32 Agreement 13329 – Design Optimization of Piezoceramic Multilayer Actuators for Heavy-Duty Diesel Engine Fuel Injectors ............................................................................................................ 42 Agreement 17058 – Compact Potentiometric NOx Sensor ......................................................................... 52 Agreement 17257 – Materials for Advanced Turbocharger Designs ......................................................... 57 Agreement 18571 – Materials Issues Associated with Exhaust Gas Recirculation Systems ...................... 62 Agreement 23284 – Friction Reduction Through Surface Modification: Integrated Surface Texturing and Coating ...................................................................................................................... 71 Agreement 23425 – Lightweight Heavy-Duty Engine ............................................................................... 77 Agreement 23725 – Tailored Materials for Improved Internal Combustion Engine Efficiency ................ 82 Agreement 24034 – High-Strength and High-Temperature Materials for Heavy-Duty Engines ............... 94 Agreement 25736 – Computational Design and Development of a New, Lightweight Cast Alloy for Advanced Cylinder Heads in High-Efficiency, Light-Duty Engines........................................ 103 Agreement 25737 – ICME Guided Development of Advanced Cast Aluminum Alloys for Automotive Engine Applications ................................................................................................... 110 Agreement 26190 – High-Temperature Materials for High-Efficiency Engines ...................................... 114 Project 18519 – Materials for Exhaust and Energy Recovery ............................................................ 118 Agreement 9130– Development of Materials Analysis Tools for Studying NOx Adsorber Catalysts (CRADA with Cummins Inc.) ........................................................................................ 118 Agreement 10461 – Durability of Diesel Particulate Filters (CRADA with Cummins, Inc.) .................. 127 Agreement 10635 – Catalysis by First Principles ..................................................................................... 134 Agreement 19214 – Biofuels Impact on Diesel Particulate Filters Durability ......................................... 147 Agreement 26462 – International Characterization Methods ................................................................... 154 Agreement 26463 – Biofuel Impact on Aftertreatment Devices .............................................................. 156 Project 18865 – Application-Specific Materials Simulation, Characterization, and Synthesis ....... 158 Agreement 9105 – Ultra-High Resolution Electron Microscopy for Characterization of Catalyst Microstructures and Reaction Mechanisms .................................................................................... 158 Agreement 14957 – Modeling of Thermoelectrics ................................................................................... 165 Agreement 15529 – Erosion of Materials by Nanofluids ......................................................................... 171 Agreement 16308 – Thermoelectrics Theory and Structure ..................................................................... 176 Agreement 26391 – Applied ICME for New Propulsion Materials ......................................................... 184 Agreement 26464 – Materials Characterization and Evaluation .............................................................. 188 ii Propulsion Materials FY 2013 Progress Report INTRODUCTION Propulsion Materials Research and Development: Enabling Materials Technologies to Meet Vehicle Technologies Office Goals The U.S. Department of Energy’s Vehicle Technologies Office (VTO) is pleased to introduce the FY 2013 Annual Progress Report for the Propulsion Materials Research and Development Program. Together with Department of Energy national laboratories and in partnership with universities and private industry across the United States, the Propulsion Materials Program continues to invest in research and development (R&D) that provide enabling materials technologies for fuel-efficient and environmentally friendly commercial and passenger vehicles. This introduction summarizes the objectives and progress of the program in fiscal year 2013. The Propulsion Materials Program actively supports the energy security and reduction of greenhouse emissions goals of VTO by investigating and identifying the materials properties that are most essential for continued development of cost-effective, highly efficient, and environmentally friendly next-generation heavy and light-duty powertrains. The technical approaches available to enhance propulsion systems focus on improvements in both vehicle efficiency and fuel substitution, both of which must overcome the performance limitations of the materials currently in use. Propulsion Materials Program activities include work with national laboratories, industry experts, and VTO powertrain systems (e.g., Advanced Combustion Engines [ACE], Advanced Power Electronics and Electrical Machines [APEEM], and fuels) teams to develop strategies that overcome materials limitations in future powertrain performance. The technical maturity of the portfolio of funded projects ranges from basic science to subsystem prototype validation. Propulsion Materials Program activities are structured to serve as an enabling partner and supporter of the following VTO R&D activities: Hybrid and vehicle systems Energy storage APEEM ACE Fuels and lubricants Projects within a Propulsion Materials Program activity address materials concerns that directly impact critical technology barriers within each of the above programs, including barriers that impact fuel efficiency, thermal management, emissions reduction, improved reliability, waste-heat recovery, and reduced manufacturing costs. The program engages only the barriers that result from material property limitations and represent fundamental, high-risk materials issues. Enabling Advanced Technologies A Propulsion Materials Program activity focuses on key technical deficiencies in materials performance that limit the expanded capabilities of advanced combustion engines, electric-drive systems, and fuels and lubricants. It provides materials R&D expertise and advanced materials testing and development that support the goals of combustion, hybrid, and power electronics development. The program provides enabling materials support for combustion, hybrid, and power electronics development, including the following: 1 Propulsion Materials FY 2013 Progress Report Materials for high-efficiency combustion strategies such as homogenous-charge compression ignition Materials for 55% thermal efficiency for heavy-duty diesel engines Materials for waste-heat recovery using mechanical (such as turbo compounding) and solid-state approaches, with the potential for a 10% increase in fuel efficiency Materials technologies for effective reduction of tailpipe emissions, including diesel particulate filters, low-temperature catalyst development, characterization and testing, and exhaust gas recirculation coolers Materials technologies for electric and hybrid-electric vehicles, including thermal management of advanced power electronics materials and reducing dependence on rare earth elements in electric motors Materials for alternate-fuels, including engine and exhaust aftertreatment materials compatibility and corrosion in biofuels Support for the Materials Genome Initiative through identifying effective computational approaches and tools to accelerate the development and deployment of new materials with improved properties. The program supports these core technology areas by providing materials expertise, testing capabilities, and technical solutions for materials problems. The component development, materials processing, and characterization that the program provides are enablers of the successful development of efficient, durable, and emissions-compliant engines. Program Organization The Propulsion Materials Program consists of the following four R&D projects, which support VTO propulsion technologies.