Vehicle Technologies Program

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					OESA Automotive Supplier Technology Forum
June 2010

                                      Materials Technologies
                                      Carol Schutte, PhD
                                      Team Lead for Materials Technology
                                      Vehicle Technologies Program

Program Name or Ancillary Text                               
Key Administration Goals Relevant to Vehicle Technologies
       • Reduce green house gas emissions by 50% in 2030 (from 2005 baseline)
       and by 80% in 2050

  What does this really mean?

  • In 2050 we need 50mpg vehicles
    with 45% miles electrified
  • If we only achieve 45mpg with 0%
    electrified miles then reduce the
    total number of miles traveled by

 Vehicle Technologies Program                                 
Lightweighting improves efficiency of all vehicles:
Vehicle lightweighting: 6-8% improvement in fuel economy with every 10% weight savings
Secondary compounded benefits: reducing the power requirement for the motor or engine

Propulsion materials supports achieving combustion efficiency:
Passenger vehicle up to 45% and commercial vehicles 55% at today’s cost :
    • Requirements are demanding
         • High pressure fuel injection materials up to 45,000 psi for diesel engines
         • Peek cylinder pressure > 2,700 psi

 Vehicle Technologies Program                                                 
     Vehicle Technologies Program
                                                          Program Manager                                              Administration
                                                             Patrick Davis                                            Maxine Robinson
                                                                                                                     Bernadette Jackson
                                                                                                                      Johnathan Wicker
                   FreedomCAR and Fuel Partnership                              21st Century Truck Partnership
                       Director – Christy Cooper                                    Director – Ken Howden
                              Yury Kalish
                             Chief Scientist                                            Phil Patterson
                            James Eberhardt                                              Jake Ward

                        Education and Outreach                                     Budget Program Analyst
                           Connie Bezanson                                                Noel Cole
                          Jennifer Krajewski*

                                                                                  Supervisory General Engineer
                      Supervisory General Engineer
                                                                                        Drew Ronneberg
                               Ed Owens

                                                                          Fuels Technology               Advanced Combustion Engine R&D
       Hybrid Electric Systems           Materials Technology
                                                                       Team Lead – Kevin Stork              Team Lead – Gurpreet Singh
      Team Lead – Dave Howell          Team Lead – Carol Schutte

          Vehicle Systems                                          Advanced Petroleum Based Fuels        Combustion & Emission Controls
                                         Lightweight Materials            Steve Przesmitzki                        Ken Howden
              Lee Slezak
                                               Will Joost               Non-Petroleum Fuels                        Roland Gravel
          David Anderson
                                          Propulsion Materials               Dennis Smith                         Kellen Schefter
          Energy Storage
                                              Jerry Gibbs             Technology Integration/             Solid State Energy Conversion
           Steve Goguen
                                                 HTML                        Clean Cities                         John Fairbanks
             Tien Duong
                                            James Eberhardt                  Dennis Smith
         Brian Cunningham
             Peter Faguy                                                   Linda Bluestein
 Power Electronics & Electric Motors                                        Shannon Shea
            Susan Rogers                                                      Mark Smith
            Steven Boyd                                                Legislation/Rulemaking
                                                                                                                      *detailed to another location
                                                                             Dana O’Hara
Vehicle Technologies Program                                                                                             
Fiscal Year 2010 Budget

  Vehicle Technologies Budget                Materials Technology Budget

                       $33M          Fuels              Lightweight

    Hybrid Electric
    Systems                                     Propulsion
    $146M                                       Materials
                                                $13M           HTML


              Total – $311M                             Total – $51M

Vehicle Technologies Program                                     
Supplier Community is valuable to
the VTP
    1) You have with DOE VTP
    How to work the technical core competency necessary to do
       the work
    2) You know your customers needs and understand the
       technical challenges/gaps that keep you from reaching
       the technical goals
           •        Provide valuable input to our roadmapping process
    3) You commercialize directly the successful outcome of the
    4) You can respond to funding opportunity announcements
       such as BAA’s (broad agency announcements) – you
       lead or are on a team; you keep your IP

Vehicle Technologies Program                                  
                           How to work with DOE?

Vehicle Technologies Program             

Advanced Technologies Vehicle Manufacturing (ATVM)
Loan Program
 Type                     Loan
 Description              Provides loans to automobile and automobile part manufacturers
                          for the cost of re-equipping, expanding, or establishing
                          manufacturing facilities in the United States to produce
                          advanced technology vehicles or qualified components, and for
                          associated engineering integration costs.
 Funding                  $25B; individual award sizes vary
 Timeline                 Final rule established November 2009; rolling applications
 Examples                 Tenneco ($24M), Fisker ($528M), Ford ($5.9B), Nissan ($1.6B),
                          Tesla ($465)
                          Includes final rule and guidance for applicants

Vehicle Technologies Program                                                 

Advanced Research Projects Agency – Energy (ARPA-e)

 Type                     Grant
 Description              Focuses exclusively on high risk, high payoff concepts -
                          technologies promising genuine transformation in the ways the
                          United States generates, stores and utilizes energy
 Funding                  $400M in second round; individual award sizes vary
 Timeline                 Current round closed
 Examples                 Michigan State Univ. – Wave Disc Engine ($2.5M), General
                          Motors – Lightweight Thermal Energy Recovery System ($2.7M)
                          Includes current Funding Opportunity Announcements (FOA)

Vehicle Technologies Program                                                
Loan Guarantee Program

Loan Guarantee Program

 Type                     Loan guarantee
 Description              Issues loan guarantees to eligible projects that "avoid, reduce, or
                          sequester air pollutants or anthropogenic emissions of
                          greenhouse gases" and "employ new or significantly
                          improved technologies as compared to technologies in service
                          in the United States at the time the guarantee is issued".
 Funding                  $8.5B in current round
 Timeline                 Ongoing in stages; last Part I due 8/24/10
 Examples                 SAGE Electrochromics ($72M), BrightSource Energy ($1.4B)

                          Includes guidance documentation for applicants

Vehicle Technologies Program                                                    

Upcoming: Vehicle Technologies Program
           Wide Broad Area Announcement
 Type                     Cooperative Agreement
 Description              Involves near and mid-term projects in technology areas that
                          support the vehicle technologies mission and goals.

 Funding                  Individual awards will vary
 Timeline                 Schedule yet to be announced
 Examples                 DOE envisions awarding multiple financial assistance awards in
                          the form of cost-shared grants/cooperative agreements. The
                          estimated period of performance for each award will be
                          approximately two to three years in duration.
 Contact                  Notice of intent:

Vehicle Technologies Program                                                   

Small Business Innovation Research (SBIR) and Small
Business Technology Transfer (STTR)
 Type                     Grant
 Description              Provides funding to stimulate technological innovation in
                          small businesses to meet federal agency R&D needs. STTR
                          projects must involve substantial (at least 30%) cooperative
                          research collaboration between the small business and a non-
                          profit research institution.
 Funding                  2.8% of DOE R&D budget ($155M in 2009); Phase I awards up
                          to $100,000, Phase II up to $750,000
 Timeline                 Solicitations at beginning of every fiscal year (around October)
 Examples                 Fuel Cell Energy Inc. (electrolyte), Precision-Combustion Inc.
                          (catalytic combustor)
                          Grant proposals accepted only through

Vehicle Technologies Program                                                       
Other resources

• Current funding opportunities through the Vehicle
  Technologies Program (VTP) are available at
• State Energy Program provides financial and technical
  assistance through formula and competitive grants:
• More information on Recovery Act-funded projects is
  available at
• Testing/demonstration partnerships may also be
  available through:
   - State and local governments
   - Local universities
   - Military

Vehicle Technologies Program                    
New Initiatives: Lightweighting
average vehicle weight reduced by 50%
                        BAA – to be released
 Multimaterial vehicle:
 •the design, build and validation of a light weight material vehicle
     that is 50 percent lighter weight than the standard vehicle.
   •(under Clean Energy Dialogue between the US and Canada)

 Domestic source of Mg
 •low cost, clean and efficient

 Industry lead low cost carbon fiber

Vehicle Technologies Program                                    
New Initiatives: VTP

  Advanced Fuels and Lubricants Technologies
  - Fuels and Lubricants for Advanced Combustion Regimes;
  - Direct Petroleum Displacement by Liquid Alternative Fuels for Compression-Ignition Engines
  -Higher efficiency natural gas (CNG. LNGI engines and vehicle platforms .for medium- and
  heavy-duty trucks and buses
  Hybrid and Electric Systems R&D for Advanced Energy Storage and Electric Drive
  - Develop Advanced Cells for Electric Drive Vehicle Batteries
  - Improve Electric Drive Vehicle Battery Design
  - Modular, Scalable Inverter for Advanced Electric Drive Vehicle Electric Traction Drives
  - Motors Using No Rare Earth Permanent Magnets for Advanced EDV Electric Traction Drives
  Advanced Thermoelectrics and Enabling Technologies for Energy Efficient Powertrains
  - Solid State Thermoelectric Energv Conversion Devices
  - Enabling Technologies for Engine and Powertrain Systems

Vehicle Technologies Program                                                    
Super Truck takes a systems approach to
improved efficiency including lightweighting

   Systems Level Technology Development, Integration, and Demonstration for Efficient
   Class 8 Trucks (SuperTruck) and Advanced Technology Powertrains For Light-Duty
   Vehicles (ATP-LD)

     • Objectives are to develop and demonstrate advanced
       engine and vehicle technology as follows:
            – Heavy-Duty Class 8 Trucks
                    • 20% improvement in engine brake thermal efficiency (50% BTE)
                    • 50% improvement in freight efficiency (ton-miles/gallon)
                    • Modeling and analysis for pathway to 55% Brake Thermal Efficiency
            – Light-Duty Vehicles
                    • 25% fuel economy improvement over for gasoline engines
                    • 40% fuel economy improvement over for diesel engines baseline*
     • Funding:                              *Baseline is state-of-the-art port-fuel injected gasoline engine

            – $100M in ARRA Funding
            – $87M in annual appropriations over six fiscal years
Vehicle Technologies Program                                                                    
 Previous demonstration projects
 for lightweighting heavy vehicles
      Component                       Material(s) used          Weight savings                  Team

           door and aperture          hybrid composites and                 40%                      PACCAR, PNNL
                                      composite metal hybrid
                  hood                 Carbon Fiber Sheet                   30%                     Volvo Trucks North
                                       Molding Compound                                             America, Meridian
                                                                                                   Automotive Systems
       tie rods, trailing arms, and        Composites            50% lift axle (100lbs saved)   Delphi, National Composite
                   axles                   and aluminum             50% tie rods (11 lbs)                 Center
                                                                    Trailing arm (56 lbs)
       Composite Cab Structures       Resin transfer molding               30% +                Delphi, National Composite
                                          of composites                                                   Center

       Bus structure and chassis         Ultra high strength                64%                        Autokinetics Inc
                                          Stainless Steel
           Truck Body Panels          Superplastically Formed               40%                   International Truck and
                                         (SPF) Aluminum                                              Engine Company

           Support Structures           polymer composite                   50%                 National Composite Center

      large area structural panels      hybrid composite                    45%                  Freightliner, LLC, Profile
                                                                                                   Composites, PNNL
      Light duty frame for Dodge             Aluminum                      > 40%                 DaimlerChrysler, PNNL
             cab component              Superplastic formed                 50%                           Peterbilt
Vehicle Technologies Program                                                                                
 Previous demonstration projects
 for lightweighting light duty vehicles
      Component                       Composite(s) used                   Weight savings       Team

             Focal Project I          Resin Transfer Molding:                    25%            Automotive Composite
                Front end             Braided glass fiber                                         Consortium (ACC)
          (passed 35 mph front        (Polyurethane form core)
            barrier crash test)       Or random chopped glass fiber
                  ‘91-’96             Vinyl ester resin
             Focal Project II            SRIM urethane                           18%                   ACC
               Truck Box                 Glass fiber resin P4 (powdered
      (rear impact was carried by           programmable preform
                the rails)                  process)
                 ’94 -’00
       Focal Project III – Carbon        Injection/compression molding:          60%                   ACC
                 Fiber                   SRIM urethane
            Body-in-White                Carbon fiber P4
       (Learned to tailor stiffness      Manufactured only the B pilar
          where it is needed)
               ‘01 – ’06
        Focal Project IV – Floor      Floor                               Floor 31%                    ACC
                 Pan                  SMC Vinyl ester resin
           and Rear Seats             • Glass fabric reinforcement        Seat
               ‘06 – ‘10              • High elongation core              - 32% glass
                                      • 2 ½ min cycle time                (cost penalty
                                      Seat- Either injection or           157%)
                                      compression molding
                                         • Nylon                          - 58% carbon (cost
                                         • Glass fiber                    penalty 415%)

Vehicle Technologies Program                                                                         

                                        Carol Schutte, PhD
                                Team Lead for Materials Technology
                                  Vehicle Technologies Program

Vehicle Technologies Program                               
Technology and System Demonstration of Highly-
Efficient and Clean Diesel Powered Class 8 Trucks
                                                                                        HEAVY DUTY ATP SELECTIONS

 GOALS                                                 PROJECT TEAM

  Comprehensive approach                               Cummins, Inc.
   • 50% increase in vehicle freight efficiency over    Partners: Peterbilt, Eaton, Delphi, Bridgestone,
     the defined drive cycle; and                        Modine, U.S. Xpress, Purdue University,
   • 68% or greater increase in vehicle freight          University of Wisconsin, and Oak Ridge National
     efficiency over a 24 hour operating cycle           Laboratory

 KEY ELEMENTS                                          PROJECT FUNDING AND SCHEDULE
  highly efficient and clean diesel engine             Total Project Cost:     $77,662,230
  50% or greater brake thermal efficiency,             DOE Share:              $38,831,115
  an aerodynamically efficient Peterbilt tractor       Industry Share:         $38,831,115
   and trailer combination,                             Project Duration:       48 months
  reduced rolling resistance tire technology,
  and a new highly efficient transmission.

Vehicle Technologies Program                                                               
Class 8 Truck Freight Efficiency Improvement
                                                                                              HEAVY DUTY ATP SELECTIONS

 GOALS                                                      PROJECT TEAM

  Multi-faceted approach to                                 Daimler Trucks North America
  • Improve freight efficiency by 50% and                    Partners: Detroit Diesel, Oak Ridge National Lab,
  • Improve engine brake thermal efficiency by                MIT, University of Oregon

 KEY ELEMENTS                                               PROJECT FUNDING AND SCHEDULE
    Engine efficiency:                                      Total Project Cost:     $79,119,736
    Vehicle improvements; hybridization, integrated         DOE Share:              $39,559,868
     engine-drivetrain systems, tractor/trailer/tractor-
     trailer-gap aerodynamics, axle disengagement,           Industry Share:         $39,559,868
     rolling resistance, light weighting, electrification    Project Duration:       60 months
     of pumps, idle reduction, route planning, eco-
     driver feedback and predictive technologies

Vehicle Technologies Program                                                                     
Class 8 Truck Freight Efficiency Improvement
                                                                                           HEAVY DUTY ATP SELECTIONS

 GOALS                                                 PROJECT TEAM
    Increase vehicle freight efficiency of Class 8     Navistar, Inc.
     tractor and trailer combination by 50%             Partners: Arvin Meritor, ATDynamics, Bosch, FEV,
     compared to Navistar’s industry-leading 2009        Federal Mogul, Michelin, Modine Swift, Sheppard,
                                                         and Safeway University of Illinois, Southwest
     ProStar vehicle                                     Research Institute, Wabash National, University of
    Improve brake thermal efficiency by a minimum       Wisconsin, Argonne National Laboratory, Lawrence
     50%                                                 Livermore National Laboratory

 KEY ELEMENTS                                          PROJECT FUNDING AND SCHEDULE
    Truck and trailer aerodynamics, advanced           Total Project Cost:      $74,657,866
     high-efficiency combustion techniques, waste       DOE Share:               $37,328,933
     heat recovery, dual-mode hybrid powertrain,        Industry Share:          $37,328,933
     dual fuel concepts, reduced rolling resistance,
     friction reduction, weight reduction, and idle     Project Duration:        60 months

Vehicle Technologies Program                                                                   

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