Browse Topic: Rare earth metals
This specification covers a magnesium alloy in the form of welding wire (see 8.5
This specification covers a magnesium alloy in the form of welding wire (see 8.5
System optimization and lifecycle analysis are key to taking heavy rare earths out of next-gen motors for commercial EVs. All components of an electric propulsion system - the motor, battery pack and inverter, in particular - are interrelated and optimized for a system function. Still, there are significant trade-offs in cost and what's best for sustainability when developing today's e-drive systems, according to David Fulton, director of rotating electric machines, PowerDrive Systems at BorgWarner Inc. “The dominant design for motors today is probably the worst for sustainability in terms of KPIs [key performance indicators] as well as highest in cost. But it serves the greater good of the system [by enabling] the lowest cost for the battery pack and inverter,” Fulton said at the 2023 SAE COMVEC conference, during his presentation on next-gen motor technology for commercial vehicles
Automobile Catalyst are used to convert Harmful gases emitted by vehicle (CO, HC, and NOx) to less Harmful gas (CO2, H2O and N2), Catalyst Loading comprises of Platinum, Palladium and Rhodium (Rare earth metals) metal powders combined in slurry and wash-coated onto a ceramic brick. Ever since the introduction of BS6 Emissions norm (stricter emission regulation), Catalyst loading content has increased in all vehicles. The Price of these rare earth metal are increasing day by day. Typically, a BS6 regulation catalyst contains a few grams of loading content. In some vehicles there are more than one catalyst (due to regulation requirement) and in some cases catalysts are also located in the underbody, in such cases, Number and location of catalyst makes the vehicle an easy target for thieves. Recently local police authorities around the country have captured many catalysts theft gangs. In this paper, Case study of a particular model is used to understand the modus operandi of theft and
Thermal Barrier Coating (TBCs) is one of the most promising technologies for reducing heat dissipation through the combustion chamber in Internal Combustion (IC) Engines. In this paper, Gadolinium Zirconate (GZ) was chosen as a coating material and prepared using a solid-state synthesis process. Cast iron (GJL 300) was selected as the substrate, which is predominantly used as the cylinder head material, and GZ was deposited using Electron Beam Physical Vapor Deposition technique (EB-PVD). The mechanical, thermal, and tribological properties were evaluated as per the ASTM standards. Improved hardness and wear resistance is noted on coated substrates. The thermal conductivity and Coefficient of Thermal Expansion (CTE) of the coated substrates decreased by 3.43% and 5.03% respectively when compared with uncoated substrates. Hence, it is confirmed that thin-film TBCs has potential to provide the thermal and wear protection inside the combustion chamber of IC engines
Global warming due to exhaust emissions, rapid depletion of crude oil, and strict carbon control legislation has forced researchers to search biofuels as substitute for petroleum diesel fuels. Biodiesel is a renewable and oxygenated fuel. It is free from sulfur, non-toxic and a biodegradable. The different non-edible vegetable oils such as Algae, Karanja and Jatropha could be used to produce biodiesel. Biodiesel is a green fuel with an exception that it emits 15-20% more NOx as compared to diesel fuel. The emissions of nanoparticles are more hazardous to human health. The nanoparticles emission of biodiesel must be measured according to the new strict regulations. The engine performance and the lower emission characteristics, except for NOx emission, for Algae, Karanja and Jatropha oil biodiesels are similar to those of diesel fuel. Present study has investigated the performance, combustion and emissions, including nanoparticle emissions, for Algae, Karanja and Jatropha oil biodiesel
Research activities in the development of reliable computational models for aftertreatment systems are constantly increasing in the automotive field. These investigations are essential in order to get a complete understanding of the main catalytic processes which clearly have a great impact on tailpipe emissions. In this work, a 1D chemical reaction model to simulate the catalytic activity of a Pd/Rh Three-Way Catalyst (TWC) for a Natural Gas heavy-duty engine is presented. An extensive database of tests carried out with the use of a Synthetic Gas Bench (SGB) has been collected to investigate the methane abatement pathways, linked to the lambda variation and oxide formation on palladium surface. Specific steady-state tests have shown a dynamics of the methane conversion even at fixed λ and temperature conditions, essentially due to the Pd/PdO ratio. Furthermore, combining the results of such test with dedicated Rich-Lean λ transitions it has been demonstrated that the presence of NO
Piston is the most imperative part of an automotive engine in which it exchanges drive due to expanding gas in the cylinder to the crankshaft through the piston rod. During the combustion of fuel charge inside the ignition chamber, high pressure and temperature are developed and the piston is imperiled to high mechanical and thermal stresses. The main objective of the proposed work is to analyse the stress distributions and thermal behaviour of uncoated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown and Plasma sprayed Yttrium Stabilized Zirconia (Y-PSZ) coated A356 with 5wt% SiC and 10wt% Fly Ash HMMC piston crown. A356 with 5wt% SiC and 10wt% Fly Ash HMMC were fabricated via squeeze casting to improve the performance of a petrol engine. A structural model of an HMMC piston crown was made using CREO software and structural and thermal analysis was done using ANSYS. Further coupled field analysis is done to find the stress and temperature distribution on the piston. Output
In this study, an experimental investigation was carried out to evaluate the effect of Iron Oxide Nanofluids on the performance, emission and combustion characteristics of Low Heat Rejection (LHR) diesel engine operated with methyl esters of Waste Cooking Oil (WCOME). In the first phase of the work, single-cylinder, direct injection diesel engine test rig was developed and tested for its baseline readings with diesel at different power outputs. In the second phase of the work, the test engine was operated with WCOME and tested for its characteristics. In the third phase of the work, the test engine was modified to operate in the LHR mode so the engine components such as cylinder head, valves, and piston crown were initially machined to 300 microns for the required coating thickness to maintain the compression ratio and then the components were firstly coated with 100 microns bond- coat of Nickel, Chromium, and aluminum alloys (NiCrAl) and on the top of it 200 microns of lower thermal
The fuel injection pressures used in gasoline direct injection (GDI) engines have increased in recent years to improve fuel efficiency and reduce emissions. Current GDI engines use injection pressures of up to 350 bar, and there is evidence that even higher fuel injection pressures could yield further improvements in atomization. Higher injection pressures could also improve mixture formation by increasing the spray velocity; however, the research with higher injection pressures over 1000 bar is limited due to a limit of mechanical components. This manuscript summarizes experimental investigations into the effect of injection pressure, injection mass, and nozzle shape on spray-induced air motion with ultrahigh injection pressure over 1000 bar. Fuel sprays were generated at a range of injection pressures with different injection masses and nozzle geometries, and Particle Image Velocimetry (PIV) was performed using a Charge-coupled device (CCD) camera and an Nd:YAG (neodymium-doped
A growing interest towards heavy-duty engines powered with NG, dictated by stringent regulations in terms of emissions, has made it essential to study a specific Three-Way Catalyst (TWC). Oxygen storage phenomena characterize the catalytic converter efficiency under real world driving operating conditions and, consequently, during strong dynamics in Air-to-Fuel ratio (AFR). A numerical “quasi-steady” model has been set-up to simulate the chemical process inside the reactor. A dedicated experimental campaign has been performed in order to evaluate the catalyst response to a defined λ variation, thus providing the data necessary for the numerical model validation. In fact, goal of the present research activity was to investigate the effect of very fast composition transitions of the engine exhaust typical of the mentioned driving conditions (including fuel cutoffs etc.) on the catalyst performance and on related emissions. A surface reactions kinetic mechanism, representing CH4, CO, H2
Rapid depletion of petroleum reserves, stringent emission legislations and global warming has given us an opportunity to find biodiesel as an alternative to diesel fuel. Biodiesel is a biogradable, renewable, sulphur free, non-toxic, and oxygenated green fuel. Recent emission legislations have also restricted the nano particles emission in addition to particulate matter, due to their adverse impact on health. Karanja and Jatropha oils are non-edible vegetable oils. Karanja and Jatropha oil methyl ester biodiesel are prepared by the process of transesterification. Biodiesel emits lesser gaseous emission as compared to diesel fuel. However, the only major concern in the use of biodiesel is that it increases NOx emission. Nano particle fuel additive is one of the essential techniques to overcome the NOx emission drawback of biodiesel. In the present study, the engine performance and emission of CO, UHC, NOx and PM including nano particle emission, were compared for diesel, Karanja and
Biodiesel fuels are an alternative to diesel fuel. Biodiesel is an oxygenated, sulphur free, non-toxic, biogradable and renewable fuel. It is derived from vegetable oils. Since straight vegetable oils have quite high viscosity compared to mineral diesel, they have to be modified to bring their combustion-related properties and viscosity closer to mineral diesel. This is done by modifying their molecular structure through a transesterification process. In the present study, a military heavy duty 38.8 liter, 585 kW supercharged, compression ignition diesel injection (CIDI) engine was fuelled with diesel, Karanja oil methyl ester (KOME) biodiesel, and KOME biodiesel with cerium oxide fuel additive, respectively. These were subjected to 100 hours long term endurance tests. Lubricating oil samples, drawn from the engine fuelled with these fuels after a fixed interval of 20 hours, were subjected to elemental analysis. Atomic absorption spectroscopy was done for quantification of various
Global warming with stringent emission legislation along with the depletion of fossil fuel has given us an opportunity to find biodiesel as alternative to diesel fuel. Biodiesel has been widely accepted as comparable fuel to diesel in diesel engine. This is due to its renewable property, better lubricity, along with lesser gaseous emission as compared to diesel fuel. However, there is a major disadvantage in the use of biodiesel as it increases NOx emission. Fuel additive becomes one of the essential tools to overcome the drawback of biodiesel required to meet the international standard of performance and emission. In this study, the performance, combustion, and gaseous emission of CO, CO2, HC, NOx and PM including particle size number distribution characteristics, were compared for diesel, Karanja oil biodiesel, and Karanja oil biodiesel with Cerium Oxide Nano particles fuel additive, in a 12 cylinder, 585 kW, CIDI military diesel engine. The experimental result showed that engine
The rising awareness of environmental protection on a global level is leading to more stringent automobile emissions regulations. In addition, there are calls to reduce the use of precious metals as catalysts due to concerns about resource depletion. Recently, the number of hybrid vehicles and vehicles featuring idling engine stop functionality is increasing as fuel-efficient vehicles rapidly becoming the norm for all models. In these vehicles the amount of NOx emissions increases when the engine restarts after an idling stop and it is difficult to reduce the use of precious metals in the catalyst. Consequently, it is necessary to develop a catalytic technology that can make effective use of the Rh component because this is essential to NOx conversion. In this study, an examination was conducted using the following two approaches for the purpose of reducing the amount of transient NOx. Approach (1) It was found that the use of a Praseodymium (Pr)-doped oxygen storage capacity (OSC
This paper describes a newly developed motor and inverter system with maximum torque of 320 Nm and maximum power of 110 kW for a 2018 model year EV. The system achieves this performance with no increase in size from the previous 2013 model year system with maximum torque of 254 Nm and maximum power of 80 kW. The specific features of the new system described in this paper are summarized below. A new inverter power module that adopts a direct cooling structure produces higher current density than the previous model. The designs of components experiencing structural and electrical variation that affects heat generation by the power semiconductors were confirmed. Furthermore, the motor temperature is estimated for thermal protection. These features allow for control logic that can optimally manage the temperatures of the power semiconductors and the motor to facilitate the high torque performance of the system. The motor voltage management has also been optimized in order to reduce the
Four lasers can be used for micro welding: pulsed neodymium-doped yttrium aluminum garnet (Nd:YAG), continuous wave (CW) fiber, quasi continuous wave (QCW) fiber, and nanosecond fiber. Each laser type offers unique features that work best for specific applications. This article presents a comparison of the pulsed Nd:YAG laser with the three fiber laser options and discusses why and when one might be chosen over the other. In some cases, several options may work; in that case, cost of ownership and serviceability can tip the scales
The main objective of this research was to construct an optical pump system that would allow the study of Er:GaN materials under 980 nm resonant excitation to be carried out. The results obtained from the optically pumped studies could then be utilized to guide crystal growth and laser design
With Increasing environmental concerns and high fuel prices, the automotive industry is shifting its focus to electric vehicles (EVs). Electric motor being the heart of an electric vehicle, faces a major design challenge to have optimum performance and structural strength at an affordable cost. Synchronous reluctance motor offers higher power density at low cost since the rotor is free from rare earth permanent magnets or field excitation. However, torque fluctuations and resulting vibrations are a major concern. This is amended by optimizing the end-barrier width and end-barrier orientation angle in the rotor so as to maximize the torque and minimize the ripple. Simulations are also performed with ferrite magnets assistance to achieve an enhanced torque output. In each case, a structural analysis is done to verify the mechanical strength and rotor deformation considering structural and electromagnetic forces. The analyses are performed using finite element simulations. A comparison
In order to achieve NOx tailpipe targets of current diesel regulation standards two main catalytic technologies have been employed, specifically NH3-SCR and LNT. However both of these technologies face challenges with the implementation of newer / colder test cycles such as “Real Driving Emissions” (RDE), combined with CO2 targets (95 g/km is 2020 target in Europe). These cycles will require higher NOx Storage Capacity (NSC) in the low temperature region (120-350°C). Conversely, lean-burn Gasoline vehicles, with their higher operational temperatures, will require improved NSC over a broader temperature range (200-500°C). Therefore, the development of NSC materials to meet these opposing requirements is an area of extensive study by Original Equipment Manufacturers (OEMs), washcoaters, and raw materials suppliers. Today, ceria is a key component in the formulation of active NSC washcoats. It is often combined with barium in order to improve its high temperature NSC, but this also leads
YAG-based fiber lasers could offer efficient operation at power levels beyond those achievable in current state-of-the-art silica-based fiber lasers if losses can be minimized. To address this, researchers have investigated creating both single-crystal and polycrystalline YAG fibers. Among the cases reported is the preparation of single-crystal YAG fibers using laser heated pedestal growth (LHPG), which resulted in fiber diameters of 400 μm and optical losses around 1–2 dB/m in the 1–3 μm wavelength range. Single-crystal YAG fibers with diameters of ~ 30 μm have even been reported
In the early 1980's, some promising research and development efforts focused on powder metallurgy revealed that aluminum alloys containing 4 wt% cerium exhibit high temperature mechanical properties exceeding those of the best commercial aluminum casting alloys currently in production. Cerium oxide is an abundant rare earth oxide that is often discarded during the refining of more valuable rare earths such as Nd and Dy. Therefore, the economics are compelling for cerium as an alloy additive. In this paper, we report select results obtained during an investigation of the castability of aluminum-cerium alloys and determine compositional modifications that may be required to ensure the compatibility of the alloy with near net shape casting methods such as advanced sand casting, die casting, permanent mold casting and squeeze casting. Al-Ce alloys were cast in binary composition of 6-16 wt% Ce. Commercially pure aluminum ingots were melted and held at approximately 785°C. Ternary and
This paper describes a new catalyst powder has been developed that provides cleaner exhaust emissions and reduces the consumption of precious metals. In recent years, precious metal usage has been increasing due to the tightening of emission regulations and the increase in automobile production worldwide. Minimizing the use of precious metals in exhaust catalysts is crucial not only for reducing the cost of vehicles but also for effective utilization of scarce resources. Iron is one of the alternative material candidates for precious metals. It was found that the Iron catalyst was activated by iron becoming the low oxidation state while iron oxide and cerium oxide synchronized in a nanostructure interface. A catalyst with improved iron support technology that enables better contact between highly dispersed particles of iron and ceria was found to exhibit higher exhaust gas cleansing performance than precious metal catalysts even after aging
Diesel particulates are mainly composed of elemental carbon (EC) and organic carbon (OC) with traces of metals, sulfates and ash content. Organic fraction of the particulate are considered responsible for its carcinogenic effects. Diesel oxidation catalyst (DOC) is an important after-treatment device for reduction of organic fraction of particulates. In this study, two non-noble metal based DOCs (with different configurations) were prepared and evaluated for their performance. Lanthanum based perovskite (LaMnO3) catalyst was used for the preparation of DOCs. One of the DOC was coated with support material ceria (5%, w/w), while the other was coated without any support material. Prepared DOCs were retrofitted in a four cylinder water cooled diesel engine. Various emission parameters such as particulate mass, particle number-size distribution, regulated and unregulated emissions, EC/OC etc., were measured and compared with the raw exhaust gas emissions from the prepared DOCs. It was
Thin films deposited by magnetron sputtering are review in terms of their potential and present uses in the aircraft industry. The aircraft alloys substrates were Ti-6Al-4V and Incoloy 800HT, using a target of yttrium stabilized zirconia (YSZ) with nominal composition of 8% Y2O3 (wt%) and the remainder of ZrO2. The chemical composition of the films was determined by X-ray energy dispersion (EDS). The electrochemical noise behavior show that the coatings decreased propagation of pitting, leading to a state of passivation or uniform corrosion, and also possess superior corrosion resistance over the individually substrates
On-board hydrogen generation technology using a fuel reforming catalyst is an effective way to improve the fuel efficiency of automotive internal combustion engines. The main issue to be addressed in developing such a catalyst is to suppress catalyst deterioration caused by carbon deposition on the catalyst surface due to sulfur adsorption. Enhancing the hydrocarbon and water activation capabilities of the catalyst is important in improving catalyst durability. It was found that the use of a rare earth element is effective in improving the water activation capability of the catalyst. Controlling the hydrocarbon activation capability of the catalyst for a good balance with water activation was also found to be effective in improving catalyst durability
At present, vast numbers of problems are triggered due to growing global energy crisis and rising energy costs. Since, on-road vehicles constitute the majority share of transportation; any energy losses in them will have a direct effect on the overall global energy scenario. Most of the energy lost is dissipated from the exhaust, cooling, and lubrication systems, and, most importantly, in the braking system. About 6% of the total energy produced is lost with the airstream in form of heat energy when brakes are applied. Thus, various technological systems need to be developed to conserve energy by minimize energy losses while application of brakes. Regenerative Braking is one such system or an energy recovery mechanism causing the vehicle to decelerate by converting its kinetic energy into another form (usually electricity), which further can be used either immediately or stored until needed. This study aims at regenerative systems attached at the wheels, although, Regenerative Braking
This research is aimed at development of the catalyst for gasoline automobiles which uses only palladium (Pd) among platinum group metals (PGMs). And the conformity emission category aimed at LEV III-SULEV30. For evaluation, the improvement effect was verified for 2013 model year (MY) ACCORD (LEV II-SULEV) as the reference. As compared with Pd-rhodium (Rh) catalyst, a Pd-only catalyst had the low purification performance of nitrogen oxides (NOx), and there was a problem in the drop in dispersion of Pd by sintering, and phosphorus (P) poisoning. The following was performed in order to improve these. 1) NOx purification performance was improved using an enhanced basicity support material by promoting the dissociation of N and O in NOx 2) sintering of Pd was controlled using the anchoring effect of praseodymium-zirconia (PrZrOx) 3) poisoning inhibition of Pd and the support material was carried out utilizing the P trapping effect of praseodymium (Pr) Tail pipe emission was set to the LEV
In the context of evolving market conditions the Three-Way Catalyst (TWC) is entering an exciting new phase. It remains the main emission control strategy for gasoline powered vehicles but a period of rapidly evolving engine development, tighter tailpipe regulations and material supply issues present a unique challenge to catalyst developers. This paper presents an initial study outlining the development of spinel mixed metal oxides for application in modern TWC and addresses some specific challenges underlying this application. Lab and flow reactor data in the study showed how the spinel structure has significant potential in various aspects of the TWC with the necessary improvement in thermal stability. Some initial engine data show three-way performance at or near stoichiometric in a PGM and rare earth free spinel coating and a synergy effect when combined with PGM. An example of a simple calibration modification is shown exploiting the improved three-way window in a combined spinel
The typical approach for producing laser output at the 1651-nm wavelength is via nonlinear frequency conversion. Lasers based on nonlinear conversion are complex, and it is very difficult to provide stability over time and over a wide range of operating temperatures. The efficiency of such optical sources is also low. A much more promising approach is the use of active media that allows for the development of solid-state lasers (SSL) with spectral emission at 1651 nm. An important requirement for this active medium is the ability to support in-band pumping with a low quantum defect since this approach leads to significant improvement in efficiency of SSLs and excellent beam characteristics due to low thermal stress of the active media
Increased demands on rare earth fossil fuels and the global warming have led to development of alternative technology vehicles. Electrical vehicle (EV) is chosen as one of the alternative technology to overcome these hindrances. In EVs the battery and the motor are the two most critical components used for generating the required power output. In this paper, work was done for selection battery technology and relevant packaging for a small car. The work done is described in four stages: i) battery selection based on literature, ii) car selection based on virtual reality (VR) study iii) battery package design, and iv) finally specification sheet was developed for an EV. Key Objectives considered for the battery selection are: i) minimal maintenance, ii) modular and scalable, iii) high energy density, iv) optimized thermal management, and v) low cost implications. A detailed study was conducted on current literature and state of art of batteries and solution adopted in available
Nickel electroplating is commonly used with substrates including steel, aluminum, plastic and zinc die-cast parts because of its high resistance to temperature, corrosion and wear in harsh conditions. To further enhance its tribological and mechanical properties, research works are going on to produce nano-reinforced composites of Ni with various ceramic and rare earth oxides like CeO2, ZrSiO4, SiC, TiO2, etc. The aim of present work is synthesis and characterization of Ni films and Ni based TiO2 nano-composite coating processed by pulse co-electrodeposition technique. Also, to investigate the various properties such as mechanical, wear and corrosion resistance, conductivity & thermal stability of Ni-TiO2 nanocomposites electrodeposited on steel substrate, especially the effects of the amount of nanosized TiO2 particles in Ni-TiO2 nanocomposites. The nanocomposite thin films have been characterized by x-ray diffraction (XRD) and scanning electron microscopy (SEM) equipped with an
This paper proposes a new multi air gap motor with trench-shaped coil. The proposed motor has high torque without rare earth magnets compared to conventional single air gap motors due to its multiple air gap and ferrite permanent magnet (PM) assisted segment rotor poles. Firstly, the basic structure and features of proposed motor is shown: three stator cores, integrated a set of three phase windings, and an annular rotor core with magnetic saliency at three sides and ferrite magnets. Then, the performance of proposed new motor and well-known single air gap IPMSM with rare earth magnet are compared by FEA. Secondly, the simple winding method similar to the conventional motor is clarified. Next, practical design of the 3-D magnetic circuit with laminated steel is discussed. Eddy current generated by the magnetic flux passing through the laminated steel in the core stacking direction is focused, and methods for reducing eddy current loss are shown. Finally, performances of proposed motor
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