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CRADA NFE-08-01671 – Materials for Advanced Turbocharger Design
PI – Philip J. Maziasz, ORNL and Marc Wilson, Honeywell
Oral – June 19, 2014
Project ID – PM038
Agreement - 17257
Project Area – Materials for Combustion Systems/High Efficiency Engines
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Overview
• Project began – September, 2009
• Project ends – September, 2014
• Project is >75% complete
Timeline
• Total Project Funding
• DOE Share – 50%
• Honeywell – 50%
• FY12 Funding - $300,000
• FY13 Funding - $0
• FY14 Funding – $150,000
Budget
• Barriers addressed include:
• Difficulty in simultaneously increasing efficiency and reducing emissions
• HECC Technologies increase exhaust temperatures for turbochargers
Barriers
Partners
• Honeywell suppliers for turbocharger components • Engine customers for turbochargers (LD and HD engines)
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Relevance
This CRADA project is relevant to a key technical gap in Propulsion Materials that supports the following Advanced Combustion Engine goal: 2015 Commercial Engine – Improve Efficiency by 20% over 2009 baseline efficiency Turbocharging improves fuel efficiency particularly in gasoline engines
Technical Objective – Higher temperatures (>750oC, diesel, >950oC gasoline) exceed the strength and temperature capability of current materials, particularly cast-iron for turbocharger housings
Impact – Turbocharger housing and other components with more temperature capability and strength will enable higher, sustained operating temperatures. Stainless steel turbo-housings will also reduce weight and retain exhaust heat relative to cast-irons
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Approach - Caterpillar Commercialized CF8C-Plus steel for the CRS component that are on all heavy-duty highway truck diesel engines since 2007 (Oct, 2006)
CF8C-Plus steel
SiMo Cast-iron
• Exhaust combustor (turbo exhaust + injected fuel) to clean out particulate filters: very high temperature and rapid cycling conditions
Over 500 tons of CF8C-Plus cast for CRS application (no failures, some >6 y)
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Approach – Cast Keel Bars or Blocks for Properties Testing
alloy Cr Ni Mn Mo Nb C N Si Fe
CF8C-Plus
19.1 12.5 3.5 0.35 0.94 0.09 0.24 0.6 bal
HK30-Nb
25.2 19.4 1.2 0.27 1.2 0.30 1.6 bal
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Approach – Follow Honeywell Requirements for Qualifying Turbocharger Materials
Phase 1 Screening
Phase 2 •Thermal •Physical •Monotonic
Phase 3 •Fatigue •Creep •Oxidation •Damping
Phase 4
Interaction
Thermal - Thermal Expansion - Heat Capacity - Thermal Conductivity - Thermal Diffusivity
Monotonic - Room Temp. Tensile - Elevated Temp. Tensile
Physical - Density - Poisson's Ratio - Young's Modulus
Strain/Stress controlled LCF Stress Controlled HCF
J-MAT-PRO simulation tool Materials Engineering
Thermo-Mech Fatigue Fatigue-Creep Fatigue-Oxidation
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Milestones • FY2013, Q1 – complete neutron-scattering residual-
stress measurements on wheel/shaft assemblies with stress-relief heat-treatments (Dec, 2012, complete)
• FY2013, Q3 – begin creep-tests of cast CF8C-Plus stainless steels to facilitate gasoline turbocharger applications (July, 2013, complete)
• FY2014 , Q1– Complete diesel engine exhaust testing of CF8C-Plus steel at 800C (Dec. 2013, complete)
• FY2014 , Q2– Evaluate oxidation resistance of CF8C-Plus tested in diesel exhaust environment (Mar. 2014, complete)
• FY2014 , Q3 – Assist Honeywell in indentifying appropriate foundries for prototyping CF8C-Plus housings (June 2014, on track)
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Technical Accomplishments – Upgrade Turbo-Housing to Cast Stainless Steel
Current SiMo cast-iron turbocharger housing for diesel engine product
ORNL developed CF8C-Plus cast stainless steel with more strength than HK30Nb stainless alloy > 750oC. Both have ten times more strength than SiMo cast-iron above 500-600oC
0
500
1000
1500
2000
2500
750C/100 MPa 800C/75 MPa 850C/50 MPa
Cree
p Ru
ptur
e Life
(h)
Creep Testing Conditions
HK30-Nb
CF8C-Plus
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Technical Accomplishments – Upgrade Turbo-Housing to Cast Stainless Steel for More High-Temperature Creep Resistance
• CF8C-Plus cast stainless steel has significantly better creep-resistance than SiMo and Ni-resist cast irons at 700-900oC
•CF8C-Plus stainless steel cost is about 33% less than HK30-Nb alloy
10
100
1000
10 15 20 25 30Cre
ep-R
uptu
re S
tres
s (M
Pa)
LMP (x10-3)
LMP of Heat-Resistant Alloys CF8C-Plus N277CF8C-PlusHK30-NbNi-ResistKN2SiMo cast-iron
600C
900C
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Technical Accomplishment – Oxidation Testing in a Diesel Exhaust Environment at 800C
-0.1
-0.05
0
0.05
0.1
0 50 100 150 20
800C comparison(Lab - 100h cycles, Genset - 1h cycles)
Hours
SiMoB: Genset
CF8CP: Lab.800C.WV
SiMoB: Lab.800C.WV
HK: Lab.800C.WV
HK: Genset
CF8CP: Genset
Preliminary tests indicated a substantially lower rate of oxidation after testing in actual diesel exhaust vs. laboratory air + 10%water vapor at 800C
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Technical Accomplishment -Physical Properties – Thermal Expansion
CTE Data for CF8C-Plus and HK-30Nb Steels
15
16
17
18
19
20
21
22
0 200 400 600 800 1000 1200 1400
Temperature (C)
CTE
(alp
ha/K
)
heat 1N277HK-30Nb
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Technical Accomplishment - Physical Properties – Thermal Conductivity
Thermal Conductivity Data for CF8C-Plus and HK-30Nb Steels
10
15
20
25
30
35
0 500 1000 1500
Temperature (C)
Ther
mal
Con
duct
ivity
(W/m
K)
heat 1N-277HK-30+Nb
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What’s Next - High Temperature Material Testing
Material testing
LCF Iso-Thermal
Thermo Mechanical Fatigue
Creep/ Stress Relaxation
Fatigue with Dwell
Creep-Fatigue-Oxidation
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Issues and Barriers
• Decreased funding with increased Honeywell need for expensive testing ( fatigue, creep, TMF)
• Upgrade of creep machines and fatigue machines after extended high temperature testing
• Installation of new diesel exhaust facility at ORNL • Honeywell CRADA needs to be extended for 2 more
years before September, 2014
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Summary
• Relevance – Turbocharging improves fuel efficiency of gasoline engine vehicles
• Approach/Strategy – Work with Honeywell phased approach to qualifying CF8C-Plus steel for turbochargers
• Accomplishments – Completed Phase 1 testing creep, fatigue and thermal fatigue qualifying CF8C-Plus steel
• Collaborations – SF&E, Honeywell and potential engine customers (Caterpillar, Ford, etc.)
• Proposed Future Work – Phase 2 – 4 testing of CF8C-Plus, particularly fatigue and creep testing.