Awarded Projects
These are the projects awarded funding by LightMAT, listed by year.
A Machine Learning Assisted Weld Quality Diagnostic Tool to Assure Structural Integrity of Electric Vehicle Battery Enclosure
Industry Participant:General Motors LLC
National Laboratories:Oak Ridge National Laboratory
Contact
DFAbstract
Structural battery enclosures must meet the most stringent quality and performance requirement in electric vehicle body structures, including being leak-proof to prevent the battery inside malfunctioning and creating a safety hazard. Since battery enclosures are a key contributor to the weight of a battery system, the third generation (3rd GEN) advanced high-strength steel considered for significant mass savings at affordable cost. However, the 3rd GEN advanced high-strength steel have a propensity for weld cracking, causing leaking through welds. These cracks are difficult to detect with today’s commercial non-destructive evaluation. This project will develop and demonstrate a weld quality diagnostic tool by innovative use of advanced non-destructive evaluation technology powered by machine learning to meet industry’s needs for accurate, reliable, fast, and cost-effective leak inspection of welded battery enclosures.
Atmospheric Plasma Deposition for Adhesive Bonding of Multi-Material Systems
Industry Participant:General Motors LLC
National Laboratories:Pacific Northwest National Laboratory
Contact
KSAbstract
Atmospheric pressure plasma deposition using a new, low-energy process was recently demonstrated as a replacement for conversion coatings for surface treatment to bond dissimilar, lightweight materials, offering significant cost savings and elimination of chemical waste. The system shows potential to overcome limitations of existing commercial systems in the chemical bonding and structures that can be produced. The proposed work is aimed at establishing the capabilities of the new process, improving the robustness for manufacturing, and evaluating alternative precursors for expanding the surface characteristics and performance for different lightweight materials. The advanced surface characterization capabilities and expertise at Pacific Northwest National Laboratory will be leveraged to develop the fundamental understanding needed to accelerate the path to implementation in manufacturing.
Development of Sustainable Aluminum Alloy for Lightweight Ultra-Large Castings
Industry Participant:General Motors LLC
National Laboratories:Oak Ridge National Laboratory
Contact
GMAbstract
Ultra-large aluminum (Al) castings are increasingly used in critical automotive applications to reduce number of parts and production lead time, and especially to reduce mass, energy, and tooling cost. Associated challenges include the use of high fractions of costly primary Al to achieve ductility, potential high casting scrap rates due to increased geometric complexity, and increasing uncertainty of material properties and component performance. This project will develop a new cast Al alloy with greater sustainability (larger fractions of secondary Al) and robust high-integrity die casting process for high-performance, ultra-large castings. The project will apply integrated computational materials engineering tools and leverage national laboratory advanced experimental capabilities to accelerate alloy development, culminating in demonstration of a large rear rail casting with 42 percent mass reduction.
Direct Extrusion of 6082 and 7xxx Battery Tray Structures Using Shear Assisted Processing and Extrusion (ShAPE™)
Industry Participant:Vehma International of America, Inc.
National Laboratories:Pacific Northwest National Laboratory
Contact
SWAbstract
This project will address the key technology gaps that are presently limiting the industrialization of Shear Assisted Processing and Extrusion (ShAPE™) for manufacturing electric vehicle battery tray structures. In order for Vehma International of America, Inc. and its affiliates (collectively, “Vehma”) to accelerate commercialization, two critical aspects of the ShAPE™ technology must be demonstrated. First, ShAPE™ must operate as a direct extrusion process in contrast to the indirect process presently in use. Second, multicell extrusion profiles with high aspect ratio must be achieved to show relevance for battery tray structures. ShAPE™ is a new technology developed by Pacific Northwest National Laboratory which combines friction-stir processing and conventional extrusion to recycle secondary aluminum scrap directly into automotive components. The unique process of ShAPE™ can expand the breadth of secondary aluminum alloy scrap which can be successfully extruded (7xxx, 6xxx, 2xxx, metal matrix composites, lower cost, reduce carbon emissions, and potentially simplify the overall manufacturing route compared to conventional extrusion. Additionally, the properties obtained with ShAPE™ have been shown to be equal to (or better than) conventionally extruded aluminum product specifications. Research performed on this project will enable Vehma to finalize business plans and proceed with development of industrial-scale ShAPE™ machines, tooling, and process configurations for use in production of automotive components.
Wholly Sustainable, Cost-Effective Carbon Fiber-Nylon Compounds
Industry Participant:DowAksa USA LLC
National Laboratories:Pacific Northwest National Laboratory
Contact
KSAbstract
Carbon fiber composites have attracted considerable attention due to the potential for substantial mass savings, with many examples now implemented in the low volume luxury car market. However, migration to higher volume applications has been hindered by: (a) high material cost, (b) high processing times, and (c) perception of low sustainability. This project will address all three of these barriers: (a) carbon fiber material to replace aluminum in structural components at a cost penalty of no more than $5/Kg-saved (aka weight buy); (b) fitting into high-speed auto process, like injection molding; and (c) end-to-end sustainable material based on post-industrial waste carbon fiber and nylon 66, and the ability to recycle end-of-life auto parts. The opportunity lies in combining DowAksa USA LLC capabilities in carbon fiber manufacturing and resin chemistry intermediate production with the unique testing capabilities inherent within Pacific Northwest National Laboratory.
fengz@ornl.gov
865-576-3797