February 2025
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Frontiers in Thermal Engineering
The U.S. Department of Energy Supertruck 2 program placed emphasis on development of heavy-duty trucks with high freight efficiency using commercially realizable technology suites. This paper describes the research and development process used to pursue a high thermal efficiency heavy-duty engine under Supertruck 2 . The team focused on over-expanded engine cycles and advanced piston designs. This paper describes how single-cylinder engine studies using thermal barrier coated pistons, high compression pistons, and over-expanded cycles informed the development process of a multi-cylinder demonstration engine that achieved 49.9% peak thermal efficiency. While tailoring the injection strategy and other control parameters optimized the demonstration engine, more than half of the efficiency improvement came from the over-expanded cycle.