The Energy Department today announced a total of $4.4 million for two projects in Michigan and Pennsylvania to support the use of advanced materials and manufacturing techniques in the development of new “low-head” hydropower technologies.

The United States has major opportunities across the country to add new hydropower generating capabilities at low-head sites, which operate with a change in elevation between 2 and 20 meters, including waterways at existing non-powered dams, canals, and conduits. According to Energy Department assessments, there is a technical resource potential of more than 50 GW of potential capacity at these low-head sites.

• Eaton Corporation of Southfield, Michigan, will develop a turbine and generator system that uses lightweight advanced materials and advanced manufacturing techniques such as laser-assisted welding, surface treatments, and processing. The turbine will be designed to deliver a constant source of energy despite changes in water flow by using a system that operates efficiently across a range of ebbs and flows. The Eaton Corporation will design, fabricate, and test its turbine at 1/10th scale. 
• Pennsylvania State University will develop and demonstrate a low-head hydropower turbine and generator system prototype that combines lightweight, corrosion-resistant metallic components that can be produced through an additive manufacturing process. A condition-based monitoring system will also facilitate improved operation and maintenance.