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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sources NASA NTRS DOE OSTI

NASA NTRS2007

A Symmetrical, Planar SOFC Design for NASA's High Specific Power Density Requirements

Solid oxide fuel cell (SOFC) systems for aircraft applications require an order of magnitude increase in specific power density (1.0 kW/kg) and long life. While significant research is underway to develop anode supported cells which operate at temperatures in the range of 650-800 C, concerns about Cr-contamination from the metal interconnect may drive the operating temperature down further, to 750 C and lower. Higher temperatures, 900-1000 C, are more favorable for SOFC stacks to achieve specific power densities of 1.0 kW/kg. Since metal interconnects are not practical at these high temperatures and can account for up to 75% of the weight of the stack, NASA is pursuing a design that uses a thin, LaCrO3-based ceramic interconnect that incorporates gas channels into the electrodes. The bi-electrode supported cell (BSC) uses porous YSZ scaffolds, on either side of a 10-20 microns electrolyte. The porous support regions are fabricated with graded porosity using the freeze-tape casting process which can be tailored for fuel and air flow. Removing gas channels from the interconnect simplifies the stack design and allows the ceramic interconnect to be kept thin, on the order of 50 -100 microns. The YSZ electrode scaffolds are infiltrated with active electrode materials following the high temperature sintering step. The NASA-BSC is symmetrical and CTE matched, providing balanced stresses and favorable mechanical properties for vibration and thermal cycling.

Cable, Thomas L.↗

NASA NTRS1998

Sodium Transport Modes in AMTEC Electrodes

Transport of alkali metal atoms through porous cathodes of alkali metal thermal-to-electric converter (AMTEC) cells is responsible for significant, reducible losses in the electrical performance of these cells.

Sodium↗

DOE OSTI2025

Porous carbon from lignocellulosic biomass with emphasis on corn plant waste residue for energy storage

The rising global demand for sustainable energy storage materials has driven the search for environmentally friendly and cost-effective electrode options. Hydrothermal conversion of lignocellulosic biomass has gained attention due to its low energy requirements and operation at relatively low temperatures, presenting a green alternative to traditional thermochemical methods. The resulting solid product, hydrochar, has been used as an adsorbent and soil amendment; however, chemical/thermal treatment significantly enhances its physical properties. These structural modifications transform hydrochar into an effective porous carbon electrode, offering abundant sites for electrolyte ion transport, critical for high-performance devices like supercapacitors and batteries. This review first discusses various waste biomass and sustainable feedstocks available globally. It compares two primary thermochemical conversion techniques, pyrolysis and hydrothermal carbonization/liquefaction, and examines their respective solid products, biochar and hydrochar, analyzing differences in their physical and chemical characteristics. The focus is placed on hydrochar, summarizing activation methods to produce porous carbon suitable for energy storage applications. Additionally, this review will include a dedicated section on the application of porous carbon derived from corn plant waste residue, considering that corn is one of the most abundant crops grown worldwide, which makes it an important and promising source for sustainable porous carbon production. The role of machine learning models in optimizing hydrothermal processes to produce high-quality hydrochar is also discussed, emphasizing how data-driven approaches can streamline process development. Finally, the review identifies the current challenges and prospects for lignocellulosic biomass-derived porous carbon as a sustainable electrode material in next-generation energy storage technologies.

25 ENERGY STORAGE↗

NASA NTRS1973

Fabrication and testing of negative-limited sealed nickel-cadmium cells

The design, construction, and testing of 100,20Ah and 100,3Ah negative-limited sealed cells are reported. The required physical dimensions of the hardware and components necessary to produce 20 and 3 Ah cells were established. The stainless steel cans and covers have been ordered. The covers contain two ceramic seals. The fabrication of electrodes was started. About 55% (879 electrodes) of the required cadmium electrodes has been prepared. About 44% of the porous nickel substrates (plaques) required for the preparation of the nickel oxide electrodes has been completed.

Luksha, E.↗

DOE OSTI2025

SOC Microstructural Property Estimator

This pre-trained ML model is a tool that uses basic compositional parameters for porous solid oxide cell (SOC) electrodes - the phase fractions and mean particle/pore diameters – as inputs and uses them to estimate additional electrochemical performance parameters: active (i.e., connected) TPB density, all tortuosity factors, and phase pair specific interfacial areas. The electrode is assumed to be composed of two solid phases and a pore phase. The property calculations are performed using neural network regression models trained on a large bank of synthetic electrode microstructural data that NETL has generated using the program DREAM3D (that bank is also hosted on EDX: https://edx.netl.doe.gov/dataset/soc-synthetic-microstructure-bank). This means the generated parameters are based on training from actual measured properties from 3D microstructures, not estimated from geometric simplifications. This tool was developed and is intended to replace percolation theory calculations in models that use hypothetical electrode properties. An example use case would be running SOC performance simulations across a parametric sweep of electrode designs (e.g., varying phase fractions and particle sizes) and assessing how it impacts the electrochemical performance of the SOC. Within the parameter space of the training data (statistics of that parameter space is provided in the readme file), this model achieves sub-5% mean absolute percent errors, an order of magnitude less error than percolation theory across the same parameter space. However, be aware that this tool was developed with parametric simulations in mind, and users are encouraged to assess accuracy for their own specific use case rather than taking accuracy metrics at face value. More info, including a usage guide, is in the included readme file. This tool should be cited with the DOI number provided.

Electrode Microstructure↗

NASA NTRS1991

Effect of ohmic, mass-transfer, and kinetic resistances on linear-sweep voltammetry in a cylindrical-pore electrode

A means is presented to account for the effect of ohmic, mass-transfer, and kinetic resistances on linear-sweep voltammograms by modeling a pore in a porous matrix as a cylindrical-pore electrode, and solving the mass and charge conservation equations in the context of this geometry for the simply redox reaction O + ne(-) yield R where both O and R are soluble species. Both analytical and numerical techniques are used to solve the governing equations. The calculated peak currents and potentials are correlated by empirical formulas to the measurable parameters: sweep rate, concentration of the redox species, diffusion coefficient, conductivity of the electrolyte, and pore dimensions. Using the correlations, a methodology is established for determining if the redox reaction kinetics are irreversible or reversible (Nernstian). If the reaction is irreversible, it is shown how the standard rate constant and the transfer coefficient may be extracted from linear-sweep voltammetry data, or, if the reaction is reversible, how the number of electrons transferred may be deduced.

Weidner, John W.↗

DOE OSTI2026

Evaluation of Three Types of Electric Field Sensors

On June 3-4, 2025, we evaluated three types of electric-field (E-field) sensors: capacitive electrodes, stainless-steel stakes, and porous pots - at two electromagnetic (EM) stations (PWBVI and PWAOF) on Aqueduct Mesa at the Nevada National Security Site. We compared calibrated time series and derived metrics including power spectral density, root-mean-square (RMS) amplitude, signal-to-noise ratio (SNR), and detectability of power line harmonics and Schumann resonance. The objective was to identify an alternative E field sensor with higher SNR than the existing capacitive electrodes. Our data demonstrates that stainless-steel electrodes perform best, with the highest SNR and the most consistent detection of power-line harmonics and Schumann resonance among the three sensor types; they may be used as a supplement to, or replacement for, the existing capacitive electrodes.

58 GEOSCIENCES↗

DOE OSTI2024

Binder-Coated Carbon Cloth Electrodes for All-Vanadium Redox Flow Batteries

Vanadium redox flow batteries (VRFBs) are a promising solution for integrating intermittent renewable energy sources into the existing power grid. However, enhancing the electrochemical performance of VRFBs is critical for their widespread adoption in grid-scale energy storage. This study investigates the impact of adding a porous binder to a carbon-cloth electrode, with a focus on optimizing thermal activation conditions. The electrochemical performance of the binder-coated electrodes compared to uncoated electrodes is evaluated through electrochemical impedance spectroscopy, polarization curve measurements, and charge-discharge cycling. The surface morphology and structural integrity of the binder-coated electrodes at each activation stage are examined using various material characterization techniques to assess the effects of thermal activation. The results are benchmarked against the experiments using non-coated electrodes to determine the performance improvements offered by the binder coating. Notably, the study reveals that binder-coated electrodes exhibit significantly lower resistance and improved efficiency compared to their uncoated counterparts, with optimal activation conditions enhancing performance metrics crucial for VRFB applications. These findings provide valuable insights for further optimizing electrode design and activation strategies, advancing the development of more efficient VRFB systems for large-scale energy storage.

Caiado, Ashley A.↗

DOE OSTI2025

Modeling Electrodeposition in 3D Porous Architectures for Solid-State Li-Metal Batteries

Li-metal storage in three-dimensional (3D) electrodes is considered a potential dendrite-mitigation strategy. The large surface area and high porosity of these electrodes result in reduced local Li-plating current densities. The porous topology provides a scaffold for Li-deposition and stripping, maintaining both mechanical integrity and Li accessibility. The goal of this study is to understand how characteristics, such as geometry and material properties, affect the current distribution and deposition pattern. To this end, we developed a computational method to track material growth driven by electrodeposition within a complex geometry. This method ensures that the finite-element discretization remains conforming to the moving boundary while preserving an adequate mesh quality, and thus maintains solution accuracy. Using this new computational tool, we analyze the conditions under which porous anode architectures effectively expand the surface area of the charge-transfer interface, and self-regulate current density and dendrite growth.

3D electrode architectures↗

NASA NTRS1992

Testing and analyses of electrochemical cells using frequency response

The feasibility of electrochemical impedance spectroscopy as a method for analyzing battery state of health and state of charge was investigated. Porous silver, zinc, nickel, and cadmium electrodes as well as silver/zinc cells were studied. State of charge could be correlated with impedance data for all but the nickel electrodes. State of health was correlated with impedance data for two silver/zinc cells, one apparently good and the other dead. The experimental data were fit to equivalent circuit models.

Norton, O. A., Jr.↗

NASA NTRS2000

Direct methanol feed fuel cell and system

Improvements to non-acid methanol fuel cells include new formulations for materials. The platinum and ruthenium are more exactly mixed together. Different materials are substituted for these materials. The backing material for the fuel cell electrode is specially treated to improve its characteristics. A special sputtered electrode is formed which is extremely porous.

Surampudi, Subbarao↗

NASA NTRS2001

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2004

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2008

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2008

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2009

Direct methanol feed fuel cell and system

Improvements to non acid methanol fuel cells include new formulations for materials. The platinum and ruthenium are more exactly mixed together. Different materials are substituted for these materials. The backing material for the fuel cell electrode is specially treated to improve its characteristics. A special sputtered electrode is formed which is extremely porous. The fuel cell system also comprises a fuel supplying part including a meter which meters an amount of fuel which is used by the fuel cell, and controls the supply of fuel based on said metering.

Surampudi, Subbarao↗

NASA NTRS2015

Graphene-Based Electrode for a Supercapacitor

A supercapacitor electrode mechanism comprising an electrically conductive, porous substrate, having one or more metallic oxides deposited on a first surface and a chemically reduced graphene oxide deposited on a second surface, to thereby provide an electrical double layer associated with the substrate. The substrate may be carbon paper or a similar substance. The layers of the supercapacitor are optionally rolled into an approximately cylindrical structure.

Chen, Bin↗

NASA NTRS1972

Thin film fuel cell electrodes.

Earlier work shows that fuel cell electrodes prepared by sputtering thin films of platinum on porous vycor substrates avoid diffusion limitations even at high current densities. The presented study shows that the specific activity of sputtered platinum is not unusually high. Performance limitations are found to be controlled by physical processes, even at low loadings. Catalyst activity is strongly influenced by platinum sputtering parameters, which seemingly change the surface area of the catalyst layer. The use of porous nickel as a substrate shows that pore size of the substrate is an important parameter. It is noted that electrode performance increases with increasing loading for catalyst layers up to two microns thick, thus showing the physical properties of the sputtered layer to be different from platinum foil. Electrode performance is also sensitive to changing differential pressure across the electrode. The application of sputtered catalyst layers to fuel cell matrices for the purpose of obtaining thin total cells appears feasible.

Asher, W. J.↗