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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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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Freeze Tape Casting Electrode with Bilayered Architecture for High-Performance Lithium-Ion Batteries

A facile freeze tape casting (FTC) strategy is utilized to prepare bilayered 4 mAh cm –2 high-loading LiNi 0.6 Co 0.2 Mn 0.2 O 2 cathodes. The bottom layer is a conventional nonaqueous electrode, which has a dense structure for high-energy purposes. Further, the top layer is prepared by the proposed FTC, exhibiting a porous feature for high-power requirement. With the assistance of FTC, the bilayered electrodes successfully deliver enhanced rate and cyclic performance due to the improved lithium-ion diffusion kinetics and pathways. Therefore, the proposed FTC strategy and its delivered electrodes are promising for energy- and power-density lithium-ion batteries, potentially enlightening the research and development of lithium-ion battery manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2018

Nitrogen‐doped Carbon–CoO x Nanohybrids: A Precious Metal Free Cathode that Exceeds 1.0 W cm −2 Peak Power and 100 h Life in Anion‐Exchange Membrane Fuel Cells

Abstract Efficient and durable nonprecious metal electrocatalysts for the oxygen reduction (ORR) are highly desirable for several electrochemical devices, including anion exchange membrane fuel cells (AEMFCs). Here, a 2D planar electrocatalyst with CoO x embedded in nitrogen‐doped graphitic carbon (N‐C‐CoO x ) was created through the direct pyrolysis of a metal–organic complex with a NaCl template. The N‐C‐CoO x catalyst showed high ORR activity, indicated by excellent half‐wave (0.84 V vs. RHE) and onset (1.01 V vs. RHE) potentials. This high intrinsic activity was also observed in operating AEMFCs where the kinetic current was 100 mA cm −2 at 0.85 V. When paired with a radiation‐grafted ETFE powder ionomer, the N‐C‐CoO x AEMFC cathode was able to achieve extremely high peak power density (1.05 W cm −2 ) and mass transport limited current (3 A cm −2 ) for a precious metal free electrode. The N‐C‐CoO x cathode also showed good stability over 100 hours of operation with a voltage decay of only 15 % at 600 mA cm −2 under H 2 /air (CO 2 ‐free) reacting gas feeds. The N‐C‐CoO x cathode catalyst was also paired with a very low loading PtRu/C anode catalyst, to create AEMFCs with a total PGM loading of only 0.10 mg Pt‐Ru cm −2 capable of achieving 7.4 W mg −1 PGM as well as supporting a current of 0.7 A cm −2 at 0.6 V with H 2 /air (CO 2 free)—creating a cell that was able to meet the 2019 U.S. Department of Energy initial performance target of 0.6 V at 0.6 A cm −2 under H 2 /air with a PGM loading <0.125 mg cm −2 with AEMFCs for the first time.

Peng, Xiong↗
DOE OSTI2018

Nitrogen‐doped Carbon–CoO x Nanohybrids: A Precious Metal Free Cathode that Exceeds 1.0 W cm −2 Peak Power and 100 h Life in Anion‐Exchange Membrane Fuel Cells

Abstract Efficient and durable nonprecious metal electrocatalysts for the oxygen reduction (ORR) are highly desirable for several electrochemical devices, including anion exchange membrane fuel cells (AEMFCs). Here, a 2D planar electrocatalyst with CoO x embedded in nitrogen‐doped graphitic carbon (N‐C‐CoO x ) was created through the direct pyrolysis of a metal–organic complex with a NaCl template. The N‐C‐CoO x catalyst showed high ORR activity, indicated by excellent half‐wave (0.84 V vs. RHE) and onset (1.01 V vs. RHE) potentials. This high intrinsic activity was also observed in operating AEMFCs where the kinetic current was 100 mA cm −2 at 0.85 V. When paired with a radiation‐grafted ETFE powder ionomer, the N‐C‐CoO x AEMFC cathode was able to achieve extremely high peak power density (1.05 W cm −2 ) and mass transport limited current (3 A cm −2 ) for a precious metal free electrode. The N‐C‐CoO x cathode also showed good stability over 100 hours of operation with a voltage decay of only 15 % at 600 mA cm −2 under H 2 /air (CO 2 ‐free) reacting gas feeds. The N‐C‐CoO x cathode catalyst was also paired with a very low loading PtRu/C anode catalyst, to create AEMFCs with a total PGM loading of only 0.10 mg Pt‐Ru cm −2 capable of achieving 7.4 W mg −1 PGM as well as supporting a current of 0.7 A cm −2 at 0.6 V with H 2 /air (CO 2 free)—creating a cell that was able to meet the 2019 U.S. Department of Energy initial performance target of 0.6 V at 0.6 A cm −2 under H 2 /air with a PGM loading <0.125 mg cm −2 with AEMFCs for the first time.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A Novel Multiagent Resource Sharing Algorithm for Control of Advanced Energy Systems

This paper implements a novel resource sharing control strategy on a fuel cell–gas turbine hybrid power system at the National Energy Technology Laboratory’s Hybrid Performance Facility (Hyper). In a fuel cell–gas turbine hybrid power system, the simultaneous interaction of the gas turbine and the fuel cell creates a tightly coupled environment characterized by conflicting dynamics. In this paper, a model-free control approach is applied to solve the tightly coupled control problem posed by this challenging environment. Specifically, this control problem is presented as a resource sharing problem that can be solved using a resource sharing algorithm that is defined based on the distribution construction concept. This algorithm creates computational agents and solves the problem through the distribution and redistribution of shared resources defined as blocks. Furthermore, two agents were created; the first agent (agent 1) controls the gas turbine speed by adjusting the electric load, and the second agent (agent 2) controls the cathode mass flow through the fuel cell using the cold-air bypass valve. A parametric study was performed over the course of 15 experimental tests for both agents 1 and 2 through an evaluation of the responses based on setpoint changes. The algorithm was shown to have behavior comparable to a previously implemented multi-input multioutput state-space controller, which was designed through a model-based control approach. The resource sharing algorithm was able to find stable performance during run-time operations without any prior system knowledge identification on the power plant and without creating models used in traditional control strategies.

25 ENERGY STORAGE↗
DOE OSTI2019

Electrocatalytic Hydrogen Evolution in Neutral pH Solutions: Dual-Phase Synergy

Electrolysis in neutral pH solutions (e.g., wastewater and seawater) presents a transformative way for environmentally friendly, cost-effective hydrogen production. However, one of the biggest challenges is the lack of active, robust hydrogen evolution reaction (HER) catalysts. Herein we present a catalyst with dual active sites of MoP2 and MoP which function synergistically to promote HER in neutral pH solutions. In our microbial electrolysis cell (MEC) which uses neutral pH wastewater as a feedstock, the new catalyst generates an average HER current density of ~157 A m-2Cathode-Surface-Area, higher than Pt/C (~145 A m-2Cathode-Surface-Area), ~5 times higher than the state-of-art platinum-group-metal (PGM)-free catalysts in MECs. The new catalyst also outperforms Pt/C in natural seawater with ~10% higher and more stable HER current density. The fundamental reason for the enhanced HER performance is identified to be the synergy between MoP2 and MoP phases, with MoP2 promoting H2O chemisorption/dissociation and MoP efficiently converting Hads to H2.

Xie, Xiaohong↗
DOE OSTI2023

Engineered Catalyst Support with Improved Durability at Higher Weight Percentage of Platinum

Proton Exchange Membrane (PEM) fuel cells are a suitable electrochemical power source for heavy duty vehicle (HDV) applications due to their high efficiency and durability. The cathode of the fuel cell uses a higher geometric loading of platinum (∼0.2 to 0.4 mg Pt /cm 2 ) for the electrocatalysis of the kinetically sluggish Oxygen Reduction Reaction (ORR) which requires higher weight percent loading of the metal (∼50%) on the carbon support to decrease the catalyst layer thickness and hence, the reactant transport losses. The conventionally used supports for platinum catalyst, such as the KetjenBlack TM type high surface area carbon (HSC) features limited mesopore area for the dispersion of Pt nanoparticles leading to increased aggregation and poor durability. Here, we show a new class of carbon materials known as the Engineered Catalyst Support (ECS) developed by Pajarito Powder with higher mesopore fraction for the dispersion of higher weight percentage of Pt nanoparticles. ECS materials can disperse up to 50% Pt by weight of the catalyst thereby enabling lower catalyst layer thickness with higher performance retained after durability test. A comprehensive set of physico-chemical and electrochemical studies in membrane electrode assembly (MEA) are reported to understand the performance and durability of Pt/ECS catalysts.

08 HYDROGEN↗
DOE OSTI2019

A highly active and Cr-resistant infiltrated cathode for practical solid oxide fuel cells

A critical obstacle to the commercialization of modern solid oxide fuel cells (SOFCs) loaded with metallic interconnects is the unacceptable degradation rate resulting from Cr (an element richly present in metallic interconnects) volatilization and its subsequent reaction with the cathode, forming insulating SrCrO 4 that blocks oxygen reduction reaction (ORR) active sites. Here we report a Cr-tolerant, yet ORR-active, cathode for sustainable operation of solid oxide fuel cells (SOFCs). The new resilient cathode consists of a continuous, nanoscaled, ORR-active SrCo 0.9 Ta 0.1 O 3–δ (SCT) as the capping layer and a commercial (La 0.6 Sr 0.4 ) 0.95 Co 0.2 Fe 0.8 O 3–δ (LSCF)–Ce 0.8 Gd 0.2 O 1.9 (GDC) composite as the underlying skeleton. Stability testing in a high-Cr-content environment shows that the cathode has a remarkable resistance to Cr-attack while retaining superior ORR activity. In conclusion, a successful implantation of this bilayer cathode into practical SOFC stacks will advance the commercialization of SOFC technology.

25 ENERGY STORAGE↗
DOE OSTI2024

Additive manufacturing of LiCoO 2 electrodes via vat photopolymerization for lithium ion batteries

Additive manufacturing has the potential to revolutionize the fabrication of lithium-ion batteries for a diversity of applications including in portable, biomedical, aerospace, and the transportation fields. Standard commercial batteries consist of stacked layers of various components (current collectors, cathode, anode, separator and electrolyte) in a two-dimensional manner. By leveraging the latest advances in additive manufacturing and computer-aided design, an improved geometric and electrochemical configuration of these batteries can maximize energy efficiency while allowing design optimization to reduce dead space for a given application. In this work, a composite UV photosensitive resin was prepared and used as feedstock in a vat photopolymerization system. The resin was loaded with LiCoO 2 acting as electrochemically active material for the cathode of a lithium-ion battery, and was further improved with the addition of conductivity-enhancing carbonaceous additives. Challenges to additive manufacturing arise from the opacity and high viscosity of the composite nature of these electrochemically-active resins, which cause light refraction during selective UV curing. Subsequently, items were printed and subjected to a thermal post-processing step to obtain an adequate compromise between electrochemical performance and mechanical integrity. Both sintered and green state 3D printed cathodes were assembled into half-cell lithium-ion batteries using lithium metal as a reference and counter electrode. Electrochemical cycling of these batteries yielded satisfactory results approaching commercial LiCoO 2 cathodes’ performance, with the potential advantages of additive manufacturing – high surface area anode–cathode configurations for power performance as well as shape conformability.

25 ENERGY STORAGE↗
DOE OSTI2022

Meshfree Methods for Modeling Chemo-Mechanical Cathode Cracking in Li-Ion Batteries

Through repeated charging and discharging, the electrodes of a Li-ion battery experience cyclic loading causing swelling and contraction due to the movement of lithium, also known as intercalation. This research focuses specifically on the chemo-mechanical cracking in the cathode. Because cathode particles are comprised of many randomly-oriented grains, which have highly anisotropic material properties, the expansion and contraction is very non-uniform. As a result, stress concentrations tend to form between grains, which necessitates the modeling of crack propagation largely along grain boundaries. Chemo-mechanical models are simulated mainly by two methods: the cohesive zone model (CZM) and the continuous damage model (CDM). The CZM is more accurate at capturing the sharp discontinuities of a crack but is very computationally expensive and intractable for large-scale models as a result. Conversely, the CDM is easily computed but not well-suited to easily allow for discontinuous field variables, which are inherent across a crack. This study aims to improve the CDM's ability to capture discontinuous cracks. Current versions of the CDM use the finite element method (FEM), which is one of the most widely used approaches for spatial discretization. This research investigates the use of the Reproducing Kernel Particle Method (RKPM), a meshfree method, for spatial discretization and aims to achieve a chemo-mechanical crack propagation model that achieves both intermediate accuracy and computational time between a CDM and CZM. To gain a better understanding of how the meshfree model compares to the current FEM model in capturing cathode crack propagation, further investigation is needed.

cathode cracking↗
DOE OSTI2023

Stationary Direct Methanol Fuel Cells Using Pure Methanol

This project developed stationary direct methanol fuel cells (DMFCs) using pure methanol as the fuel, integrating complementary institutional expertise on platinum group metals free (PGM-free) cathode catalyst (UB), supported anode catalysts (KSU), electrode fabrication, characterization, and optimization (CMU), and multi-phase mass transfer (KU). The proposed cost-effective prototype will deliver reliable and durable performance using a methanol-tolerant PGM-free cathode and a high-performance anode with low PtRu loading. At the end of the project, the research team is expected to deliver a single cell (50 cm 2 ) with ≤3 mg PGM /cm 2 that achieves 300 mW/cm 2 using pure methanol.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Excessive charge, beam loading, and impedance collapse thresholds for a velvet emitter

Excess emission has been observed from velvet cathodes with total emission times >150 ns. In this diode experiment, we produce a sub-relativistic electron beam with the ability to consistently change γ from 1.2 to 1.5 and β = 0.5–0.75. Electron emission in this particular diode geometry requires electric fields >40 kV/cm. The current increases at steady rates >0.05 A/ns after the head of the pulse, indicating an expansion of the emission surface and reduction in the effective AK gap. Small transients of excess emission (or arcs) are consistently observed for current pulses exceeding 150 ns. The excess emission results in beam loaded levels ≥10 kV on the diode voltage. The effects described here are compounded as diode voltage is increased. The principal objective of these experiments is to quantify electric field emission thresholds, current ramps, excess emission delays, effective beam loading, and impedance collapse.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Python catemis package for DARHT Axis-II Dispenser-Cathode Emissivity and Temperature Analysis

The catemis python package includes the analysis methods used in paper "DARHT Axis-II Dispenser-Cathode Emissivity and Temperature", which was presented at the 2021 Weapons Engineering Symposium and Journal (WESJ) hosted by Los Alamos National Laboratory. The paper (LA-UR-21-25647) and presentation (LA-UR-21-28231) report on a temperature and emissivity model that has been developed and applied to data from diagnostics used to measure the surface temperature of the DARHT Axis-II hot dispenser cathode over more than a decade of operation. The catemis package provides all the methods used in reporting these results along with the data files used to create the plots and tables in the paper. This includes methods for loading and processing FAR spectral pyrometer data along with methods for temperature calibration of cathode images.

Koglin, Jason↗
DOE OSTI2018

An ant-nest-like cathode substrate for lithium-sulfur batteries with practical cell fabrication parameters

We report that electrochemical performances of lithium-sulfur batteries have received much progress in recent years. However, their practical deployment encounters challenges with respect to optimizing the cell-fabrication parameters (e.g., amounts of the active material and electrolyte). We present here an “ant-nest-like” cathode substrate with unique architecture to synchronously attain high electrochemical performance and necessary cell-fabrication parameters. The cells with a high sulfur loading (11.5 mg cm -2 ), a high sulfur content (75 wt.%), and a low electrolyte/sulfur ratio (9 μL mg -1 ) display a high areal capacity and energy density of, respectively, 7 mA h cm -2 and 14 mW h cm -2 with a capacity retention of 70% after 150 cycles. Moreover, the cells exhibit a low self-discharge behavior with a low self-discharge constant of 0.0013 per day and a long rest period of one month. Lastly, these dynamic and static electrochemical stabilities are attributed to the ant-nest-like structure and low surface area of the cathode substrate that allows, respectively, the accommodation and encapsulation of a high amount of active material and reduces the consumption of electrolyte.

25 ENERGY STORAGE↗
DOE OSTI2024

High mass loading potassium ion stabilized manganese dioxide nanowire forests for rechargeable Zn batteries

Manganese dioxide (MnO 2 ) represents an ideal cathode material for rechargeable aqueous Zn batteries due to its high theoretical capacity (308 mAh g -1 ), suitable potential (1.4 V vs. Zn 2+ /Zn), natural abundance, and negligible toxicity. However, the capacity and rate capability of MnO 2 deteriorate significantly in thick electrodes owing to its low electrical and ionic conductivities. Herein, we report the design of high mass loading potassium ion stabilized α-MnO 2 (K 0.133 MnO 2 ) nanowire forests on carbon cloth through a seed-assisted hydrothermal method for Zn batteries. Further, the vertically aligned K 0.133 MnO 2 nanowire forests with uninterrupted charge transport afford a high area capacity of 3.54 mAh cm -2 and a capacity retention of 79.2% over 1000 cycles in aqueous electrolyte. Moreover, the high area capacity and cyclability can be readily transferred to quasi-solid-state devices.

25 ENERGY STORAGE↗
DOE OSTI2023

High-Performance Low-Cobalt Cathode Materials for Li-ion Batteries

The layer-structured Li[Ni x Co y Mn 1-x-y ]O 2 (NCM) cathode materials have been the best choice for increasing electric vehicle driving distance per charge. The high Ni layered oxide represents successfully commercialized NCM cathodes (such as NCM622 and NCA) in lithium-ion batteries (LIBs) for EV applications due to their high energy density and acceptable cycling stability. However, the price of cobalt, the key element within LIBs for stability, has nearly tripled over the past few years due to increased demand from the cell phone industry. As mentioned in the DOE Funding Opportunity Announcement, the current materials shortage will also cause speculation for a future global shortage. Therefore, to meet the requirement and sustainability of the next-generation long-range and low-cost EVs, developing cathode materials with low-Co content to achieve higher energy density and lower cost is both essential and urgent. The overarching objective of this work is to develop stabilized NCM cathode materials with low Co content (namely LiNi x Co y Mn 1-x-y O 2 , y ≤ 0.04) to meet DOE’s goal of reducing Co loading below 50 mg Wh -1 while maintaining energy density greater than 600 Wh kg -1 based on cathode material. Via various dopings and coatings scalable methods, we explored and enhanced the cycling performance of low-cobalt cathodes. The final obtained NCM cathodes paired with graphite anode aim to deliver batteries with a high initial specific energy density of over 240 Wh kg -1 and a low capacity fading rate of less than 20% in 1000 cycles under a C/3 discharge rate. To accomplish this goal, a multidisciplinary team with several co-investigators has been formed from three organizations: The Pennsylvania State University (PSU), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL). The PI and co-investigators are Dr. Donghai Wang (PI) from PSU with expertise in the synthesis of nanostructured materials and manipulation of interfacial properties of electrochemically active materials, Dr. Jagjit Nanda, with substantial knowledge of and expertise in state-of-the-art cathodes from ORNL, Dr. Chao-Yang Wang with significant experience in advanced cell design and fabrication and cell diagnostics from PSU, and Dr. Chongmin Wang with world-wide known expertise of advance atomic scale characterization of electrode materials from PNNL. Furthermore, this project will leverage and synergistically work with the current DOE-funded programs on battery materials at PSU and ORNL and electrode materials characterization at PNNL. During this funded period, we have accomplished milestones stated as follows: • Scale up production of LiFePO 4 (LFP) coated NCM811 with a production of 300g/batch. Fifteen (≥2 Ah) pouch cells with LFP-coated NCM811 cathode are delivered. Self-evaluated pouch cells in PSU show superior over 80% capacity retention performance even after 1500 cycles at C/3 rate. • Various cations (Al, Ti, Zr, and Mo) substitute cobalt in low-cobalt partially and Co-free cathodes. Their effects on crystal structure and electrochemical behavior are explored. • Phosphate compounds as coating materials represent promising surface protection precursors for low-cobalt cathode materials. Therefore, several metal phosphates were selected for improving the NMC cycling performance and are regarded as effective approaches for a scalable and practical surface protection method. • Production of NCM92, where Nickel content is 92% among transition metals, is scaled up from synthesis to coating and heat treatment procedures. Fifteen 2.7Ah pouch cells with Ti-doped NCM92 cathodes and industrial graphite anode are delivered to Idaho National Lab for testing.

25 ENERGY STORAGE↗
NASA NTRS1990

Space Electrochemical Research and Technology Conference, 2nd, Cleveland, OH, Apr. 11-13, 1989, Proceedings

Attention is given to topics of advanced concepts, hydrogen-oxygen fuel cells and electrolyzers, nickel electrodes, and advanced rechargeable batteries. Papers are presented on human exploration mission studies, advanced rechargeable sodium batteries with novel cathodes, advanced double-layer capacitors, recent advances in solid-polymer electrolyte fuel cell technology with low platinum loading electrodes, electrocatalysts for oxygen electrodes in fuel cells and water electrolyzers for space applications, and the corrosion testing of candidates for the alkaline fuel cell cathode. Other papers are on a structural comparison of nickel electodes and precursor phases, the application of electrochemical impedance spectroscopy for characterizing the degradation of Ni(OH)2/NiOOH electrodes, advances in lightweight nickel electrode technology, multimission nickel-hydrogen battery cell for the 1990s, a sodium-sulfur battery flight experiment definition study, and advances in ambient-temperature secondary lithium cells.

O'Donnell, Patricia M.↗
DOE OSTI2026

Deciphering the Conflict Between Ion and Electron Percolating Networks in Solid-State Battery Cathodes

High-energy- and power-density solid state batteries require an optimal cathode composition and microstructural arrangement of cathode active material, solid-state electrolyte, conductive carbon, and binder to simultaneously support lithium-ion transport, electron conduction, and storage capacity. The ion and electron conducting phases in solid-state cathodes counteract each other's percolating networks as their mass ratios increase or decrease relative to each other. Here, we investigate targeted mass ratio variations of argyrodite solid electrolyte and two different types of conductive carbon (particles and fibers) in composite LiNi0.8Mn0.1Co0.1O2 (NMC811) solid-state cathodes to ascertain the ionic-electronic tradeoffs in cathode performance. Through ionic and electronic conductivity measurements on composite cathodes, as well as rate-testing and cycling performance in full cells, it is shown that the conductive carbon fibers form a percolative electronic network within the composite at a lower mass ratio (3-5 wt%) than particulate carbon (>5 wt%). The threshold to achieve electronic percolation coincides with higher accessible capacity in the cathode as the active material particles become electronically connected. However, carbon loadings beyond this percolation threshold lead to increased ion transport resistance, arising from disruptions to ionic conduction pathways and degraded contact at the interface between the electrolyte and active materials. Imaging, spectroscopy, and physics-based models quantitatively describe the relationship between carbon and electrolyte compositions and the cell's capacity and rate performance through percolation theory. This work demonstrates the importance of quantitatively understanding percolating networks in solid-state cells and that strategic engineering of conductive carbon morphologies can further increase the energy- and power-density of solid-state cells.

25 ENERGY STORAGE↗
DOE OSTI2023

Insights into the Chemistry of the Cathodic Electrolyte Interphase for PTFE-Based Dry-Processed Cathodes

Dry processing is a promising method for high-performance and low-cost lithium-ion battery manufacturing which uses polytetrafluoroethylene (PTFE) as a binder. However, the electrochemical stability of the PTFE binder in the cathodes and the generated chemistry of the cathode electrolyte interphase (CEI) layers are rarely reported. In this work, the CEI properties and PTFE electrochemical stability are studied via cycling the high-loading dry-processed electrodes in electrolytes with LiPF 6 or LiClO 4 salt. Using LiClO 4 salt can eliminate other possible F sources, allowing the decomposition of PTFE to be studied. The detection of LiF in cells with the LiClO 4 salt confirms that PTFE undergoes side reaction(s) in the cathodes. When compared with LiClO 4 , the CEI layer is much thicker when LiPF 6 is used as the electrolyte salt. These results provide insights into the CEI layer and may potentially enlighten the development of binders and electrolytes for the high efficiency and long durability of DP-based LIBs.

25 ENERGY STORAGE↗