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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Effect of Weld Consumable Conditioning on the Diffusible Hydrogen and Subsequent Residual Stress and Flexural Strength of Multipass Welded P91 Steels

P91 steel weld joint was prepared using the shielded metal arc welding process and four different conditions of weld consumable that provide the different levels of diffusible hydrogen in deposited metal. In the present research, the effects of diffusible hydrogen content on the flexural strength, lower critical stress, and tensile strength of P91 steel welds were also determined with respect to different electrode conditions. To investigate the effect of diffusible hydrogen on multipass welding, top and root side flexural tests were performed. The residual stresses (axial stress and transverse stress) were also measured using the blind hole drilling method for different conditions of welding consumable. The peak value of residual stresses was measured at the center of the weld fusion zone. The maximum value of transverse stress was measured to be 355 MPa for case II (6.21 mL/100 g of diffusible hydrogen), while the maximum axial stress was about 218 MPa for case IV (12.43 mL/100 g of diffusible hydrogen). A three-dimensional finite element simulation was also performed to predict the residual stress distribution and thermal profile along the welded joint. The experimentally determined residual stresses correlated well with the numerically estimated residual stresses. The diffusible hydrogen content was not observed to have any significant effect on the residual stresses. The corrected residual stress values were also predicted by considering the plasticity-induced error. However, the flexural performance of the welded joint was affected by the diffusible hydrogen content. The top and root flexural strength was measured to be optimum for the low level of diffusible hydrogen content, and the values decreased with an increase in diffusible hydrogen content.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Process design tools and techno-economic analysis for capacitive deionization

Capacitive deionization (CDI) devices use cyclical electrosorption on porous electrode surfaces to achieve water desalination. Process modeling and design of CDI systems requires accurate treatment of the coupling among input electrical forcing, input flow rates, and system responses including salt removal dynamics, water recovery, energy storage, and dissipation. Techno-economic analyses of CDI further require a method to calculate and compare between a produced commodity (e.g. desalted water) versus capital and operational costs of the system. In this work, we demonstrate a new modeling and analysis tool for CDI developed as an installable Matlab program that allows direct numerical simulation of CDI dynamics and calculation of key performance and cost parameters. The program is provided for free and is used to run open-source Simulink models. The Simulink environment sends information to the program and allows for a drag and drop design space where users can connect CDI cells to relevant periphery blocks such as grid energy, battery, solar panel, waste disposal, and maintenance/labor cost streams. The program allows for simulation of arbitrary current forcing and arbitrary flow rate forcing of one or more CDI cells. We employ validated well-mixed reactor formulations together with a non-linear circuit model formulation that can accommodate a variety of electric double layer sub-models (e.g. for charge efficiency). The program includes a graphical user interface (GUI) to specify CDI plant parameters, specify operating conditions, run individual tests or parameter batch-mode simulations, and plot relevant results. The techno-economic models convert among dimensional streams of species (e.g. feed, desalted water, and brine), energy, and cost and enable a variety of economic estimates including levelized water costs.

42 ENGINEERING↗
DOE OSTI2012

Leak Detection and H 2 Sensor Development

Low-cost, durable, and reliable Hydrogen safety sensor for vehicle, stationary, and infrastructure applications. A new zirconia, electrochemical-based sensor technology is being transitioned out of the laboratory and into an advanced testing phase for vehicular and stationary H 2 safety applications. Mixed potential sensors are a class of electrochemical devices that develop an open-circuit electromotive force due to the difference in the kinetics of the redox reactions of various gaseous species at each electrode/electrolyte/gas interface, referred to as the triple phase boundary (TPB). Therefore, these sensors have been considered for the sensing of various reducible or oxidizable gas species in the presence of oxygen. Based on this principle, a unique sensor design was developed by LANL and LLNL. The uniqueness of this sensor derives from minimizing heterogeneous catalysis (detrimental to sensor response) by avoiding gas diffusion through a catalytically active material and minimizing diffusion path to the TPB. Unlike the conventional design of these devices that use a dense solid electrolyte and porous thin film electrodes (similar to the current state-of-the-art zirconia-based sensors and fuel cells), the design of this sensor uses dense electrodes and porous electrolytes. Such a sensor design facilitates a stable and reproducible device response, since dense electrode morphologies are easy to reproduce and are significantly more stable than the conventional porous morphologies. Moreover, these sensors develop higher mixed potentials since the gas diffusion is through the less catalytically active electrolyte than the electrode. Lastly, the choice of electrodes is primarily based on their O2 reduction kinetics and catalytic properties vis-a-vis the target gas of interest.

08 HYDROGEN↗
DOE OSTI2025

A Perspective on Pathways Toward Commercial Sodium‐Ion Batteries

Lithium-ion batteries (LIBs) have been widely adopted in the automotive industry, with an annual global production exceeding 1000 GWh. Despite their success, the escalating demand for LIBs has created concerns on supply chain issues related to key elements, such as lithium, cobalt, and nickel. Sodium-ion batteries (SIBs) are emerging as a promising alternative due to the high abundance and low cost of sodium and other raw materials. Nevertheless, the commercialization of SIBs, particularly for grid storage and automotive applications, faces significant hurdles. This perspective article aims to identify the critical challenges in making SIBs viable from both chemical and techno-economic perspectives. First, a brief comparison of the materials chemistry, working mechanisms, and cost between mainstream LIB systems and prospective SIB systems is provided. The intrinsic challenges of SIBs regarding storage stability, capacity utilization, cycle stability, calendar life, and safe operation of cathode, electrolyte, and anode materials are discussed. Furthermore, issues related to the scalability of material production, materials engineering feasibility, and energy-dense electrode design and fabrication are illustrated. Finally, promising pathways are listed and discussed toward achieving high-energy-density, stable, cost-effective SIBs.

25 ENERGY STORAGE↗
DOE OSTI2018

Modeling flow distribution and pressure drop in redox flow batteries

The combination of interdigitated flow fields (IDFF) with porous electrodes offers lower pressure drop and better performance than conventional flow‐through porous electrodes in redox flow batteries. Comprehensive three‐dimensional and simplified one‐dimensional + two‐dimensional models describing flow uniformity and pressure losses within flow through, parallel, and interdigitated flow fields were developed and used to demonstrate the benefits of IDFF. Analytical solutions for IDFF that compare favorably with computational fluid dynamics quantify the trade between pressure loss and velocity maldistribution both along the channels and within the electrode. © 2018 American Institute of Chemical Engineers AIChE J , 64: 3746–3755, 2018

MacDonald, Malcolm↗
DOE OSTI2017

Investigation of Solid Electrolyte Interphase Formed on Si Nanoparticle Composite Electrodes Using Hyperpolarized 129 Xe Nuclear Magnetic Resonance Spectroscopy

Solid electrolyte interphase (SEI) plays an important role in determining electrochemical performances of Li-ion batteries. The ideal SEI layer protects the electrolyte from being further reduced on the electrode surface and allows Li-ion diffusion in and out of electrodes without any consumption. However, degradation of the SEI layer over time, which contributes to the thickening of the SEI layer, is a leading pathway for gradual capacity fade. In this study, a hyperpolarized (HP) 129 Xe nuclear magnetic resonance (NMR) technique was applied for the first time to probe changes in porosity and connectivity in Si nanoparticle composite electrodes as a result of the SEI formation. Nanopores are present in nanocomposite electrodes as a result of aggregation of the constituting nanoparticles. The connectivity among nanopores greatly affects the ion transport property of the electrode materials, which has a substantial influence on the overall energy output of Li-ion batteries. Here, information on thickness, uniformity of the SEI layer, and connectivity of the pores in the composite electrodes upon growing SEI was obtained from the analysis of temperature-dependent HP 129 Xe NMR spectra. Such information is useful for gaining a better understanding of the degradation mechanism of SEI. This study demonstrates that HP 129 Xe NMR is a potentially unique tool in probing the porosity and connectivity changes in porous practical electrodes during electrochemical cycling.

25 ENERGY STORAGE↗
DOE OSTI2026

Buried Interfaces in Organic Photocathodes for H 2 Evolution: Fermi-Level Pinning and Recombination

Herein, we demonstrate how Fermi-level pinning at buried contacts impacts solar fuel generation in all-polymer photocathodes by systematically comparing the effects of work function, hydroxyl coverage, and hydrogen evolution using chemically modified indium tin oxide (ITO) supports. Photovoltages and net photocathode performance are improved when the ITO is passivated using phosphonic acids, independent of work function, suggesting that the passivation reduces Fermi-level pinning at the buried interface arising from blended heterojunction interactions with surface metal hydroxyls. Transient photovoltage decay reveals differences in recombination mechanisms, supported by light intensity-dependent measurements. Briefly, nonpassivated, hydrophilic contacts exhibit trap-assisted recombination, while passivated, hydrophobic contacts follow bimolecular recombination. We then investigate changes in electroactivity of hole-transfer processes as a function of scan rate and repetitive cycling using a diffusion-controlled molecular redox probe, analogous to a hole-only device achieved via the electrolyte. The nonpassivated buried contacts exhibit higher overpotentials for oxidation, indicative of hole injection/extraction barriers. We observe irreversible electron transfer via the hole-transport level of the blended heterojunction and a strong cycle dependence, consistent with changes in the hole trap state density. Passivation results in more reversible redox behaviors, consistent with more Ohmic-like contacts. Collectively, these results provide context toward the realization of durable organic photoelectrodes with optimized photovoltages and net solar-to-hydrogen conversion efficiencies via fundamental understanding of the rates of carrier generation, recombination, and transport in high-dielectric aqueous environments and opportunities to characterize buried interfaces under device-relevant electric fields.

buried interfaces↗
DOE OSTI2025

Building High-Energy Silicon-Containing Batteries Using Off-The-Shelf Materials

The technology of silicon anodes appears to be reaching maturity, with high-energy Si cells already in pilot-scale production. However, the performance of these systems can be difficult to replicate in academic settings, making it challenging to translate research findings into solutions that can be implemented by the battery industry. Part of this difficulty arises from the lack of access to engineered Si particles and anodes, as electrode formulations and the materials themselves have become valuable intellectual property for emerging companies. Here, we summarize the efforts by Argonne’s Cell Analysis, Modeling, and Prototyping (CAMP) Facility in developing Si-based prototypes made entirely from commercially available materials. We describe the many challenges we encountered when testing high-loading electrodes (>5 mAh cm −2 ) and discuss strategies to mitigate them. With the right electrode and electrolyte design, we show that our pouch cells containing ≥ 70 wt% SiO x can achieve 600–1,000 cycles at C/3 and meet projected energy targets of 700 Wh L −1 and 350 Wh kg −1 . These results provide a practical reference for research teams seeking to advance silicon-anode development using accessible materials.

25 ENERGY STORAGE↗
DOE OSTI2012

Micro-Gas-Analyzer MEMS Active Pressure Valves Testing and Design

Micro-Gas-Analyzers have many applications in detecting chemical compounds present in the air. MEMS valves are used to perform sampling of gasses, as they enable control of fluid flow at the micro level. Current generation electrostatically actuated MEMS valves were tested to determine their ability to hold off a given gauge pressure with an applied voltage. Current valve designs were able to hold off 98 psi with only 82 V applied to the valves. The valves were determined to be 1.83 times more efficient than older valve designs, due to increasing the electrostatic area of the valve and trapping oxide between polysilicon layers. Newer valve designs were also proposed and modeled using ANSYS multiphysics, which should be able to hold off 100 psi with only 29 V needed. This performance would be 2.82 times more efficient than current designs, or 5.17 times more efficient than older valve designs. This will be accomplished by further increasing the valve radius and decreasing the gap between the valve boss and electrode.

42 ENGINEERING↗
DOE OSTI2019

Microstructure Characterization and Modeling for Improved Electrode Design

This presentation summarizes fiscal year 2018-2019 work under U.S. Department of Energy's Computer-Aided Engineering of Batteries (CAEBAT) program to develop computational tools for improved electrode design and to provide deeper fundamental understanding of the physics that limit the performance and cause degradation in lithium-ion batteries. Successes include (1) development of an electrode microstructure characterization tool box to be published open source later in 2019, (2) development of a large deformation electrochemical model capturing the volume expansion and performance limits of electrodes utilizing silicon and (3) development of a solid mechanics damage model describing the fracture of polycrystalline nickel-manganese-cobalt cathode materials with cycling.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2013

Improving microstructure of silicon/carbon nanofiber composites as a Li battery anode

We report the interfacial study of a silicon/carbon nanofiber (Si/CNF) nanocomposite material as a potentially high performance anode for rechargeable lithium ion batteries. The carbon nanofiber is hollow, with a graphitic interior and turbostratic exterior. Amorphous silicon layers were uniformly coated via chemical vapor deposition on both the exterior and interior surfaces of the CNF. The resulting Si/CNF composites were tested as anodes for Li ion batteries and exhibited capacities near 800 mAh g1 for 100 cycles. After cycling, we found that more Si had fallen off from the outer wall than from the innerwall of CNF. Theoretical calculations confirmed that this is due to a higher interfacial strength at the Si/Cedge interface at the inner wall than that of the Si/C-basal interface at the outer wall. Based upon the experimental analysis and theoretical calculation, we have proposed several interfacial engineering approaches to improve the performance of the electrodes by optimizing the microstructure of this nanocomposite.

Howe, Jane Y↗
DOE OSTI2026

Adsorption-Engineered Hydrocarbon Ionomers for Durable Proton-Exchange Membrane Fuel Cells

Reducing reliance on perfluoroalkyl substances (PFAS) in proton-exchange membrane fuel cells requires hydrocarbon ionomers that combine high performance with long-term durability, a persistent challenge in catalyst-layer design. Here, we identify oxidation-driven ionomer-catalyst interfacial degradation as a dominant failure pathway in hydrocarbon ionomer-bonded cathodes and introduce an adsorption-engineering strategy to overcome this limitation. The comparison of a commercial sulfonated poly(phenylene) (Pemion) with structurally engineered sulfonated poly(fluorene)s demonstrated that electrode durability is governed by the interplay between ionomer adsorption strength and resistance to oxidative degradation on carbon-supported Pt catalysts. A poly(fluorene) ionomer with mobile alkyl sulfonic acid groups forms resilient interfaces, delivering 1.28 A cm−2 at 0.65 V under fully humidified H2/air conditions (80°C and 150 kPaabs), comparable to Pemion. After 90,000 accelerated potential cycles, the poly(fluorene)-bonded cathode exhibits significantly improved durability, with only 29% performance loss compared to 58% for Pemion; further molecular refinement reduces the loss to 17%, approaching that of Nafion-bonded cathodes (14%). These findings establish adsorption-engineered ionomer design that decouples interfacial anchoring from oxidative degradation as a general strategy for achieving durable, high-performance PFAS-free PEM fuel cell electrodes.

08 HYDROGEN↗
DOE OSTI2022

Developing novel electrodes with ultralow catalyst loading for high-efficiency hydrogen production in proton exchange membrane electrolyzer cells

Hydrogen plays more crucial roles for decarbonizing the planets and meeting the climate challenges because of its high energy density and zero-emission. It can be produced with proton exchange membrane electrolyzer cells (PEMECs) driven by sustainable and renewable energy resources. Although PEMECs have a number of advantages, including high purity production, quick response, and the ability to operate at high pressure facilitating the gas delivering, their performance and cost greatly hinder their commercial-scale applications. To achieve high-efficiency and cost-reduced hydrogen production in PEMECs, we proposed thin engineered liquid/gas diffusion layers (LGDLs) and associated electrodes, i.e., catalyst-coated LGDLs (CCLGDLs), over conventional porous transport layers (PTLs) and catalyst-coated membranes (CCMs). The research approaches in this project are based on material synthesis, in-situ and ex-situ characterizations, component design and treatment, numerical modeling, and cost analysis. The thin and tunable LGDLs (TT-LGDLs) and CCLGDLs were successfully developed with great performance improvement as demonstrated in lab-scale, bench-scale, and system-scale electrolyzer tests. The electrode thickness was reduced from 370 µm to less than 100 µm with simplified fabrication processes. With the catalytically enhanced Ir-based catalyst coating, the as-developed CCLGDLs with a catalyst loading of 0.34 mg Ir /cm 2 achieved a cell performance of 1.77 V at 2 A cm -2 , exhibiting the catalyst mass activity enhanced by >20 times with significant catalyst saving over conventional catalyst cell design. In-situ PEMEC characterizations, including the current distribution mapping and high-speed and multiscale visualizations, were conducted for a deeper understanding of mass transport and electrochemical reactions within an electrolyzer with LGDLs and CCLGDLs. A 2D cell model was developed and validated for the enhanced performance on TT-LGDL through reducing ohmic losses due to nonuniform hydration and water transport. Further, the cost analysis results have shown a path to move beyond equivalency and surpass costs associated with the project baseline. In this project, the design and fabrication of TT-LGDLs and CCLGDLs will contribute to the performance enhancement, manufacturing simplification, and cost reduction for PEMECs and other energy conversion devices, thus shortening their pathways towards commercialization. This project also provides a good foundation for furthering the in-situ reaction interface research.

08 HYDROGEN↗
DOE OSTI2016

Efficient Colorful Perovskite Solar Cells Using a Top Polymer Electrode Simultaneously as Spectrally Selective Antireflection Coating

Organometal halide perovskites have demonstrated excellent optoelectronic properties and have been used to demonstrate a variety of semiconductor devices. Colorful solar cells are desirable for photovoltaic integration in buildings and other aesthetically appealing applications. Yet, the realization of colorful perovskite solar cells is challenging because of their broad and large absorption coefficient that commonly leads to cells with dark-brown colors. Herein, for the first time, we report a simple and efficient strategy to achieve colorful perovskite solar cells by using the transparent conducting polymer (poly(3,4-ethylenedioxythiophene):poly- (styrenesulfonate), PEDOT:PSS) as a top electrode and simultaneously as an spectrally selective antireflection coating. Vivid colors across the visible spectrum are attained by engineering optical interference effects among the transparent PEDOT:PSS polymer electrode, the hole-transporting layer and the perovskite layer. The colored perovskite solar cells display power conversion efficiency values from 12.8 to 15.1% (from red to blue) when illuminated from the FTO glass side and from 11.6 to 13.8% (from red to blue) when illuminated from the PEDOT:PSS side. The new method offers an advanced solution for fabricating colorful perovskite solar cells with easy processing and high efficiency.

42 ENGINEERING↗
DOE OSTI2014

Mixing in a liquid metal electrode

Fluid mixing has first-order importance for many engineering problems in mass transport, including design and optimization of liquid-phase energy storage devices. Liquid metal batteries are currently being commercialized as a promising and economically viable technology for large-scale energy storage on worldwide electrical grids. But because these batteries are entirely liquid, fluid flow and instabilities may affect battery robustness and performance. Here we present estimates of flow magnitude and ultrasound measurements of the flow in a realistic liquid metal electrode. We find that flow does substantially affect mass transport by altering the electrode mixing time. Above a critical electrical current density, the convective flow organizes and gains speed, which promotes transport and would yield improved battery efficiency. (C) 2014 AIP Publishing LLC.

Kelley, DH↗