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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Nano-Engineered Interfaces in Dual-Layer Electrodes for Protonic Ceramic Cells with Enhanced Stability and Kinetics

Enhancing interfacial stability and charge transfer in protonic ceramic cells (PCCs) remains a critical challenge, as structural degradation and interfacial resistance often compromise durability and efficiency. Here, we report a nanoengineered dual-layer oxygen electrode architecture designed to address these limitations by introducing a fine-grained nanoparticle interfacial contact layer beneath a porous catalytic backbone. The nanoscale powders, through enhanced sintering activity, densify into a robust interfacial layer that promotes strong chemical bonding, uniform adhesion, and continuous ionic/electronic pathways with the BCZYYb electrolyte. This hierarchical architecture mitigates delamination, redistributes mechanical stress, and establishes efficient charge and mass transport channels without relying on corrosive surface treatments. Electrochemical evaluation demonstrates that the dual-layer design markedly reduces interfacial polarization resistance and accelerates electrode kinetics. Compared to the single-layer counterpart, the architecture achieves a peel strength of 44.53 N/cm 2 , a 40% improvement in peak power density (0.96 W cm –2 at 600 °C), and a 130% enhancement in electrolysis current density (4.78 A cm –2 at 1.57 V). Faradaic efficiency remains as high as 88% under high steam concentrations, underscoring minimal charge loss during practical operation. Notably, the electrode retains stability across 450–600 °C and under transient voltage cycling, with impedance spectra confirming suppressed interfacial resistance growth over prolonged use. These results highlight nanoscale interface engineering as a powerful route to enhance both mechanical robustness and electrochemical kinetics in PCCs. The demonstrated scalability and durability of this architecture provide a versatile platform for advancing solid-state electrochemical systems, including reversible fuel cells and high-efficiency hydrogen production technologies.

Faradaic efficiency↗
DOE OSTI2026

Tunable Multisite Proton-Coupled Electron Transfer Mediators: Distinct Pathways for Substrate Reduction Versus Competing Hydrogen Evolution

Proton-coupled electron transfer (PCET) reagents have emerged as powerful tools for transferring net H atoms to organic substrates from relatively weak X–H bonds. One advantage of employing PCET reagents is the tunability of the X–H bond strength by independently varying their redox potential and/or p K a for selective substrate reductions; however, the rational development of modular catalytic PCET reagents based on these features remains underdeveloped. In this work, we address important mechanistic questions relevant to a dimethylaniline-appended cobaltocene PCET mediator that our lab has previously introduced. Specifically, we examine where protonation occurs within the reactive Co(II, NH) + intermediate of a Brønsted-base modified cobaltocene mediator, whether substrate reduction and hydrogen evolution reaction (HER) proceed by a common or bifurcated mechanistic pathway, and how the redox, acid–base, and structural properties of PCET mediators can dictate their reactivity and selectivity. We show that substrate compatibility can be tuned and, via a model study with N -aryl imine substrates, provide data pointing to a multisite PCET (MS-PCET) pathway. Moreover, we rigorously characterize the site of protonation in the reactive reduced, protonated form of the mediator, and through kinetic analysis establish that the pathway for undesired competing HER is fundamentally different and involves Cp-ring protonation. Our findings point to a high degree of flexibility in the design of reductive PCET mediators.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Superdiffusion resilience in Heisenberg chains with two-dimensional interactions on a quantum processor

Superdiffusive spin transport in the one-dimensional (1D) Heisenberg model is a key theoretical discovery in nonequilibrium quantum many-body physics. Although extensively studied in 1D systems, the breakdown and sustenance of superdiffusion in two-dimensional (2D) lattices with integrability-breaking terms, as found in real materials, remains an open question. To address this, we develop a toy model that extends the 1D Heisenberg model with a representative set of 2D interaction types and tunable strengths. Our model exhibits varying degrees of superdiffusion breakdown depending on the interaction type, spanning ballistic to diffusive regimes. We establish and justify a hierarchy of 2D interactions based on their resilience against superdiffusion breakdown: Heisenberg >𝑋⁢𝑋 > Ising. This precise control over the superdiffusive behavior also enables rigorous benchmarking of quantum hardware, and our simulations on IBM's Heron devices confirm the hardware's ability to accurately capture these many-body nonequilibrium phenomena. Overall, our results are relevant not only to simulating superdiffusion in real materials, such as the 1D Heisenberg compound KCuF3, which contains modest nonintegrable 2D terms, but also to extending superdiffusive behavior to larger 2D qubit lattices and other 2D materials.

Alagarsamy Manikandan, Keerthi Kumaran [ORNL]↗
DOE OSTI2024

Surface Tagging of Al 6061-T6 using Photoluminescent Oxides

The goal of tagging nuclear fuels (or related materials, such as fuel cladding) is to provide a persistent marker, traceable to the fuel manufacturer, that can be detected after some length of time, likely after the fuel has been lost, rerouted, or partially destroyed. Ideally, the tag is complicated enough to encode data pertaining to the provenance (manufacturer, date or time, constituents, etc.) and robust enough to survive in-pile exposure and/or further destruction. The taggant should not change the behavior or performance of the fuel in any meaningful way. Photoluminescent tagging was an attractive solution to many of these challenges, as it is undetectable under normal lighting conditions, visible to the naked eye under specific lighting conditions, does not require a significant quantity of material to be photoluminescent, observable with simple commercial detection tools, and is versatile and robust in application. In FY23, the team focused on embedding photoluminescent taggants onto the replicate fuel cladding surface using welding. From a welding standpoint, photoluminescent taggants, in the form of oxides, are a viable option for tagging because the taggants have high melting points, and thus likely to survive welding temperatures (i.e., remain as a secondary phase particle and maintain luminescent properties). Additionally, these taggants have the potential to act as a metal matrix composite which may increase the strength-to-weight ratio, stiffness, and ductility of the base material, all beneficial to cladding and fuel performance.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

Using θ' interfaces as templates for planar L1 2 precipitation in AlCuMnZr alloys

Controlled Mn and Zr additions to Al-Cu alloys have allowed for the improved retention of mechanical properties after extended 350°C exposures by stabilizing the main strengthening θ' (Al 2 Cu) phase. Ultimately, θ'/L1 2 (Al 3 Zr) co-precipitate formation stabilizes θ' most effectively; however, Zr diffuses sluggishly and has low solubility in aluminum castings. Increasing the Zr segregation rate would allow for faster and more effective θ'/L1 2 co-precipitation. It is demonstrated that the Zr segregation rate is faster when the Zr matrix content is higher. A much higher Zr matrix content was achieved by rapid cooling during additive manufacturing (AM) that produces θ'/L1 2 co-precipitation faster, which is shown by scanning transmission electron microscopy and atom probe tomography experiments. It was also found that Zr continuously segregates to θ' interfaces up to the most aggressive heat treatment studied such that planar L1 2 precipitates remain after the metastable θ' dissolves. In this manner, we demonstrate that θ' coherent interfaces serve as perfect templates to form stable planar L1 2 precipitates that can provide strength at higher temperatures than traditional θ' strengthened AlCu alloys. This work introduces an alloy design strategy that uses metastable precipitates to quickly nucleate and grow co-precipitates with a desired geometry that contain slow diffusing elements. These ideas can be applied to engineer more heat resistant alloys by taking advantage of high solute matrix contents enabled by rapid cooling during additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Enhanced Interface-Driven Perpendicular Magnetic Anisotropy by Symmetry Control in Oxide Superlattices

Perpendicular magnetic anisotropy (PMA) has recently been shown to emerge at interfaces of 3d and 5d transition-metal oxides (TMOs). However, strategies to systematically stabilize such interface-driven PMA still remains elusive, hindering further applications of this design approach. Here, tuning crystal symmetry is shown to be an effective means to engineer this interfacial phenomenon. The evolution of PMA strength as a function of ferromagnetic oxide thickness quantitatively reveals the competition between volume- and interface-specific contributions that determine the magnetic anisotropy. By applying different degrees of epitaxial strain, the relative contributions to PMA are modulated, clearly revealing their correlations with crystal symmetries. To be more specific, the volume anisotropy energy is found to be correlated with the tetragonal distortion of the ferromagnetic layer, while the interface anisotropy energy is mainly modulated by the octahedral tilting at the interface. With these insights, superlattices with enhanced interface-driven PMA and higher Curie temperature are realized. These findings reveal a route to engineering interface-driven PMA and associated magnetic phenomena in TMO heterostructures for future spintronic applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Flaw Tolerance of Octet Truss Lattices with Random Flaws

We investigate the behavior of octet truss lattices in which some proportion of the bars are randomly removed from a perfect lattice. Using a lattice specimen of 9 × 9 × 9 octet truss unit cells as the nominal design, we simulate the response of prefect and flawed lattices with a finite element method implementation of rod theory. For each of two simple load cases, we perform a Monte Carlo analysis where we consider many instantiations of flawed lattices where between 1% and 20% of the bars are missing, and compare the axial loads in the remaining bars to those in the perfect lattice. We also compare the overall stiffness of the flawed lattices to the perfect lattice. Our results show progressive deterioration of lattice strength and stiffness with increasing proportion of missing bars, as expected, with the location and magnitude of the highest-loaded (most failure-prone) bars depending more on the load case and bar orientation than on the location and connectivity of missing bars. As such, the results reported herein may not be directly transferable to different lattice geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Age hardening response of Cu-30Ni alloys: The role of Si microalloying additions

Cu-30Ni alloys offer high strength and excellent corrosion resistance for maritime applications. While primarily a solid solution system, industrial alloys typically include microalloying additions of Fe, Mn, Nb and/or Si to enable age hardening. However, an understanding of the microstructural evolution during age hardening remains incomplete. Here, we conduct systematic ageing treatments and report the resulting hardness and microstructures. The Cu-30Ni alloy with Si aged at 650 °C for 6 h demonstrates significantly enhanced Vickers hardness, reaching ∼201 HV 1 compared to 103 HV 1 for the as-homogenised sample. Si-rich clusters and γ′ precipitates are identified, with their composition, size, and volume fraction quantified to determine their strengthening contributions. First-principles atomistic simulations elucidate the underlying formation mechanisms of these clusters and precipitates, highlighting the critical role of Si in driving their nucleation and growth. This study advances the design of high-strength, Cu alloys with the potential for corrosion resistance in demanding maritime environments.

Age hardening↗
DOE OSTI2024

Response of Graphite to Dynamic Loading and Hypervelocity Jet Impacts

The compressive strengths of three varieties of high purity graphite, PCEA, NBG-18, and NBG-25, as well as the depth of penetration of small-scale charges into these materials was experimentally determined. These grades are similar in density, ranging from 1.80 – 1.85 g/cc, and nominal apparent porosity, ranging from 18% to 20%, but provide a wide range in maximum grain or particle size from 10s to 1000s of µm. Two very different manufacturing methods are also represented; PCEA is extruded while NBG-18 and NBG-25 are iso-molded. The quasistatic and dynamic strengths of each grade were determined on a load frame and split-Hopkinson pressure bar, respectively. The depth of penetration (DOP) of two small-scale shaped charges, the Teledyne RP-1 and RP-4, was determined against graphite. The global response of the RP-4 impacts was markedly different as the PCEA samples remained intact while all the NBG-25 samples split into 2 or 3 pieces after the jet penetration had completed. However, for all tests, the trusted DOPs fell within 2 cm. Preliminary hydrocode modeling of the penetration events used existing models that were not designed for graphite. The results can be tuned to reasonably reproduce the DOP, but the wound channel geometry is not reproduced well. A model designed for graphite would need to represent graphite’s non-linear and energy dissipation characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Coal to Carbon Fiber (C2CF) Continuous Processing for High Value Composites (Final Report)

Coal tar is a condensed and recovered by-product of the coking of metallurgical coal for steel production. The heaviest fraction of distilled coal tar is an isotropic pitch largely used as a binder in the manufacturing of carbonaceous electrodes for primary aluminum smelting and in electric arc furnaces. Coal tar pitch offers high carbon yield upon carbonization. In this project, a process to convert the domestically sourced isotropic coal tar pitch, containing very low particulates (QI = 0.32 wt.%), to form flow-domain mesophase pitch amenable for melt spinning into precursor (green) fibers for carbon fiber, was developed and optimized. The final reproducible processing developed is reviewed in this report, along with several characterizations of the mesophase pitch. A final definition of the characteristics of a ‘spinnable’ mesophase pitch is presented. With this mesophase pitch, reproducible and stable multifilament melt spinning was developed, producing green fiber tows with filament diameters of approximately 20 m. The multifilament melt spinning was the most challenging aspect of the project and required the most effort. The best practices learned from this project for melt spinning are reviewed in this report. Once spun, the green fibers were oxidatively stabilized, carbonized and graphitized under inert gas atmosphere to form the final carbon fibers. Given the relatively high softening point of the mesophase pitch, no issues of interfilament fusion were observed during batch oxidation, and subsequent batch carbonization and graphitization went smoothly in all cases. An ~ 80 wt.% conversion of the green fiber mass to final carbon fiber was achieved. After graphitization, the carbon fibers showed high tensile moduli (most were ~ 600 GPa, or 87 Msi) consistent with commercially-available high-performance pitch-based carbon fiber. However, tensile strength and strain to failure were comparatively low. Further work to reduce defects in and on the fiber surfaces would increase these properties. SEM imaging of the graphitic fiber textures is presented herein. Rudimentary composites were fabricated from the carbon fibers and characterized showing similar modulus to baseline composites fabricated with commercial carbon fiber. Finally, a basic economic analysis was done showing the potential to increase the value of the isotropic coal tar pitch by up to 13.6 to 136 times based on a carbon fiber value of $\$$5/lb to $\$$50/lb, respectively. Moreover, the site case study suggests that the coal tar from the single integrated steel mill could supply production of up to 16 kt/yr of carbon fiber. Finally, a technological gap analysis was done which shed light on remaining technical challenges. These challenges included: recovery and utilization of condensates from the mesophase pitch processing, further advancing and increasing stability of the multifilament melt spinning processing, optimization of the oxidation processing, defect reduction for increased carbon fiber strength, and the development of a weaving process towards carbon fiber fabrics. To maximize the coal value chain, the primary objectives of this project were to (a) develop and scale efficient processing technology for producing melt-spinnable mesophase pitch from isotropic coal tar pitch, (b) clarify and simplify tedious continuous fiber processing technologies (particularly multifilament melt spinning of mesophase pitch) towards the efficient production of high performance carbon fiber, and (c) demonstrate and characterize representative composite parts derived from the final carbon fiber. Immense progress was made on all 3 objectives and is detailed in this report.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Extreme hardness at high temperature with a lightweight additively manufactured multi-principal element superalloy

Materials are needed that can tolerate increasingly harsh environments, especially ones that retain high strength at extreme temperatures. Higher melting temperature alloys, like those consisting primarily of refractory elements, can greatly increase the efficiency of turbomachinery used in grid electricity production worldwide. Existing alloys, including Ni- and Co-based superalloys, used in components like turbine blades, bearings, and seals, remain a performance limiting factor due to their propensity, despite extensive optimization efforts, for softening and diffusion-driven elongation at temperatures often well above half their melting point. To address this critical materials challenge, we present results from integrating additive manufacturing and alloy design to guide significant improvements in performance via traditionally difficult-to-manufacture refractory alloys. We present an example of a multi-principal element alloy (MPEA), consisting of five refractory elements and aluminum, that exhibited high hardness and specific strength surpassing other known alloys, including superalloys. The alloy shows negligible softening up to 800°C and consists of four compositionally distinct phases, in distinction to previous work on MPEAs. Density functional theory calculations reveal a thermodynamic explanation for the observed temperature-independent hardness and favorability for the formation of this multiplicity of phases.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Plastic anisotropy and tension-compression asymmetry in nanotwinned Al–Fe alloys: An in-situ micromechanical investigation

The mechanical strength of commercial Al alloys rarely exceeds 700 MP. Recent studies show that nanotwinned Al alloys and other nanocolumnar metals exhibit superb mechanical behaviors but a discrepancy between tensile and hardness measurements often emerges and their orientation dependent deformation mechanisms remain unclear. Here, we inspect the mechanical response of columnar nanotwinned Al–Fe alloys with emphasis on response of grain boundaries to in-situ tension and compression tests along both in-plane and out-of-plane directions inside a scanning electron microscope. Our studies reveal ultra-high out-of-plane tensile and compressive stress, exceeding 1.8 GPa, and an in-plane tensile and compressive stress of 1.1 and 1.6 GPa, respectively. Post-mortem TEM analyses were performed to elucidate the orientation-dependent plastic anisotropy and tension-compression asymmetry in columnar nanotwinned Al–Fe alloys. This study provides an important forward step towards the understanding of deformation mechanisms in high-strength nanotwinned Al alloys and metals with nanocolumnar or non-equiaxed grains.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Impact of Gold Thickness on Interfacial Evolution and Subsequent Embrittlement of Tin–Lead Solder Joints

Although gold remains a preferred surface finish for components used in high-reliability electronics, rapid developments in this area have left a gap in the fundamental understanding of solder joint gold (Au) embrittlement. Furthermore, as electronic designs scale down in size, the effect of Au content is not well understood on increasingly smaller solder interconnections. As a result, previous findings may have limited applicability. The current study focused on addressing these gaps by investigating the interfacial microstructure that evolves in 63Sn-37Pb solder joints as a function of Au layer thickness. Those findings were correlated to the mechanical performance of the solder joints. Increasing the initial Au concentration decreased the mechanical strength of a joint, but only to a limited degree. Kirkendall voids were the primary contributor to low-strength joints, while brittle fracture within the intermetallic compounds (IMC) layers is less of a factor. The Au embrittlement mechanism appears to be self-limiting, but only once mechanical integrity is degraded. Sufficient void evolution prevents continued diffusion from the remaining Au.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Symmetry-Protected Moiré Band Engineering and Enhanced Electron–Phonon Coupling in Xe/Bi 2 Se 3 Superlattices: Path to Topological Superconductivity

Observation of superconductivity, magnetism, and correlated insulating phases driven by the moiré potential in twisted graphene bilayer has opened the exciting new field of “twistronics”. Even richer physics is expected if moiré superlattice could be generated on topological insulators; however, until now, experimental studies have been scarce. Here, we demonstrate topological moirés generated by adsorbing a monolayer of noble gas on a topological insulator. By angle-resolved photoemission spectroscopy, we show that the moiré potential replicates the topological surface state and affects it in a way fundamentally different from the trivial states. Replicated Dirac cones generally avoid crossings, except at the time-reversal invariant momenta that remain gapless. This creates van Hove singularities at the moiré Brillouin zone corners, providing the mechanism of enhancing correlations. Indeed, we observe a strong enhancement of the electron–phonon coupling strength that, if properly tuned, might lead to topological superconductivity and Majorana Fermions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Challenges and transformative opportunities in superconductor vortex physics

In superconductors, the motion of vortices introduces unwanted dissipation that is disruptive to applications. Fortunately, material defects can immobilize vortices, acting as vortex pinning centers, which engenders dramatic improvements in superconductor material properties and device operation. This has motivated decades of research into developing methods of tailoring the disorder landscape in superconductors to increase the strength of vortex pinning. Yet, efficacious materials engineering still eludes us. The electromagnetic properties of real (disordered) superconducting materials cannot yet be reliably predicted, such that designing superconductors for applications remains a largely inefficient process of trial and error. This is ultimately due to large gaps in our knowledge of vortex dynamics: the field is challenged by the extremely complex interplay between vortex elasticity, vortex-vortex interactions, and material disorder. Here, we review obstacles and recent successes in understanding and controlling vortex dynamics in superconducting materials and devices. We further identify major open questions and discuss opportunities for transformative research in the field. This includes improving our understanding of vortex creep, determining and reaching the ceiling for the critical current, advanced microscopy to garner accurate structure-property relationships, frontiers in predictive simulations and the benefits of artificial intelligence, as well as controlling and exploiting vortices in quantum information applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

The pathfinder X-Ray axion telescope for the International Axion Observatory (IAXO) and axion searches at the CERN Axion Solar Telescope (CAST)

The axion, a hypothetical pseudo-scalar particle proposed by Peccei and Quinn to resolve the strong CP problem in quantum chromodynamics, remains one of the most compelling dark matter candidates. Axions and Axion-Like Particles (ALPs) are characterized by a broad and largely unconstrained parameter space in mass and coupling strength, motivating extensive experimental searches. The International Axion Observatory (IAXO) is a next-generation axion helioscope designed to achieve over an order of magnitude improvement in sensitivity to the axion-photon coupling constant gaγ relative to previous experiments such as the CERN Axion Solar Telescope (CAST). IAXO will employ large-scale superconducting magnets, precision x-ray optics, and ultra-low-background detectors to search for solar axions produced primarily via the Primakoff effect. This work presents the design and performance of the IAXO pathfinder x-ray optic, a technological demonstrator that validated the optical concepts for IAXO through axion searches at CAST. Comprehensive ray-tracing simulations and experimental measurements were conducted to assess the optic's effective area, detection efficiency, and background suppression capabilities. Deployed at CAST in conjunction with Micromegas and GridPix detectors, the Pathfinder demonstrated record-setting sensitivity to both gaγ and the axion-electron coupling gae, establishing the most stringent laboratory constraints on solar axions to date. These results confirm the viability of the IAXO optical design and detector concept, providing a critical technological benchmark that informs the ongoing development of the BabyIAXO and full-scale IAXO telescopes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Polished diamond X-ray lenses

High-quality bi-concave 2D focusing diamond X-ray lenses of apex-radius R = 100 µm produced via laser-ablation and improved via mechanical polishing are presented here. Both for polished and unpolished individual lenses and for stacks of ten lenses, the remaining figure errors determined using X-ray speckle tracking are shown and these results are compared with those of commercial R = 50 µm beryllium lenses that have similar focusing strength and physical aperture. For two stacks of ten diamond lenses (polished and unpolished) and a stack of eleven beryllium lenses, this paper presents measured 2D beam profiles out of focus and wire scans to obtain the beam size in the focal plane. These results are complemented with small-angle X-ray scattering (SAXS) measurements of a polished and an unpolished diamond lens. Again, this is compared with the SAXS of a beryllium lens. The polished X-ray lenses show similar figure errors to commercially available beryllium lenses. While the beam size in the focal plane is comparable to that of the beryllium lenses, the SAXS signal of the polished diamond lenses is considerably lower.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Lifting at higher levels in the D1D 5 CFT

The D1D 5 P system has a large set of BPS states at its orbifold point. Perturbing away from this ‘free’ point leads to some states joining up into long supermultiplets and lifting, while other states remain BPS. We consider the simplest orbifold which exhibits this lift: that with N = 2 copies of the free c = 6 CFT. We write down the number of lifted and unlifted states implied by the index at all levels upto 6. We work to second order in the perturbation strength λ. For levels upto 4, we find the wavefunctions of the lifted states, their supermultiplet structure and the value of the lift. All states that are allowed to lift by the index are in fact lifted at order O(λ 2 ). We observe that the unlifted states in the untwisted sector have an antisymmetry between the copies in the right moving Ramond ground state sector, and extend this observation to find classes of states for arbitrary N that will remain unlifted to O(λ 2 )

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗