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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 253 records · Page 14

Temperature-Dependent Sheet and Contact Resistivity Measurements on Ag and Ag-Ni Circuit Pastes

The metal circuits and brazes used in electronic, energy conversion, and/or energy storage devices often have difficulty wetting and adhering to ceramic and/or ceramic-passivated metal substrates. Here, a novel Particle Interlayer Directed Wetting and Spreading (PIDWAS) technique is demonstrated that utilizes screen printing, the low wetting angle of silver on nickel, and the high work of adhesion between nickel and various ceramics to produce well-adhered, self-assembled silver patterns on ceramic and/or stainless-steel substrates not normally wet by silver. The resulting Ag-Ni circuits have higher sapphire adhesion strengths (up to 30 MPa on sapphire), higher densities (>97% on sapphire), and similar high-temperature electronic resistivities to those made using commercially-available Heraeus C8710 or DAD-87 silver circuit pastes. Similarly, Ag-Ni brazes between a variety of ceramic and/or stainless-steel substrates have better microstructural stability with rapid thermal cycling, reduction-oxidation cycling, and dual atmosphere isothermal aging than conventional Ag-CuO brazes. In addition, the residual Ni in these Ag-Ni circuits and brazes can be used to chemically getter surface segregated Al, ensuring low contact resistances on a variety of chromia- and/or alumina-passivated stainless steels. Reference: [1] Hu G, Zhou Q, Bhatlawande A, Park J, Termuhlen R, Ma Y, Bieler TR, Yu HC, Qi Y, Hogan T & Nicholas JD. Patterned Nickel Interlayers for Enhanced Silver Wetting, Spreading and Adhesion on Ceramic Substrates. Scripta Materialia, 2021; 196, 113767. 10.1016/j.scriptamat.2021.113767 [2] Park J, Phongpreecha T, Nicholas JD & Qi Y. Enhanced Liquid Metal Wetting on Oxide Surfaces via Patterned Particles. Acta Materialia, 2020; 199, 551-560. 10.1016/j.actamat.2020.08.037

Bhatlawande, Aishwarya↗

Neutron diffraction: a primer

Because of the neutron’s special properties, neutron diffraction may be considered one of the most powerful techniques for structure determination of crystalline and related matter. Neutrons can be released from nuclear fission, from spallation processes, and also from low-energy nuclear reactions, and they can then be used in powder, time-of-flight, texture, single crystal, and other techniques, all of which are perfectly suited to clarify crystal and magnetic structures. With high neutron flux and sufficient brilliance, neutron diffraction also excels for diffuse scattering, for in situ and operando studies as well as for high-pressure experiments of today’s materials. For these, the wave-like neutron’s infinite advantage (isotope specific, magnetic) is crucial to answering important scientific questions, for example, on the structure and dynamics of light atoms in energy conversion and storage materials, magnetic matter, or protein structures. In this primer, we summarize the current state of neutron diffraction (and how it came to be), but also look at recent advances and new ideas, e.g., the design of new instruments, and what follows from that.

36 MATERIALS SCIENCE↗

Nanostructured, Targeted Layered Metal Oxides as Active and Selective Heterogeneous Electrocatalysts for Oxygen Evolution

Oxygen evolution reaction (OER) is an important chemical transformation that governs the performance of technologically relevant energy conversion and storage processes, such as electrochemical water splitting in electrolyzers and metal-air batteries. This reaction involves the evolution of oxygen gas from (i) oxygen ions formed from water splitting at high temperatures, (ii) oxygen containing species (i.e., OH, OOH) formed from water splitting at low temperatures, and (iii) metal-oxide discharge products (M x O 2 ) in metal-air batteries. One of the main challenges with OER is that it is catalyzed at low temperatures by noble metal-based electrocatalysts, which are expensive (making this process economically unviable), or at high temperatures by metal-oxide based electrocatalysts that are inefficient and lead to high overpotential losses. Our preliminary results, as well as other results in the literature, show that non-noble metal-based oxide electrocatalysts with layered structures, known as nickelate oxides, exhibit promising OER activity. Nickelate oxides (A 2 MO 4+δ ) belong to the Ruddlesden-Popper series composed of alternating perovskite-like and rocksalt-like layers. They are promising OER electrocatalysts due to their high oxygen transport/exchange properties compared to the state-of-the-art perovskite-type oxides. Unfortunately, these materials are fairly unexplored and little is known about the properties that govern their OER activity. Our preliminary studies, where we combine density functional theory (DFT) calculations, selective synthesis and characterization, show that engineering their nanocrystalline structure can significantly impact their catalytic activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Material Discovery and Design Principles of Perovskite Oxides for Reversible Solid Oxide Cells (R-SOC)

Reversible solid oxide cells (R-SOCs) are highly efficient devices for energy conversion and storage, capable of operating for both hydrogen utilization and production. In fuel cell mode, an R-SOC consumes hydrogen or natural gas to generate electricity, while in electrolysis mode, it produces hydrogen from steam. The discover of new materials with rapid oxygen surface exchange kinetics and enduring stability is crucial for the economically viable commercialization of R-SOCs. To facilitate this pursuit, we conducted extensive Density Functional Theory (DFT) calculations and developed Machine Learning (ML) models to predict critical catalytic properties essential for R-SOCs, such as oxygen surface exchange/diffusivity, and area-specific resistance (ASR). BaCoxFeyZrzO3-d(BFCZ)(x+y+z=1) emerged as a promising family of electrode materials with high activity and stability, validated through systematic experimental study. Moreover, a robust numerical multiphysics model was developed to optimize materials and microstructure parameters, providing the ability to predict the performance of functional R-SOCs.

Liu, Jian↗

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗

An In-Depth Exploration of the Electrochemical Oxygen Reduction Reaction (ORR) Phenomenon on Carbon-Based Catalysts in Alkaline and Acidic Mediums

Detailed studies of the electrochemical oxygen reduction reaction (ORR) on catalyst materials are crucial to improving the performance of different electrochemical energy conversion and storage systems (e.g., fuel cells and batteries), as well as numerous chemical synthesis processes. In the effort to reduce the loading of expensive platinum group metal (PGM)-based catalysts for ORR in the electrochemical systems, many carbon-based catalysts have already shown promising results and numerous investigations on those catalysts are in progress. Most of these studies show the catalyst materials’ ORR performance as current density data obtained through the rotating disk electrode (RDE), rotating ring-disk electrode (RRDE) experiments taking cyclic voltammograms (CV) or linear sweep voltammograms (LSV) approaches. However, the provided descriptions or interpretations of those data curves are often ambiguous and recondite which can lead to an erroneous understanding of the ORR phenomenon in those specific systems and inaccurate characterization of the catalyst materials. In this paper, we presented a study of ORR on a newly developed carbon-based catalyst, the nitrogen-doped graphene/metal-organic framework (N-G/MOF), through RDE and RRDE experiments in both alkaline and acidic mediums, taking the LSV approach. The functions and crucial considerations for the different parts of the RDE/RRDE experiment such as the working electrode, reference electrode, counter electrode, electrolyte, and overall RDE/RRDE process are delineated which can serve as guidelines for the new researchers in this field. Experimentally obtained LSV curves’ shapes and their correlations with the possible ORR reaction pathways within the applied potential range are discussed in depth. We also demonstrated how the presence of hydrogen peroxide (H2O2), a possible intermediate of ORR, in the alkaline electrolyte and the concentration of acid in the acidic electrolyte can maneuver the ORR current density output in compliance with the possible ORR pathways.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Structural, Optical and Mechanical Properties of Nanocrystalline Molybdenum Thin Films Deposited under Variable Substrate Temperature

Molybdenum (Mo), which is one among the refractory metals, is a promising material with a wide variety of technological applications in microelectronics, optoelectronics, and energy conversion and storage. However, understanding the structure–property correlation and optimization at the nanoscale dimension is quite important to meet the requirements of the emerging nanoelectronics and nanophotonics. In this context, we focused our efforts to derive a comprehensive understanding of the nanoscale structure, phase, and electronic properties of nanocrystalline Mo films with variable microstructure and grain size. Molybdenum films were deposited under varying temperature (25–500 °C), which resulted in Mo films with variable grain size of 9–22 nm. The grazing incidence X-ray diffraction analyses indicate the (110) preferred growth behavior the Mo films, though there is a marked decrease in hardness and elastic modulus values. In particular, there is a sizable difference in maximum and minimum elastic modulus values; the elastic modulus decreased from ~460 to 260–280 GPa with increasing substrate temperature from 25–500 °C. The plasticity index and wear resistance index values show a dramatic change with substrate temperature and grain size. Additionally, the optical properties of the nanocrystalline Mo films evaluated by spectroscopic ellipsometry indicate a marked dependence on the growth temperature and grain size. This dependence on grain size variation was particularly notable for the refractive index where Mo films with lower grain size fell in a range between ~2.75–3.75 across the measured wavelength as opposed to the range of 1.5–2.5 for samples deposited at temperatures of 400–500 °C, where the grain size is relatively higher. The conductive atomic force microscopy (AFM) studies indicate a direct correlation with grain size variation and grain versus grain boundary conduction; the trend noted was improved electrical conductivity of the Mo films in correlation with increasing grain size. The combined ellipsometry and conductive AFM studies allowed us to optimize the structure–property correlation in nanocrystalline Mo films for application in electronics and optoelectronics.

36 MATERIALS SCIENCE↗

Mission oriented R and D and the advancement of technology: The impact of NASA contributions, volume 2

NASA contributions to the advancement of major developments in twelve selected fields of technology are presented. The twelve fields of technology discussed are: (1) cryogenics, (2) electrochemical energy conversion and storage, (3) high-temperature ceramics, (4) high-temperature metals (5) integrated circuits, (6) internal gas dynamics (7) materials machining and forming, (8) materials joining, (9) microwave systems, (10) nondestructive testing, (11) simulation, and (12) telemetry. These field were selected on the basis of both NASA and nonaerospace interest and activity.

Robbins, M. D.↗

ERDA/Lewis research center photovoltaic systems test facility

A national photovoltaic power systems test facility (of initial 10-kW peak power rating) is described. It consists of a solar array to generate electrical power, test-hardware for several alternate methods of power conversion, electrical energy storage systems, and an instrumentation and data acquisition system.

Forestieri, A. F.↗

Technology for power in space

The two distinct future directions of the NASA Space Power Research and Technology Program are toward multikilowatt power levels at low cost and toward very high performance. The development of both of these directions is reviewed and attention is given to the underlying conversion technologies: photovoltaic, chemical energy conversion and storage, and thermal-to-electric conversion. Problems of environmental compatibility are briefly discussed.

Mullin, J. P.↗

OAST space power technology program

The current research and technology (R and T) base program is first described, then special attention is directed toward outlining a new system technology specifically oriented toward providing the utility power plant technology base for semi-permanent earth orbital facilities expected to be needed in the middle to late 1980's. The R and T program involves five areas of research: (1) photovoltaic energy conversion; (2) chemical energy conversion and storage; (3) thermal-to-electric conversion; (4) environment interactions; and (5) power systems management and distribution. The general objectives and planned direction of efforts in each of these areas is summarized.

Mullin, J. P.↗

The NASA space power technology program

The objective and planning of the NASA space power research and technology program are reviewed. The areas of research covered include photovoltaic energy conversion, chemical energy conversion and storage, thermal to electric conversion, environmental interactions and power systems management of distribution.

Mullin, J. P.↗

Phase 1 of the First Small Power System Experiment (engineering Experiment No. 1). Volume 3: Experimental System Descriptions

The design and development of a modular solar thermal power system for application in the 1 to 10 MWe range is described. The system consists of five subsystems: the collector, power conversion, energy transport, energy storage, and the plant control subsystem. The collector subsystem consists of concentrator, receiver, and tower assemblies. The energy transport subsystem uses a mixture of salts with a low melting temperature to transport thermal energy. A steam generator drives a steam Rankine cycle turbine which drives an electrical generator to produce electricity. Thermal and stress analysis tests are performed on each subsystem in order to determine the operational reliability, the minimum risk of failure, and the maintenance and repair characteristics.

Holl, R. J.↗

The NASA Space Power Technology Program

This paper discusses the National Aeronautics and Space Administration's (NASA) Space Power Technology Program which is aimed at providing the needed technology for NASA's future missions. The technology program is subdivided into five areas: (1) photovoltaic energy conversion; (2) chemical energy conversion and storage; (3) thermal to electric conversion; (4) power system management and distribution, and (5) advanced energetics. Recent accomplishments, current status, and future directions are presented for each area.

Mullin, J. P.↗

Progress in space power technology

The National Aeronautics and Space Administration's Space Power Research and Technology Program has the objective of providing the technology base for future space power systems. The current technology program which consists of photovoltaic energy conversion, chemical energy conversion and storage, thermal-to-electric conversion, power systems management and distribution, and advanced energetics is discussed. In each area highlights, current programs, and near-term directions will be presented.

Mullin, J. P.↗

A standard description and costing methodology for the balance-of-plant items of a solar thermal electric power plant. Report of a multi-institutional working group

Standard descriptions for solar thermal power plants are established and uniform costing methodologies for nondevelopmental balance of plant (BOP) items are developed. The descriptions and methodologies developed are applicable to the major systems. These systems include the central receiver, parabolic dish, parabolic trough, hemispherical bowl, and solar pond. The standard plant is defined in terms of four categories comprising (1) solar energy collection, (2) power conversion, (3) energy storage, and (4) balance of plant. Each of these categories is described in terms of the type and function of components and/or subsystems within the category. A detailed description is given for the BOP category. BOP contains a number of nondevelopmental items that are common to all solar thermal systems. A standard methodology for determining the costs of these nondevelopmental BOP items is given. The methodology is presented in the form of cost equations involving cost factors such as unit costs. A set of baseline values for the normalized cost factors is also given.

Source record↗

Space Station Energy Sizing

A general schematic for a space station power system is described. The major items of interest in the power system are the solar array, transfer devices, energy storage, and conversion equipment. Each item will have losses associated with it and must be utilized in any sizing study, and can be used as a checklist for itemizing the various system components.

Rice, R. R.↗