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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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NASA NTRS2011

Flight Testing of the Forward Osmosis Bag for Water Recovery on STS-135

The Forward Osmosis Bag (FOB) is a personal water purification device for recovery of potable liquid from almost any non-potable water source. The FOB experiment was flown as a sortie mission on STS-135/ULF7 using flight-certified materials and a design based on the X-Pack(TradeMark) from Hydration Technology Innovations (Albany, OR). The primary objective was to validate the technology for use under microgravity conditions. The FOB utilizes a difference in solute concentration across a selectively permeable membrane to draw water molecules from the non-potable water while rejecting most chemical and all microbial contaminants contained within. Six FOB devices were tested on STS-135 for their ability to produce a potable liquid permeate from a feed solution containing 500 mL potassium chloride (15 g/L) amended with 0.1% methyl blue dye (w:v) tracer against an osmotic gradient created by addition of 60 mL of concentrate containing the osmolytes fructose and glucose, and 0.01% sodium fluorescein (w:v) tracer. Three FOB devices were physically mixed by hand for 2 minutes by a crewmember after loading to augment membrane wetting for comparison with three unmixed FOB devices. Hydraulic flux rate and rejection of salt and dye in microgravity were determined from a 60-mL sample collected by the crew on orbit after 6 hours. Post-flight analysis of samples collected on orbit demonstrated that the Forward Osmosis Bag achieved expected design specifications in microgravity. The hydraulic flux rate of water across the membrane was reduced approximately 50% in microgravity relative to ground controls that generated an average of 50 mL per hour using the same water and osmolyte solutions. The membrane rejected both potassium and chloride at >92% and methyl blue dye at >99.9%. Physical mixing of the FOB during water recovery did not have any significant effect on either flux rate or rejection of solutes from the water solution. The absence of buoyancy-driven convection in microgravity suggests that mass transport was dominated by diffusion, slowing the rate of permeate production across the membrane. It is possible that a predicted reduction in concentration polarization at the membrane surface that may have acted to increase the rate of permeate production in microgravity was negligible under the described test conditions.

Roberts, Michael S.↗
DOE OSTI2024

Development of Self-Assembly Supports Enabling Transformational Membrane Performance for Cost-Effective Carbon Capture

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the development of membranes with transformational performance for carbon capture under award number DE-FE0031596. The work was performed from June 1, 2018 through May 31, 2024. For more than a decade, MTR has worked in partnership with DOE to develop an innovative membrane-based CO 2 capture process. This effort has included the first test of membrane modules with coal-fired flue gas at the Arizona Public Services (APS) Cholla plant in 2010; the accumulation of >11,000 hours of flue gas operation for Polaris modules on a bench-scale 1 tonne/day (TPD) system at the National Carbon Capture Center (NCCC); scale-up of first-generation (Gen-1) Polaris to a 20 TPD small pilot system, and successful operation of this system on a flue gas slipstream at NCCC and in integrated boiler testing at Babcock & Wilcox (B&W). Through continued development efforts, a second-generation (Gen-2) version of the Polaris membrane has been scaled-up to pilot production. This membrane offers 70% higher CO 2 permeance with similar selectivity to the base case Polaris. MTR also developed planar modules designed specifically for the low-pressure, high-volumetric flow rate process conditions of flue gas operation. These new modules have significantly lower pressure-drop values compared to the type originally used (spiral-wound modules), which results in significant energy savings. The goal of the work described in this report was to improve on the Polaris Gen-2 membrane with the ultimate aim to reduce the cost of carbon capture. The majority of the effort was to develop improved support membranes for the multi-layer composite structure of MTR’s Polaris membrane. Earlier work at MTR had identified the support structure as limiting membrane permeances, not because the support itself represents a permeation resistance, but because the distribution of pores at the surface of the support imposes a geometric restriction to diffusion in the layers above it. Support membranes were prepared from a range of polymers, including commercially available block copolymers and a custom synthesized block copolymer alternative. The best support membranes developed in this project reduced the geometric restriction by a factor of two to three. These supports then were used to produce Polaris composite membranes with improved permeances. The second topic was to create a high-selectivity version of the Polaris membrane. The high-selectivity version uses a novel selective polymeric material and high selectivities were confirmed in experiments at MTR. The material is not easily made into very thin films. Consequently, the permeances are significantly lower than the Polaris Gen-2 membrane. The utility of this membrane is therefore limited to the carbon dioxide purification step that produces liquid CO 2 . A Technical and Economic Analysis (TEA) was performed for a carbon capture system that uses both advanced membrane types. The TEA shows the novel advanced membranes reduce the cost of capture by 10%, from $63.32/tonne CO 2 to $56.90/tonne CO 2 (2022 USD). Most of the development work was carried out with laboratory-scale casting and coating equipment. A number, but not all, of the improvements identified have been implemented on commercial-scale manufacturing equipment. The focus of future work at MTR is to incorporate the advancements made into the Polaris membrane manufacturing process.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2016

Evolving Our Evaluation of Lighting Environments Project

Imagine you are an astronaut on their 100th day of your three year exploration mission. During your daily routine to the small hygiene compartment of the spacecraft, you realize that no matter what you do, your body blocks the light from the lamp. You can clearly see your hands or your toes but not both! What were those design engineers thinking! It would have been nice if they could have made the walls glow instead! The reason the designers were not more innovative is that their interpretation of the system lighting requirements didn't allow them to be so! Currently, our interior spacecraft lighting standards and requirements are written around the concept of a quantity of light illuminating a spacecraft surface. The natural interpretation for the engineer is that a lamp that throws light to the surface is required. Because of certification costs, only one lamp is designed and small rooms can wind up with lamps that may be inappropriate for the room architecture. The advances in solid state light emitting technologies and optics for lighting and visual communication necessitates the evaluation of how NASA envisions spacecraft lighting architectures and how NASA uses industry standards for the design and evaluation of lighting system. Current NASA lighting standards and requirements for existing architectures focus on the separate ability of a lighting system to throw light against a surface or the ability of a display system to provide the appropriate visual contrast. Realization that these systems can be integrated is not realized. The result is that the systems are developed independent from one another and potential efficiencies that could be realized from borrowing from the concept of one technology and applying it for the purpose of the other does not occur. This project investigated the possibility of incorporating large luminous surface lamps as an alternative or supplement to overhead lighting. We identified existing industry standards for architectural luminous or brightness uniformity as part of a lighting system definition. The efficiency of the surface lighting technology was evaluated for uniformity and power consumption. Finally, the team investigated possible performance savings if the walls were made to glow via a self luminous surface system instead of creating brightness by use of direct lighting of a highly reflective diffuse surface.

Terrier, Douglas↗
DOE OSTI2026

Restoring Escaped Zincate in Rechargeable Alkaline Zinc Batteries with a Seed-in-Nanoshell Design

Rechargeable alkaline zinc batteries are promising candidates for safe and low-cost energy storage, but suffer from ZnO dissolution that causes irreversible active material loss and rapid capacity decay. Here, we report a seed-in-nanoshell ZnO anode architecture that mitigates dissolution by combining physical confinement with electrochemical restoration of dissolved zincate species. ZnO particles are encapsulated within an ion-sieving carbon nanoshell that restricts zincate diffusion, maintains electrical conductivity, and stabilizes repeated solid–solution–solid transformations. Silver (Ag) nanoparticles incorporated into the nanoshell act as zincophilic nucleation seeds, lowering the Zn deposition barrier and directing the redeposition of dissolved zincate back to metallic Zn during charging. This confinement-enabled restoration mechanism converts zincate dissolution from an irreversible loss pathway into a recoverable process, enabling improved performance under harsh test conditions. The anode also delivers 227.9 mAh g −1 at −40 °C. Finally, a scalable tens-of-gram synthesis of ZnO@Ag is demonstrated, underscoring the practical potential of this strategy for advanced aqueous zinc batteries.

25 ENERGY STORAGE↗
DOE OSTI2021

The Energizer Bunny: Dual-Use Photovoltaic and Pasture-Raised Rabbit Farms (Final Report)

This case study project lays the groundwork for the broader realization of agrivoltaics by considering the techno-economic, environmental, and social aspects of system development and assessing a novel rabbit-based concept. Research on the social and political barriers to agrivoltaic development is sparse, which emphasizes the importance of this project as it provides key insight into the consequential socio-political challenges that may hinder the diffusion of agrivoltaic technology. Additionally, the rabbit agrivoltaic concept is novel and has not been applied in experimental or commercial applications to date. This project advances our understanding of the viability of this co-location scheme through empirical assessment of integrating grazing rabbits with solar. A total of five manuscripts (3 published in peer-reviewed journals, 2 under review) have resulted from this project. The techno-economic component of the project included a) a pilot test study investigating the feasibility of the rabbit agrivoltaic concept and b) an economic analysis of the advantages available to solar operators who leverage grazing animals for lawn maintenance and a dual-revenue stream. Our calculations indicate that the co-location of solar and rabbit farms is a viable form of agrivoltaics, increasing overall site revenue by 2.5%-24.0% above projected electricity revenue. The environmental component of the project entailed an ISO 14040 and 14044 compliant life cycle assessment to quantify the impacts of the rabbit agrivoltaic concept. The results indicate pasture-based agrivoltaic systems provide a dual synergy that produces 69.3% less emissions and demands 82.9% less fossil energy per functional unit of cumulative MWh output of electricity and cumulative kg of meat compared to non-integrated production. The social component of the project included conducting two separate interview studies with agriculture and solar industry professionals and the distribution of a public survey. The interview findings identify the key socio-political opportunities for agrivoltaics include: the retention of agricultural land and rural interests, and increased local level acceptance of solar development. The key barriers to agrivoltaics include: ensuring long term agricultural productivity is not compromised, and subnational zoning strategies. The survey results indicate that support for local solar projects increase by 10% when an agricultural function is incorporated. Survey respondents prefer agrivoltaic projects that are a) designed to provide economic opportunities for farmers and the local community b) located on private property or existing agricultural land, and c) do not threaten local interests. Cumulatively, this project can inform agrivoltaic decision making, solar development practices, rabbit-based applications, land use management, and policy making in a way that supports the furtherance of the renewable energy transition, conserves arable land, and utilizes innovative solar photovoltaic technologies.

14 SOLAR ENERGY↗
DOE OSTI2017

Novel Serpentine Robot Combinations for Inspection in Hard-to-Reach Areas of Damaged or Decommissioned Structures - 17335

U.S. government agencies, particularly the Dept. of Energy, need robotic tools to handle and inspect high-consequence materials - materials for which mishandling would result in great risk to both application operators and the general public. The remediation and documentation of nuclear waste has become a problem of national significance and it cannot be addressed without robotic tools. The use of robots bypasses the danger and decreases the preparation time to handle harmful materials. In the 1980's and 90's, the US Dept. of Energy (DOE) invested heavily in robotic technologies as part of a comprehensive program of research and development aimed at enabling safer and more efficient cleanup of nuclear waste sites. For the next generation of harder, more complex clean-up problems, there is a clear need for more R and D. There is a clear need for flexible, quickly deployable robotic technologies that can be configured to respond to unforeseen situations -- or can be purpose-built for planned activities -- while keeping human workers safe, yet effective. Modularity and inter-operability are core capabilities for inspection tasks in contaminated facilities with a large variety of inspection problems. With any tool, familiarity breeds ingenuity, and ingenuity leads to new innovations in efficiency, effectiveness, safety, and performance. For example, the simple screwdriver can be held fourteen different ways by an experienced machinist who knows exactly what he or she wants to accomplish at any given moment. As a tool, robots are no different. To maximize the efficiency, effectiveness, safety and performance, redeployment and reuse of familiar tools is essential. Modularity can assist with re-deployment and modularity manifests itself in both hardware and software. In some applications of inspection of high-consequence materials, a common concern has been the simplicity of the tool -- often correlated with cost (which is not always accurate) -- in case it becomes unrecoverable. In the case of robots, which have complex user interfaces and complex dynamics of interaction, the lack of familiarity can lead to clumsy operations and reduced accumulation of knowledge. As a result, while incremental successes may be achieved with sequential uses of different robots, there often is little knowledge gain that is generalizable across multiple uses. Total cost often goes down when a more sophisticated, but more familiar tool, can be used more frequently.An example is the inspection of the H-Canyon Exhaust Air Tunnel at the Savannah River Site nuclear waste facility in the United States [1]. This is a particularly nasty environment, due to the acidic gases, large amounts of erosion and debris, and wet, mucky puddles. Over the past twelve years, six inspections have been attempted with five different robotic vehicles. In fact, these inspections have been successful with their limited, but progressively increasing objectives, although most robots have been abandoned in the tunnel. While each vehicle has cost less than $75,000 (the sacrificial part), the total costs of development have been much higher. The robots used to investigate changed much from iteration to iteration and it is not clear a strong body of generalizable expertise was built up across trials. The authors of this study demonstrated the combination of two types of modular, serpentine, re-configurable robots for locomotion over complex terrains and the inspection of hard-to-reach areas. The MOTHERSHIP is a tread/limb/serpentine hybrid robot design for locomotion over complex terrains, while the CMU snake robot provides highly articulated inspection of highly confined spaces. The demonstration at the Portsmouth Gaseous Diffusion Plant involves a combination of the two whereby gross locomotion is achieved with the MOTHERSHIP and the CMU Snake deploys a sensor package to gather data from behind and under obstacles. Although statically configured in its present state, the combined robot is built of individual modules for which reconfiguration has been demonstrated in both labs at Purdue and CMU. In future work, much higher degrees of reconfiguration and re-purposing of both software and hardware are easily achievable with these unique platforms. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Plasma Science and Innovation Center at Washington, Wisconsin, and Utah State: Final Scientific Report for the University of Wisconsin-Madison

The University of Wisconsin-Madison component of the Plasma Science and Innovation Center (PSI Center) contributed to modeling capabilities and algorithmic efficiency of the Non-Ideal Magnetohydrodynamics with Rotation (NIMROD) Code, which is widely used to model macroscopic dynamics of magnetically confined plasma. It also contributed to the understanding of direct-current (DC) injection of electrical current for initiating and sustaining plasma in three spherical torus experiments: the Helicity Injected Torus-II (HIT-II), the Pegasus Toroidal Experiment, and the National Spherical Torus Experiment (NSTX). The effort was funded through the PSI Center's cooperative agreement with the University of Washington and Utah State University over the period of March 1, 2005 - August 31, 2016. In addition to the computational and physics accomplishments, the Wisconsin effort contributed to the professional education of four graduate students and two postdoctoral research associates. The modeling for HIT-II and Pegasus was directly supported by the cooperative agreement, and contributions to the NSTX modeling were in support of work by Dr. Bickford Hooper, who was funded through a separate grant. Our primary contribution to model development is the implementation of detailed closure relations for collisional plasma. Postdoctoral associate Adam Bayliss implemented the temperature-dependent effects of Braginskii's parallel collisional ion viscosity. As a graduate student, John O'Bryan added runtime options for Braginskii's models and Ji's K2 models of thermal conduction with magnetization effects and thermal equilibration. As a postdoctoral associate, O'Bryan added the magnetization effects for ion viscosity. Another area of model development completed through the PSI-Center is the implementation of Chodura's phenomenological resistivity model. Finally, we investigated and tested linear electron parallel viscosity, leveraged by support from the Center for Extended Magnetohydrodynamic Modeling (CEMM). Work on algorithmic efficiency improved NIMROD's element-based computations. We reordered arrays and eliminated a level of looping for computations over the data points that are used for numerical integration over elements. Moreover, the reordering allows fewer and larger communication calls when using distributed-memory parallel computation, thereby avoiding a data starvation problem that limited parallel scaling over NIMROD's Fourier components for the periodic coordinate. Together with improved parallel preconditioning, work that was supported by CEMM, these developments allowed NIMROD's first scaling to over 10,000 processor cores. Another algorithm improvement supported by the PSI Center is nonlinear numerical diffusivities for implicit advection. We also developed the Stitch code to enhance the flexibility of NIMROD's preprocessing. Our simulations of HIT-II considered conditions with and without fluctuation-induced amplification of poloidal flux, but our validation efforts focused on conditions without amplification. A significant finding is that NIMROD reproduces the dependence of net plasma current as the imposed poloidal flux is varied. The modeling of Pegasus startup from localized DC injectors predicted that development of a tokamak-like configuration occurs through a sequence of current-filament merger events. Comparison of experimentally measured and numerically computed cross-power spectra enhance confidence in NIMROD's simulation of magnetic fluctuations; however, energy confinement remains an open area for further research. Our contributions to the NSTX study include adaptation of the helicity-injection boundary conditions from the HIT-II simulations and support for linear analysis and computation of 3D current-driven instabilities.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Macro-level mechanical interlocking: A rapid joining approach for additively manufactured compression molded composite panels

Composite joining typically involves multiple steps, such as drilling and surface treatment, as part of the manufacturing process, which leads to low throughput and long cycle times. In the present study, we demonstrated a macro-level mechanical interlocking (MI) based, rapid joining technique to assemble additively manufactured compression molded (AMCM) panels, enabling the production of parts larger than the mold dimensions. Composite panels made of 20 wt% short carbon fiber reinforced acrylonitrile butadiene styrene (CF/ABS) were joined using MI features of various geometries, namely tree (TR), dovetail (Dov), rectangle 2 (Rect2), and rectangle 1 (Rect1), and their in-plane strength was evaluated. The resultant strength of the tested MI joints reached up to 74 % of the baseline tensile strength (i.e., the ‘no joint’ case). Observations from optical and scanning electron microscopy revealed inadequate polymer diffusion between the adherends, indicating that the joint strength was primarily derived from mechanical interlocking. Additionally, the fracture surfaces exhibited stress-whitening marks, which were characterized using differential scanning calorimetry (DSC). The increase in melting enthalpy suggested local stretching of polymer chains due to MI. Finite element analysis (FEA) indicated that the Rect1 MI feature, which generated the lowest stress concentration, outperformed the others in terms of joint strength, achieving 42 MPa. As a demonstration of the MI joining method, a battery box tray measuring 108 cm × 34 cm using a mold with an effective dimension of 36 cm × 34 cm successfully manufactured, resulting in a part with an area three times larger than the mold. In conclusion, this study presents a promising approach to improving composite joining techniques while minimizing production complexities.

In-plane joining↗
NASA NTRS2015

Final Report on the Detection of Green Monopropellants

In 2014, National Aeronautics and Space Administration (NASA) Kennedy Space Center (KSC) funded a project titled "Familiarization and Detection of Green Monopropellants" utilizing Independent Research and Technology Development (IR&TD) and Center Innovation Fund (CIF) funding. The purpose of the project was to evaluate methods of detection for ammonium dinitramide (ADN) and hydroxylammonium nitrate (HAN). An Engineering Services Contract (ESC) task order was created with the scope of evaluation of several methods of detecting ADN- and HAN-based propellants, as well as development of methods for detection. Detection methods include developed methods such as colorimetric indicating absorbent socks, and commercial-off-the- shelf (COTS) units for ammonia detection. An additional goal of the task order was for ESC to become familiar with ADN's and HAN's material properties and material compatibility. Two approaches were initially investigated as possible methods for the detection of HAN (or AFM315E) and ADN (or LMP-103S). These approaches were colorimetric analysis and instrumentation-based COTS vapor sensors utilization. Initial testing showed that the relatively non-existent vapor pressure of the AF-M315E (of which HAN is a major component) propellant would make the use of COTS sensors difficult for real-time area monitoring of HAN; a small response was detected through the use of active COTS sensors, including the RAE Systems MultiRAE Lite and Drager X-act (registered) 5000, but the levels detected were below the threshold limit value for the toxic gas ammonia. Therefore, a detection system ased upon a colorimetric indicator impregnated into an absorbent material was developed. Preliminary analysis (ESC-245-FDG-001) identified a particularly outstanding candidate as a colorimetric indicator for the detection of the presence of AF-M315E in the form of a Methyl Red (Basic) indicator. Materials impregnated with this indicator exhibit significant color change and the materials are not susceptible to interference from exposure to water or carbon dioxide. The completed detection system for HAN/AF-M315E consists of absorbent socks packed with Fisher Universal Spill Absorbent capable of absorbing and containing any propellant spills that they come into contact with along with indicating wipes. The absorbent socks are also chemically treated with a Methyl Red (Basic) indicator solution to provide the end user with a visual indication that a leak has occurred and proper protective precautions must be undertaken. An added benefit of this detection system is that the absorbent socks should neutralize/absorb any commodity that it comes into contact with (until saturation is reached). Additional adsorbent socks can be deployed until a color change is not seen, indicating that the HAN/AF-M315E contamination has been contained. The indicating wipes provide the user the opportunity to wipe surfaces to determine if there is any HAN/AF-M315E or HAN/AFM315E residue present. The wipes should allow the detection of fuel levels that may be too small to detect with the absorbent socks. The development of a detection system for the ADN/LMP-103S focused on the use of various COTS sensors used as real-time area monitoring devices and personal dosimeters. These COTS based sensor systems were of several different types, including both actively pumped and diffusion-based passive systems, as well as a "rope"-type chemical sensing cable. The results highlighted some of the major differences between the two monopropellants undergoing evaluation. Unlike HAN, ADN (which is the major constituent of LMP-103S) exhibits a much more volatile nature in comparison to AF-M315E. In fact, testing showed that a large percentage of the fuel was lost during the sampling measurement (greater than 10 percent by mass); although this testing cannot tell if the volatile component is the ADN itself or another component of the monopropellant solution. Not surprisingly, all four of the procured vapor-based COTS sensors showed positive results when exposed to solutions of the LMP-103S (ESC-245-FDG-002). The completed detection system for ADN/LMP-103S consists of a combination of two of the tested COTS sensor systems, the RAE Systems MultiRAE Lite and the BW Technologies GasAlert Extreme. These systems are meant to be used in conjunction with one another, which allows for the end-user to have both real-time area monitoring (MultiRAE Lite) as well as a personal dosimeter device (GasAlert Extreme) which can be worn as additional personal protective equipment. An stainless steel extension wand was fabricated and included in the detection system for the MultiRAE Lite to allow for more remote sensing, and connects via the active pumping inlet of the sensor. As stated, the final results of this testing resulted in the production of two "kits" which can be used for the detection of HAN/AF-M315E and ADN/LMP-103s (ESC-245-FDG-003).

Detection↗
DOE OSTI2019

Roll-to-Roll Advanced Materials Manufacturing DOE Laboratory Collaboration - FY2018 Final Report

High-value R2R processing is used to support a wide range of products in applications which span many industrial business sectors. The overall R2R process technology can be considered as “mature” as the process methodology and has been in use for decades. This continuous processing technique traditionally involves deposition of material(s) onto moving webs or carriers or other continuous R2R, belt-fed, or conveyor-based processes that enable successive steps to build a final version which serves to support the deposited materials. Current process technologies, which typify “roll to roll”, include tape casting, silk-screen printing, reel-to-reel vacuum deposition/coating and R2R lithography. Products supported by R2R manufacturing include micro-electronics, electro-chromic window films, PVs, fuel cells for energy conversion, battery electrodes for energy storage, and barrier materials. Due to innovation in materials and process equipment, high-quality yet very low-cost multi-layer technologies can be manufactured on a very cost-competitive basis. To move energy-related products from high-cost niche applications to the commercial sector, a means must be available to enable manufacture of these products in a cost-competitive manner that is affordable by the general consumer. Fortunately, products such as fuel cells, thin- and mid-film PVs, batteries, electrochromic and piezoelectric films, water separation membranes, and other energy saving technologies readily lend themselves to manufacture using R2R approaches.Within the DOE EERE AMO, it was recognized that establishment of a program supported at the DOE National Laboratories, along with their immense design of materials and equipment modelling capabilities enabled with use of high-performance computing, could take advantage of available R2R infrastructure to manufacture new technologies. In FY 2016, a R2R Consortium was established and provided with initial “seed” funding to take an approach that was envisioned to be supportable by advanced manufacturing R2R processes. This collaborative approach was designed to foster identification and development of materials and processes related to R2R for clean-energy product development. Using computational and experimental capabilities by acknowledged subject matter experts within the supported National Laboratory system, this collaborative project would leverage the capabilities and expertise at each of four laboratories to further the development of an enabling high-volume cost-competitive platform technology. The collaboration team that is comprised of ORNL, ANL, NREL and LBNL, coordinating with EPB and other selected industry partners, was formed in April 2016 to initially address enhancing battery electrode performance and R2R manufacturing challenges. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; to evaluate mixed, active, particle size deposition and drying for novel electrode materials; to model various process condition changes and the resulting morphology and electrode performance; and to develop and validate NDE techniques for in-line measurement of battery electrode material properties. These efforts carried through FY 2017 and completed at the end of FY 2018.The approach was to look at compositions of materials with different particle sizes to make electrode samples using a R2R manufacturing process. The shape, size, and morphology of the materials, the chemistry of the formulation, the nature of slurries, their coating rate, the rate of drying all play a role in determining the final coating architecture, quality, and performance. A commercial cathode material was selected to make a series of cathodes and anodes by single pass, dual pass and slot die methods. Analysis of all the compiled results for this battery electrode development were that the best performing cathodes included: dual-pass electrode with large particles near the foil, mixed small and large particles, and small particles only. Whereas, the best performing anodes were with a mix of small and large graphite particles. An additional core project was added in FY 2017 to conduct studies of fuel cell materials that can be produced using R2R processes. The goal of this project is to explore, understand and optimize material and process parameters to support increased throughput, increased quality, and reduced cost for high volume production of gas-diffusion electrodes (GDEs) for PEMFCs. Project work in FY 2018 were to use a R2R process to fabricate electrodes without ionomer overlayer that can produce the equivalent mass activity as spray-coated electrodes with an ionomer overlayer. Oxygen-limiting current measurements were utilized to optimize oxygen mass transport. Alcohol-rich solvents were investigated, and results were that the alcohol and water ratio can be tuned to control ionomer distribution. Water-rich solvents produce a more dispersed ink which results in better high-current density performance.

36 MATERIALS SCIENCE↗