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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 271 records · Page 15
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DOE OSTI2025

Stochastic Adaptive Droop Control in Frequency Regulation of Power Systems With Intermittent Generators

Modern power systems (MPSs), including microgrids (MGs), are increasingly incorporating multiple renewable energy sources (RESs) such as wind and solar power, as well as battery storage and controllable loads. While environmentally beneficial, these sources pose challenges for control and management due to their intermittent and stochastic nature, especially in maintaining frequency stability with multiple interconnected generators of varying capacities. Traditional droop control methods are effective in systems with generators that are dispatchable and have fixed generation capacities, but they fall short when applied to systems with RESs, where generation capacities are dynamic and affected by unpredictable environmental conditions. To address these challenges, this paper introduces a novel stochastic adaptive droop control (SADC) method for load frequency control (LFC). The proposed method adapts droop coefficients in real time, based on the measured stochastic data of power generation capacities, enabling more effective frequency regulation in systems with variable and intermittent power generation. Unlike traditional adaptive control methods, which assume constant or slowly-varying system parameters, this approach accounts for stochastic processes by modeling them as Markov chains, enabling robust performance under highly dynamic and unpredictable conditions. The key contributions of this work include the development of real-time droop coefficient adaptation algorithms, derivation of their stability and convergence properties, and the demonstration of the advantages of the method through simulations. Case studies highlight the improved performance of frequency regulation, particularly in addressing the impact of stochastic weather conditions and the benefits of reducing dependence on battery reserves in dealing with intermittency of RESs. Finally, this paper provides a comprehensive analysis of the theoretical foundations of the method, as well as practical implementation insights for future power systems with high penetration of RESs.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Dislocation line tension model to improve understanding of the effects of hydrogen on the deformation of structural materials

Decarbonization efforts highlight hydrogen as an attractive alternative to fossil fuels, but its tendency to embrittle structural metals demands careful consideration when designing hydrogen infrastructure. Moreover, the mechanisms by which hydrogen degrades these materials are still being elucidated. The current work develops new computational tools to quantify the different contributions of hydrogen to the energy barrier of cross-slip, a key deformation mechanism. Novel features are implemented to a line tension model, which include the use of non-singular dislocation interactions, character-dependent dislocation energies and simulations of the constriction configurations. A new molecular dynamics technique is developed to calculate the interaction energy between the partials of a dissociated dislocation via fixing the centers of mass of the regions below and above the Shockley partials and performing time-averaged calculations. Hydrogen is found to impact the stacking fault width of dislocations in different ways depending on their characters: it decreases for dislocations with a character θ > 30°, remains unchanged for θ = 30° and increases for θ < 30°. The latter regime is a newly identified mechanism by which hydrogen inhibits cross-slip. Moreover, formation of nano-hydrides is predicted to occur around screw dislocations for high hydrogen concentrations, a phenomenon previously identified only in dislocations with an edge component. If nano-hydrides develop, their influence extending the equilibrium stacking fault width and increasing both the constriction and cross-slip energy barriers dominate over all other hydrogen contributions. The theory and tools developed will pave the way towards a comprehensive understanding of hydrogen-dislocation interactions in structural metals.

08 HYDROGEN↗
DOE OSTI2025

Magnetosphere Evolution and Precursor-driven Electromagnetic Signals in Merging Binary Neutron Stars

We detail new force-free simulations to investigate magnetosphere evolution and precursor electromagnetic (EM) signals from binary neutron stars. Our simulations fully follow a representative inspiral motion, capturing the intricate magnetospheric dynamics and their impact on EM outflows. We explore a range of stellar magnetic moment orientations and relative strengths, finding that the magnetospheres and Poynting flux evolution are strongly configuration dependent. The Poynting flux exhibits pulsations at twice the orbital frequency, 2Ω, and is highly anisotropic, following a power-law dependence on orbital frequency. The index ranges from 1 to 6, shaped by the intricate dynamics of the magnetospheres. Furthermore, we present the first computation of (1) the EM forces acting on the star surfaces, revealing the presence of torques that, for highly magnetized stars, could influence the orbital dynamics or break the crust; (2) the high-energy emission signals from these systems by adopting the established isolated pulsar theory. Assuming curvature radiation in the radiation-reaction limit, we find that photons could reach TeV–PeV energies in the last ∼ms for magnetic field strengths 10 10 –10 15 G. However, our analysis of single photon magnetic pair production suggests that these photons are unlikely to escape, with the MeV band emerging as a promising observational window for precursor high-energy emission. In this framework, we construct high-energy emission skymaps and light curves, exploring observational implications. Finally, we propose potential precursor radio emission and delayed afterglow echoes from magnetized outflows, which may contribute to late-time rebrightening in short gamma-ray bursts or to orphan afterglows.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Development of Data Reporting Standards for High-Temperature Gas-cooled Reactor (HTGR) Nuclear Energy University Program (NEUP) Thermal-Fluid Experiments

Since 2009, the U.S. Department of Energy (DOE) Office of Nuclear Energy's Nuclear Energy University Program (NEUP) has been at the forefront of nuclear research, specifically concentrating on advancing high-temperature gas-cooled reactor (HTGR) technologies. By Fiscal Year 2023, NEUP has authorized 35 projects dedicated to HTGR research, each contributing significantly to the enhancement of our understanding of this technology. The outcomes of these diverse projects have been disseminated through final NEUP reports, peer-reviewed journal articles, and presentations at academic conferences, forming a comprehensive tapestry of knowledge. Despite the substantial value of these findings, their dissemination has been fragmented, posing challenges for accessibility to researchers and policymakers and leading to underutilization of DOE investments. Recognizing this critical gap and its potential consequences for the future of nuclear research, the Advanced Reactor Technologies (ART) Gas-Cooled Reactor (GCR) program conducted an extensive survey of completed and ongoing HTGR NEUP projects. This survey enabled the compilation of crucial data, resulting in the development of a specialized public-access database tailored for computational fluid dynamics and system code validation, specifically designed for HTGR applications. However, the data collection process revealed a significant challenge in central data organization due to individual researchers from different institutes employing varying logics and preferences for recording and documenting experimental data. Consequently, an urgent need has been identified to establish a standardized reporting format for HTGR experimental projects. Addressing this issue is essential for enhancing collaboration, maximizing the impact of DOE investments, and ensuring the seamless advancement of HTGR technologies in nuclear research.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Microstructure and Properties of Inconel 718 Fabricated by Directed Energy Deposition with In-Situ Ultrasonic Impact Peening

Many inherent issues, such as the detrimental residual stress, columnar grains with anisotropy, and weak mechanical properties, have severely impeded the adoption of metal additive manufacturing (AM) techniques including powder bed fusion and directed energy deposition (DED) processes. In this study, a hybrid AM process that consists of layer-wise laser metal deposition (i.e., a DED process) and in-situ ultrasonic impact peening (UIP) was applied to obtain Inconel 718 superalloy workpieces. Also, for further property enhancement, a post-heat treatment was applied to the deposited material obtained by the hybrid AM process. Scanning electron microscopy and transmission electron microscope were used to investigate the microstructure morphology and reveal the underlying strengthening mechanism. Electron backscatter diffraction was employed to quantitatively study the microstructure resulted from the hybrid AM process and the post-heat treatment. The profile of residual stress along the depth direction was obtained through X-ray diffraction. The results demonstrate that this hybrid AM process is capable of producing high-quality metal parts with significantly refined microstructure, and beneficial compressive residual stress along the depth into surface. Severe plastic strains are introduced by UIP, and the resulted mechanical twinning and dynamic recrystallization play an important role in refining microstructure. The material microstructure is further refined down to 100 µm, and the texture anisotropy is significantly diminished after solution treatment at 980 °C for 1 hour. Under the as-built condition, in-situ ultrasonic peening alters the residual stress component from a tensile state to an overall compressive state with a maximum value of − 190 MPa within the range of measurement depth.

36 MATERIALS SCIENCE↗
DOE OSTI2022

SEI formation mechanisms and Li + dissolution in lithium metal anodes: Impact of the electrolyte composition and the electrolyte-to-anode ratio

The lithium metal battery is one of today's most promising high-energy-density storage devices. Its full-scale implementation depends on solving operational and safety issues intrinsic to the Li metal high reactivity leading to uncontrolled electrolyte decomposition and uneven Li deposition. In this work, we study the spontaneous formation of the solid electrolyte interphase (SEI) upon contact of Li metal with the electrolyte and describe the heterogeneous SEI morphological features. Multiple electrolyte formulations based on lithium bis(fluorosulfonyl)imide (LiFSI), dimethoxyethane (DME), dimethyl carbonate (DMC), 1,2,2-tetrafluoroethyl-2,2,3,3-tetrafluoropropyl ether (TTE) and bis(2,2,2-trifluoroethyl) ether (BTFE) are used. Findings include the description of the SEI evolution from dispersed LiO, LiS, LiN, and LiF clusters to a continuous and compact inorganic phase in which the LiO and LiF content depend on the presence of fluorine diluents. Further, the role of the DME ether solvent helping the growth of a “wet-SEI” is compared to that of the highly unstable carbonate DMC, which decomposes into complex radical oligomers that might contribute to further electrolyte decomposition. The impact of the electrolyte-to-anode ratio on LiFSI decomposition is highlighted. Finally, we suggest the existence of a critical LiFSI concentration and electrolyte-to-anode ratio that could potentially balance the rate of electrolyte depletion and lithium consumption.

25 ENERGY STORAGE↗
DOE OSTI2022

Overview of the MOSAiC expedition: Snow and sea ice

Year-round observations of the physical snow and ice properties and processes that govern the ice pack evolution and its interaction with the atmosphere and the ocean were conducted during the Multidisciplinary drifting Observatory for the Study of Arctic Climate (MOSAiC) expedition of the research vessel Polarstern in the Arctic Ocean from October 2019 to September 2020. This work was embedded into the interdisciplinary design of the 5 MOSAiC teams, studying the atmosphere, the sea ice, the ocean, the ecosystem, and biogeochemical processes. The overall aim of the snow and sea ice observations during MOSAiC was to characterize the physical properties of the snow and ice cover comprehensively in the central Arctic over an entire annual cycle. This objective was achieved by detailed observations of physical properties and of energy and mass balance of snow and ice. By studying snow and sea ice dynamics over nested spatial scales from centimeters to tens of kilometers, the variability across scales can be considered. On-ice observations of in situ and remote sensing properties of the different surface types over all seasons will help to improve numerical process and climate models and to establish and validate novel satellite remote sensing methods; the linkages to accompanying airborne measurements, satellite observations, and results of numerical models are discussed. We found large spatial variabilities of snow metamorphism and thermal regimes impacting sea ice growth. We conclude that the highly variable snow cover needs to be considered in more detail (in observations, remote sensing, and models) to better understand snow-related feedback processes. The ice pack revealed rapid transformations and motions along the drift in all seasons. The number of coupled ice–ocean interface processes observed in detail are expected to guide upcoming research with respect to the changing Arctic sea ice.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Lithium Metal Electrode — Understanding Its Unique Characteristics and Functions

Lithium metal electrode (LME) is attractive for the next generation of commercial high-energy rechargeable lithium battery (RLB) design and development. As a light element with a very reducing electrochemical potential, Li metal certainly has the unique characteristics that also present challenges for its application in RLBs. To overcome technical barriers with LME such as the dendrite formation that causes uneven current distributions, excessive SEI formation that consumes Li inventory, and formation of inactive Li metal in granular forms that induces safety hazards, more fundamental understanding of the unique characteristics of LME and its impact on functions in performance in RLBs is critical. Here, we present some recent work based on temporally-correlated reactive molecular dynamics simulations to understand the Li deposition and the associated nucleation and growth process on the LME or graphitic electrode surfaces. Such a study provides some intriguing perspectives on how Li reacts with electrolytes on LME and conventional graphitic electrodes in the RLB operation. Such an insight could help improving our strategy to deal with LME problems and provide functional improvements for LME’s application in RLBs. This presentation is dedicated to Professor Robert Huggins for his life-long teaching of the fundamentals on solid state ionics and its implications in understanding the electrochemical behavior of Li in RLB applications.

25 ENERGY STORAGE↗
DOE OSTI2022

AlInP-passivated III–V solar cells grown by dynamic hydride vapor-phase epitaxy

We report the development of AlInP-passivated solar cells grown by dynamic hydride vapor-phase epitaxy (D-HVPE) with AM1.5G efficiencies of 26.0% for single-junction (1J) GaAs cells and 28.0% for GaInP/GaAs (2J) tandems. We compare the device performance of solar cells passivated with AlInP versus control cells passivated with GaInP, which has already enabled near-unity carrier collection in GaAs solar cells. 1J devices passivated with either AlInP or GaInP have an identical open-circuit voltage (V OC ) of 1.06 V and long-wavelength current collection near 95%, indicating that both window materials provide a similar degree of passivation. Adding AlInP passivation to each solar cell structure improves the current collection by 1.3 and 1 mA/cm 2 for the 1J and 2J, respectively. The AlInP also results in a top cell V OC boost of ~40 mV relative to a tandem device passivated only by a thin, highly doped GaInP emitter. Secondary-ion mass spectrometry measurements indicate that although O and Si both incorporate in the AlInP window, they do not appear in the subsequently grown absorber layers and do not impact its ability to passivate the front surface. We expect that these achievements, along with continued optimization, will enable parity of hydride vapor-phase epitaxy (HVPE)-grown device efficiencies with state-of-the-art devices grown by other epitaxial methods in the near future.

14 SOLAR ENERGY↗
DOE OSTI2024

Critical mineral substitutions in IN617: A combined computational and experimental approach to performance evaluation and feasibility

Addressing the escalating demand for critical minerals (CMs) driven by global climate change initiatives, this study explores compositional modifications to Inconel 617 (IN617) by substituting cobalt (Co) with manganese (Mn) across various atomic percentages. Here, we conducted a computational feasibility study employing Molecular Dynamics (MD) simulations to provide strategic guidance for experimental validation. The simulations analyzed tensile strength and corrosion resistance for five modified compositions (M1 to M5) to identify optimal properties. Tensile tests on cubic simulation cells were performed to generate stress-strain curves, revealing the impact of Co replacement with Mn on tensile strength—a metric correlated with hardness. Oxygen penetration simulations were conducted to evaluate corrosion resistance, indicating that reduced oxygen penetration depth corresponds to enhanced resistance. Promising compositions underwent phase diagram calculations for assessing phase stability. The optimal composition (M1), characterized by high tensile strength and minimal oxygen penetration, was chosen for experimental validation using induction melting and friction stir consolidation techniques. The materials were further characterized using SEM-EDS, XRD, and Vickers hardness testing. Our findings suggest that Mn substitution in IN617 can yield mechanical performance at par with high-Co alloys in energy-critical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effects of Rapid Permafrost Thaw on CO2 and CH4 Fluxes in a Warmer and Wetter Future (Final Technical Report)

When ice-rich permafrost thaws, the ground subsides, creating thermokarst landscapes with dramatically different soil conditions and carbon fluxes than the original ecosystem. Roughly 20% of the northern permafrost region is susceptible to thermokarst formation (Olefeldt et al., 2016). Thermokarst formation is often rapid; tens of meters of permafrost can thaw within a few years (Schuur et al., 2015). In topographically low areas, thermokarst thaw converts boreal forest or tundra dry shrub ecosystems into sedge or Sphagnum moss wetlands (Olefeldt et al., 2016). While this type of landscape transformation releases carbon stored in permafrost into the atmosphere, on longer time scales, it facilitates sequestration of atmospheric carbon in plant biomass because permafrost thaw releases plant-available nutrients and wetlands are highly productive (M. C. Jones et al., 2017). However, wetlands also generate methane, which is a potent greenhouse gas. Methane emissions from thermokarst wetlands can cause these carbon-sequestering systems to have a positive global warming potential (Johansson et al., 2006; Turetsky et al., 2007). Our project objective was to improve Earth System and environmental predictability by advancing understanding of how CO 2 and CH 4 flux in permafrost thaw-induced wetlands (thermokarst) will change in the future as temperatures and climate conditions shift. Northern latitudes are expected to get warmer and wetter (IPCC 2013), and initiation and expansion of thermokarst thaw is expected to increase (Jorgenson et al. 2006; Zhang et al. 2017). Given these expected changes, our work sought to address three broad questions: Q1) How will northern latitude CO2 and CH4 emissions respond to warming temperatures? Q2) What is the impact of precipitation on permafrost thaw and carbon emissions? Q3) How do CO2 and CH4 emissions change as wetlands age after permafrost thaw? To answer these questions, we took both a modeling and measurement approach. Modeling work was conducted with DOE’s Energy Exascale Earth System Model (E3SM) land model (ELM). Empirical work took place in two primary locations. The first was a thermokarst site near Fairbanks, AK. The site is part of the Bonanza Creek Long Term Ecological Research program and is well instrumented (Neumann et al., 2019). The second was an isolated thawing permafrost wetland located on Kenai Peninsula — Brown’s Lake bog (B. M. Jones et al., 2016) — where the current climate is representative of what is expected at higher latitudes in the future. This site provides an ideal opportunity to test our hypotheses about how thermokarst wetland dynamics will respond to future environmental conditions. In addition, the project collaborated with researchers asking similar questions who were collecting measurements in high latitude post-glacial lakes located in collaborators tackling similar questions in Sweden (Stordalen Mire) (Emerson et al., 2021). Project efforts directly aligned with the stated goal of the funding opportunity announcement (FOA), which was “to improve the understanding and representation of terrestrial ecosystems in ways that advance Earth system model parameterizations and capabilities... thereby improving the quality of Earth and environmental model projections and providing the scientific foundation needed to support DOE’s science and energy missions.” Specifically, the project improved sophistication and accuracy of the Energy Exascale Earth System Model (E3SM), which is being developed primarily at DOE National Laboratories to support scientific research and decision-making.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Investigating bubble pressures in irradiated UO 2 for understanding fragmentation of high burnup structure

This report summarized work carried out to investigate mechanisms relevant to fragmentation of high burnup UO 2 fuel. High pressure bubbles that form in high burnup structure are thought to be responsible for fragmentation and pulverization, when exposed to a temperature ramp during a transient. The over-pressurization of the bubbles during normal operation is a pre-requisite for this mechanism to occur. Therefore, in this work we investigate the role of interstitials, produced through irradiation, in over-pressurizing the bubbles by using a combined molecular dynamics (MD) and cluster dynamics approach. Firstly, the energies for the annihilation of interstitials and vacancies at bubbles have been determined from MD as a function of bubble pressure. Secondly, these reaction energies have been implemented in the cluster dynamics code Centipede to determine the steady-state defect concentrations and bubble pressure under irradiation. It was found that there is a transition from low pressure bubbles, at high temperature, to high pressure bubbles, at low temperatures. This indicates the formation of over-pressurized bubbles in the low temperature periphery of the pellet, where high burnup structure forms. This result supports the hypothesis that over-pressurized bubbles form during steady-state operation and can then contribute to fragmentation during a transient. Future work will examine the influence of bubble pressure on Xe diffusion and study the impact of other sinks (e.g. grain boundaries and dislocations) that are relevant to high burnup structure. Ultimately, the goal is to provide predictions of the bubble pressure as a function of burnup that can be used to derive a more mechanistic fragmentation threshold for use in BISON.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Closed-form solutions towards real-time energy-optimal and collision-free speed planning with limited information

Under real-world driving conditions, available information is limited due to communication range, and connected and automated vehicles (CAVs) must plan and follow energy-optimal and collision-free speed trajectory with a high updating rate. To this end, this paper presents a holistic design of a speed planning algorithm using analytical closed-form optimal solutions. Using the simplest vehicle model, we derive closed-form solutions as a function of boundary conditions, and summarize them without and with state constraints imposed by speed limits and vehicle in front. Then, we introduce multiple modes (e.g., eco-approach to traffic signal) to properly respond dynamically changing situations, and present how to set boundary conditions for each mode, while guaranteeing nature of globally optimal solutions. Finally, we perform a large-scale simulation study to identify and quantify the energy impacts of CAVs for real-world driving routes. A simple but effective algorithm based on closed-form solutions shows a significant energy saving potential in comparison with human-driven vehicle and adaptive cruise controlled vehicle with connectivity.

Han, Jihun↗
DOE OSTI2022

Memory access optimization for particle operations in computational fluid dynamics-discrete element method simulations

Computational Fluid Dynamics - Discrete Element Method is used to model gas-solid systems in several applications in energy, pharmaceutical and petrochemical industries. Computational performance bottlenecks often limit the problem sizes that can be simulated at industrial scale. The data structures used to store several millions of particles in such large-scale simulations have a large memory footprint that does not fit into the processor cache hierarchies on current high-performance-computing platforms, leading to reduced computational performance. This paper specifically addresses this aspect of memory access bottlenecks in industrial scale simulations. The use of space-filling curves to improve memory access patterns is described and their impact on computational performance is quantified in both shared and distributed memory parallelization paradigms. The Morton space filling curve applied to uniform grids and k-dimensional tree partitions are used to reorder the particle data-structure thus improving spatial and temporal locality in memory. The performance impact of these techniques when applied to two benchmark problems, namely the homogeneous-cooling-system and a fluidized-bed, are presented. We report these optimization techniques lead to approximately two-fold performance improvement in particle focused operations such as neighbor-list creation and data-exchange, with ~ 1.5 times overall improvement in a fluidization simulation with 1.27 million particles.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Tetrahedral Tilting and Lithium‐Ion Transport in Halide Argyrodites Prepared by Rapid, Microwave‐Assisted Synthesis

Abstract This study demonstrates a rapid, dry, microwave‐assisted (MW) synthesis method that enables preparation of halide argyrodites ( , , ) in less than 20 min. The structures and ion transport properties of the resulting materials are compared with those synthesized by conventional solid‐state synthesis methods. The microwave‐assisted method leads to increased site disorder and elevated Arrhenius prefactors (), which lead to an order of magnitude improvement in the 30 ionic conductivity of MW‐. X‐ray pair distribution function analysis (XPDF) reveals significant rotational disorder of the units, which is impacted by the synthesis method, choice of halide, and presence of / site disorder. These rotational displacements are strongly correlated with ion transport, specifically and entropy of migration (). Overall, this study demonstrates a rapid synthesis route for preparing high‐quality halide argyrodite solid‐state electrolytes in less than 20 min, and further unravels atomistic insights into the interplay of structural disorder, rotational dynamics, and ion transport mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of Electro-chemical Battery Model for Plug-and-Play Eco-system Library

Energy storage components are fundamental to the concept of an Integrated Energy System (IES). They serve to store surplus energy during low-demand periods for later release when other IES components (i.e., Secondary Energy Source, Balance of Plant, etc.) would otherwise have to operate flexibly. This provision for storage avoids high-amplitude power ramps in these components thereby limiting thermal and mechanical stresses to their internals and providing for extended service life. This report describes a dynamic model that has been developed for an electrochemical battery. The lithium-ion (Li-ion) cell was selected as representative technology. The battery model was developed in the Dymola simulation environment and meets the requirements of the ecosystem plug-and-play library. The model accurately describes the electric dynamic response of a Li-ion battery for an imposed charging/discharging power profile. The corresponding physical limitations related to over-power scenarios, and the impact of the residual state of charge are accounted for in the model. A literature review of the major degradation processes affecting Li-ion batteries was performed. Given the purposes of the CTD-IES project, the progressive fade of the installed capacity, the reduction of the round-trip efficiency, and the limits on the number of charging/discharging cycles are aspects that need to be taken into account in techno-economic analyses. The modeling of these degradation phenomena becomes crucial when predictions over long time horizons (capacity expansion) are made. For each one of these phenomena, a brief description is given, and some figures to be implemented in the HERON optimization algorithm are presented.

25 ENERGY STORAGE↗
DOE OSTI2025

Probing the Impact of Vacancy Diffusion on Void Dynamics at the Lithium Metal–Solid Electrolyte Interface

Lithium (Li) metal-based solid-state batteries (SSBs) are considered promising candidates for next-generation energy storage due to their superior energy density and enhanced safety compared to conventional Li-ion systems. However, their practical application is limited by challenges such as void formation at the Li-solid electrolyte (SE) interface, which disrupts ion transport and accelerates interfacial degradation. This work investigates how the coupled effects of electro-dissolution kinetics and surface diffusion at the Li metal surface govern the evolution of interfacial morphology during stripping. This work examines the influence of three distinct surface diffusion modes, which are terrace diffusion, step diffusion, and interlayer diffusion, on maintaining interfacial stability. In addition, how the dominant surface diffusion mechanism can overcome the contact loss due to high reaction kinetics is explored. Furthermore, the roughness of the Li metal anode surface is quantified, and the influence of different diffusion mechanisms on the evolution of the dynamic solid–solid interface is examined. The critical role of temperature in enhancing Li surface diffusivity and expanding the regime of stable contact is highlighted. By identifying distinct regimes of interface stability, this study analyzes how non-uniform electrochemical dynamics dictate void morphology evolution and interfacial contact. These insights offer guiding principles for engineering robust Li–SE interfaces in SSBs.

lithium metal anode↗
DOE OSTI2022

Effect of coaxial nozzle wear on catchment efficiency in direct energy deposition built components

Laser based Direct Energy Deposition (DED) systems using metallic powder feedstock are recognized as a promising manufacturing method for their ability to shorten production cycles and create complex part geometries. Components are built by generating a melt pool with a high-power laser beam while material is coaxially injected and left to solidify. An impediment to large scale use of DED lies in poor powder catchment efficiency, the condition in which a portion of injected powder escapes the melt pool resulting in a ratio of decreased printed material mass to mass of supplied feedstock. The wear state of a coaxial nozzle on a DED system within a hybrid manufacturing machine tool has been observed to decrease catchment efficiency over time. Herein this study investigates this effect by adapting flow visualization techniques to an in-situ process monitoring format, the implementation of a Computational Fluid Dynamics (CFD) simulation, and deposition testing. Nozzle geometric defects due to wear are identified and categorized, and the impact of nozzle tip wear, resulting in axial tip reduction, on powder catchment efficiency is proven by multiple calculation methods. A linear correlation between catchment efficiency and powder stream diameter is identified, causing a 15–20% loss in efficiency sustained over incremental nozzle tip reduction up to − 1 mm. These results provide a foundation for further study of wear effects and Zero defect manufacturing solutions for powder fed DED systems.

42 ENGINEERING↗