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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Lithium inventory tracking as a non-destructive battery evaluation and monitoring method

Tracking the active lithium (Li) inventory in an electrode shows the true state of a Li battery, akin to a fuel gauge for an engine. However, non-destructive Li inventory tracking is currently unavailable. Here, in this work, we used the theoretical capacity of a transition metal oxide to convert capacity into a Li inventory analysis. The Li inventory in electrodes was tracked reliably to show how battery formulations and test methods affect performance. Contrary to capacity, Li inventory tracking reveals stoichiometric variations near the electrode–electrolyte interface. Verifiable results rationalized differences in measurements, clarifying and reducing interferences from cell formulations and experimental manipulations. By tracing four variables from formation to end-of-life, we characterize electrode and cell performance with a thermodynamic framework. Accurate rationalization of subtle differences in Li inventory utilization promises precise battery engineering, evaluation, failure analysis and risk mitigation. The method could be applicable from cell design optimization and fabrication to battery management, improving battery performance and reliability.

25 ENERGY STORAGE↗
DOE OSTI2025

Self-replenishing Ni-rich stainless-steel electrode toward oxygen evolution reaction at ampere-level

In the past few decades, tremendous attention has been devoted to enhancing the activity of oxygen evolution reaction (OER) catalysts for hydrogen production, while the cost and long-term stability of catalysts, which can play an even more important role in industrialization, have been much less emphasized. Herein, we engineered an OER electrode from abundant stainless steel (SS) via facile approaches, and the obtained electrode consists of a Ni-rich oxide surface layer with a Fe-rich metal substrate. An outstanding activity was observed with an overpotential of 316 mV at 100 mA cm −2 in 1 M KOH electrolyte. Additionally, an electrode self-replenishing concept is proposed in which a Ni-rich catalyst layer can be regenerated from a metallic substrate due to the difference in diffusion and dissolution rates of metal oxides/hydroxides, and this regeneration is validated by various characterizations. A recorded degradation rate of 0.012 was observed at 1000 mA cm −2 for 1000 h. The facile engineering of OER electrodes from SS combined with the self-replenishing catalyst can potentially address the cost, activity, and long-term stability barriers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Improving Lithium Metal Composite Anodes with Seeding and Pillaring Effects of Silicon Nanoparticles

Metallic lithium (Li) anodes are crucial for the development of high specific energy batteries yet plagued by their poor cycling efficiency. Electrode architecture engineering is vital for maintaining a stable anode volume and suppress Li corrosion during cycling. In this paper, a reduced graphene oxide “host” framework for Li metal anodes is further optimized by embedding silicon (Si) nanoparticles between the graphene layers. They serve as Li nucleation seeds to promote Li deposition within the framework even without pre-stored Li. Meanwhile, the LixSi alloy particles serve as supporting “pillars” between the graphene layers, enabling a minimized thickness shrinkage after full stripping of metallic Li. Combined with a Li compatible electrolyte, 99.4% Coulombic efficiency over ~600 cycles is achieved, and stable cycling of a Li||NMC532 full cell for ~380 cycles with negligible capacity decay is realized.

Wang, Hansen↗
DOE OSTI2020

Local electrical degradations of solid-state electrolyte by nm-scale operando imaging of ionic and electronic transports

We report on degradation mechanisms of solid-state electrolyte (SSE) based on insights from nm-scale ionic conduction and electronic leakage for solid-state batteries. The significantly different local degradations revealed by nm-scale ionic and electronic transport imaging demonstrate the need for this nm-scale investigation. State-of-the-art lithium-ion conductive glass ceramic (Li 2 O–Al 2 O 3 –SiO 2 –P 2 O5–TiO2-GeO2) SSE shows at least two types of degradations spatially separated within the SSE, namely: (1) ionic conduction blocking and slight electronic leaking and (2) highly electronic shunting. Degradation was significantly suppressed by application of a Li-containing polyacrylonitrile thin coating on both sides of the ceramic SSE. With this coating, the ionic conduction was not reduced by the extensive cycling; instead, it improved slightly, although accompanied by a slight increase in electronic leaking. Our nm-scale transport imaging was achieved using an atomic force microscopy (AFM)-based half-cell setup and a logarithmic-scale amplifier with current sensitivity down to the fA (10-15 A) range. This half-cell setup consisting of an AFM-probe/SSE/Li structure can distinguish the ionic from the electronic current by flipping the bias-voltage polarity. This nm-scale operando imaging opens up novel characterization of ionic and electronic transport in the field of solid-state batteries.

42 ENGINEERING↗
DOE OSTI2024

Surface Decoration of Platinum Catalysts by ZrO 2– x Nanoclusters for Durable Fuel Cell Applications

Improving the activity and durability of carbon-supported platinum catalysts for the oxygen-reduction reaction (ORR) in acidic electrolytes is crucial to reducing the high overpotentials and power loss over time in proton-exchange membrane fuel cells (PEMFCs). We found that platinum nanoparticle catalyst deposited on an engineered carbon support in the presence of zirconium enabled higher ORR activity and 25% better retention in electrochemically active surface area (ECSA), thereby improving durability. The use of zirconium precursor in the carbon synthesis process led to the formation of atomically dispersed Zr and ZrO 2 nanoparticles on the support. Upon Pt deposition and subsequent heat treatment, the ZrO 2 particles preferentially rearranged on and around the platinum nanoparticles in a chemically reduced form as zirconium suboxide (ZrO 2-x ) surface-decorated nanoclusters, which mitigated Pt nanoparticle coarsening. Finally, analysis of the here-to-fore unknown catalyst structure as well as its performance and durability in a PEM fuel cell membrane electrode assembly (MEA) is discussed.

25 ENERGY STORAGE↗
DOE OSTI2023

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Friction stir welded (FSW) aluminum–magnesium lightweight vehicle joints have gained significant interest due to their high strength-to-weight ratio. In this work, the corrosion resistance of this material is analyzed through electrochemical tests, which include open circuit potential (OCP) inspection and potentiodynamic polarization (PD) scanning. Weight loss measurements tested the corrosion rate of the FSW weld through cyclic corrosion testing (CCT) according to the standard SAEJ 2334. Mechanical properties were also investigated, including lap-shear strength, micro- and nano-hardness mapping, and true stress–strain curves as a function of local processing history. The electrochemical results indicate that the center weld zone’s corrosion property stays between the two base alloys. Indentation-based testing demonstrated that the weld zone behaves differently from base alloys. Lap shear strength surprisingly did not drop much even after eight weeks of cyclic corrosion tests, indicating that the joint did not allow any ingress of the electrolyte.

36 MATERIALS SCIENCE↗
NASA NTRS1971

A study of alternative methods for reclaiming oxygen from carbon dioxide and water by a solid-electrolyte process for spacecraft applications

Two alternative technical approaches were studied for application of an electrochemical process using a solid oxide electrolyte (zirconia stabilized by yttria or scandia) to oxygen reclamation from carbon dioxide and water, for spacecraft life support systems. Among the topics considered are the advisability of proceeding to engineering prototype development and fabrication of a full scale model for the system concept, the optimum choice of method or approach to be carried into prototype development, and the technical problem areas which exist.

Source record↗
NASA NTRS1991

NASA Space Engineering Research Center for utilization of local planetary resources

Because of a change in the NASA funding cycle, the present reporting period covers only the six months from March to September 1991. Nevertheless, remarkable progress was made in a number of areas, some of the most noteworthy of which are: (1) Engineering operation of a breadboard CO2 yields O2 demonstration plant that produced over 10 grams of oxygen per day during several runs of over 100 hours each with a single electrolytic cell. Complete automation of controls, monitoring of various inputs/outputs and critical internal variables, diagnostics, and emergency shutdown in an orderly manner were also included. Moreover, 4-cell and 16-cell units, capable of much higher rates of production, were assembled and tested. (2) Demonstration of a 200 percent increase in the carbothermal reduction of ilmenite through vapor deposition of carbon layers on particles of that material. (3) Demonstration of the deposition of strong iron films from carbonyl chemical vapor deposition, establishing the crucial role of additive gases in governing the process. (4) Discovery of an apparent 800 percent increase in the conversion rates of a modified ilmenite simulant in a plasma-augmented reactor, including direct enhancement by solar radiation absorption. (5) Proof that test specimens of lunar soil with small amounts of metallic additives, recrystallized at moderate temperatures, exhibit an improvement of several orders of magnitude in ductility/tensile strength. (6) Experiments establishing the feasibility of producing silicon-based polymers from indigenous lunar materials. (7) Application of CCD technology to the production of maps of TiO2 abundance, defining primary ilmenite deposits, on the disk of the full moon. (8) Attainment of a discovery rate of approximately 3 new near-Earth asteroids per month by Spacewatch, more than doubling the previous global rate. (9) Coordination of industry and university magma electrolysis investigations in a workshop designed to define remaining problem areas and propose critical experiments.

Ramohalli, Kumar↗
DOE OSTI2024

Development of a rate-based ENRTL-RK process model for a water-lean solvent

Advanced water-lean solvents (WLS) for post-combustion CO2 capture offer several advantages over the aqueous amine solvents . WLS have lower parasitic energy penalty, lower corrosion, lower temperature and high-pressure CO2 regeneration leading to lower cost of CO2 capture. RTI International, with funding from the US Department of Energy, has been developing its novel water-lean solvent, that has shown specific reboiler duty of 2.3 GJ/t-CO2 at the 60-kWe pilot testing unit (Tiller Plant, SINTEF, Norway) and 2.6 GJ/t-CO2 at the engineering scale testing system (12 MWe) at the Technology Centre Mongstad (TCM) in Norway. All heat duties, including the one from TCM testing, were consistent with Aspen Plus modeling of the specific configuration of each test plant. This work focuses on the development of a detailed process model using in-house laboratory measurements and process data at pilot scale. The eNTRL-RK model used in this work is based on an unsymmetric activity coefficient model with the reference states chosen to be pure liquids for solvents and ideal dilute solution at unit solute molality (resulting in activity coefficient of unity at infinite dilution) for electrolytes. It uses the Redlich-Kwong equation of state for vapor phase properties and Henry’s law for solubility of supercritical gases. The model was validated using process data from the pilot-scale campaign at the Tiller plant, and the engineering scale test campaign at TCM. Data on CO2 capture rate, absorber, and regenerator temperature profiles and specific reboiler duties from two different test campaigns at Tiller and TCM, were used to further refine and validate the model and the model compares favorably to experimental data. The validation results against TCM campaign will be presented in this work.

CO2 capture↗
DOE OSTI2026

Deciphering the Conflict Between Ion and Electron Percolating Networks in Solid-State Battery Cathodes

High-energy- and power-density solid state batteries require an optimal cathode composition and microstructural arrangement of cathode active material, solid-state electrolyte, conductive carbon, and binder to simultaneously support lithium-ion transport, electron conduction, and storage capacity. The ion and electron conducting phases in solid-state cathodes counteract each other's percolating networks as their mass ratios increase or decrease relative to each other. Here, we investigate targeted mass ratio variations of argyrodite solid electrolyte and two different types of conductive carbon (particles and fibers) in composite LiNi0.8Mn0.1Co0.1O2 (NMC811) solid-state cathodes to ascertain the ionic-electronic tradeoffs in cathode performance. Through ionic and electronic conductivity measurements on composite cathodes, as well as rate-testing and cycling performance in full cells, it is shown that the conductive carbon fibers form a percolative electronic network within the composite at a lower mass ratio (3-5 wt%) than particulate carbon (>5 wt%). The threshold to achieve electronic percolation coincides with higher accessible capacity in the cathode as the active material particles become electronically connected. However, carbon loadings beyond this percolation threshold lead to increased ion transport resistance, arising from disruptions to ionic conduction pathways and degraded contact at the interface between the electrolyte and active materials. Imaging, spectroscopy, and physics-based models quantitatively describe the relationship between carbon and electrolyte compositions and the cell's capacity and rate performance through percolation theory. This work demonstrates the importance of quantitatively understanding percolating networks in solid-state cells and that strategic engineering of conductive carbon morphologies can further increase the energy- and power-density of solid-state cells.

25 ENERGY STORAGE↗
DOE OSTI2025

High Throughput Solvent-free Manufacturing of Battery Electrodes

The project goal is to develop and demonstrate an advanced solvent-free lithium-ion battery electrode process through proposed Advanced Dry Electrode Process (ADEP) equipment, which is expected to exhibit a better binder fibrillization and high throughput and suitable for high performance electrode manufacturing, and commonize the anode and cathode dry processing equipment, supply chain and operation for lithium-ion battery OEMs for replacing the solvent-based slurry casting. Our proposed approach will facilitate low-cost battery production by addressing the following gaps in present dry electrode processing: • Extend the dry electrode fabrication process to lithium-ion battery anode manufacturing • Increase the active material content for anodes and cathodes • Intensify the process through improved mixing, powder rheology and surface modifications • Enable processing of next-generation electrode materials that are not stable to solvent or ambient air exposure. The project objectives include the development of anode-compatible binder and binder fibrillization promoter for low irreversible capacity loss, low electrode binder content yet higher film mechanical strength, and the optimization of solvent-free anode and cathode process for low cost (>60% electrode cost reduction), high performance (10% increase in energy density without sacrificing cycle life) and high throughput to enable next generation lithium-ion battery electrode production. Solvent-free electrode manufacturing will also enable next-generation cell designs based on prelithiated anodes or solid-state electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2023

Realizing high-capacity all-solid-state lithium-sulfur batteries using a low-density inorganic solid-state electrolyte

Abstract Lithium-sulfur all-solid-state batteries using inorganic solid-state electrolytes are considered promising electrochemical energy storage technologies. However, developing positive electrodes with high sulfur content, adequate sulfur utilization, and high mass loading is challenging. Here, to address these concerns, we propose using a liquid-phase-synthesized Li 3 PS 4 -2LiBH 4 glass-ceramic solid electrolyte with a low density (1.491 g cm −3 ), small primary particle size (~500 nm) and bulk ionic conductivity of 6.0 mS cm −1 at 25 °C for fabricating lithium-sulfur all-solid-state batteries. When tested in a Swagelok cell configuration with a Li-In negative electrode and a 60 wt% S positive electrode applying an average stack pressure of ~55 MPa, the all-solid-state battery delivered a high discharge capacity of about 1144.6 mAh g −1 at 167.5 mA g −1 and 60 °C. We further demonstrate that the use of the low-density solid electrolyte increases the electrolyte volume ratio in the cathode, reduces inactive bulky sulfur, and improves the content uniformity of the sulfur-based positive electrode, thus providing sufficient ion conduction pathways for battery performance improvement.

25 ENERGY STORAGE↗
DOE OSTI2020

Correlating the influence of porosity, tortuosity, and mass loading on the energy density of LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes under extreme fast charging (XFC) conditions

Extreme fast charging capabilities along with high energy density of Li-ion batteries are the key factors to increase the adoption of electric vehicles while eliminating the problem of range anxiety. The U.S Department of Energy has a goal of <12 min charging time with energy density of > 200 Wh kg -1 . A combined improvement in the electrode architecture, electrolyte properties, and separator membrane is necessary to achieve this goal. Cells with thin electrodes are capable of extreme fast charging at the expense of low energy density and high cost. Electrode engineering can maximize energy density. In this work, the influence of porosity, mass loading and charging protocols on capacity and energy density and electrode kinetics are investigated under extreme fast charging conditions. Increasing the mass loading from 11.5 mg cm -2 to 25 mg cm -2 compromises the rate performance due to the mass transport limitation and underutilization of thick electrodes. Furthermore, reducing the electrode porosity from 50% to 35% improves the rate performance ascribed to shorter Li ion diffusion length. Symmetric cells are cycled to verify the performance of the half cells, suggesting that Li metal plating is the rate limiting step under high current density.

25 ENERGY STORAGE↗
DOE OSTI2024

Absolute band-edge energies are over-emphasized in the design of photoelectrochemical materials

The absolute band-edge potentials of semiconductors, i.e., the conduction-band minimum, valence-band maximum, and their relative positions to solution redox potentials, are often invoked as design principles for photoelectrochemical (PEC) devices, especially for particulate photocatalysts. Here we show that reliance on these criteria is not necessary and limits the exploration of materials that will advance the fields of photoelectrochemistry, photochemistry, and photocatalysis. We discuss how i) band-edge energies are not singular parameters and instead shift with pH, electrolyte type, and surface chemistry; ii) the free energy of electrons and holes in comparison to that of solution redox couples dictates overall reaction spontaneity and thus reactivity; and iii) favorable charge-transfer kinetics can occur even when the relevant electrolyte redox potential(s) appear ‘outside’ the bandgap, enabled by the inversion or accumulation of electronic charge at the semiconductor surface. As a result, this discussion informs design principles for photocatalyst systems engineering for both one-electron redox reactions as well as for more complex multi-electron transfer reactions (e.g, H 2 evolution, H 2 O oxidation, CO 2 reduction).

14 SOLAR ENERGY↗
DOE OSTI2023

Engineering Redox Flow Battery Electrodes with Spatially Varying Porosity Using Non‐Solvent‐Induced Phase Separation

Redox flow batteries (RFBs) are a promising electrochemical platform for efficiently and reliably delivering electricity to the grid. Within the RFB, porous carbonaceous electrodes facilitate electrochemical reactions and distribute the flowing electrolyte. Tailoring electrode microstructure and surface area can improve RFB performance, lowering costs. Electrodes with spatially varying porosity may increase electrode utilization and provide surface area in reaction‐limited zones; however, the efficacy of such designs remains an open area of research. Herein, a non‐solvent‐induced phase‐separation (NIPS) technique that enables the reproducible synthesis of macrovoid‐free electrodes with well‐defined across‐thickness porosity gradients is described. The monotonically varying porosity profile is quantified and the physical properties and surface chemistries of porosity‐gradient electrodes are compared with macrovoid‐containing electrode, also synthesized by NIPS. Then, the electrochemical and fluid dynamic performance of the porosity‐gradient electrodes is evaluated, exploring the effect of changing the direction of the porosity gradient and benchmarking against the macrovoid‐containing electrode. Lastly, the performance is examined in a vanadium RFB, finding that the porosity‐gradient electrode outperforms the macrovoid electrode, is independent of gradient direction, and performs favorably compared to advanced electrodes in the contemporary literature. It is anticipated that the approach motivates further exploration of microstructurally tailored electrodes in electrochemical systems.

25 ENERGY STORAGE↗
NASA NTRS2005

Process Developed for Fabricating Engineered Pore Structures for High- Fuel-Utilization Solid Oxide Fuel Cells

Solid oxide fuel cells (SOFCs) have tremendous commercial potential because of their high efficiency, high energy density, and flexible fuel capability (ability to use fossil fuels). The drive for high-power-utilizing, ultrathin electrolytes (less than 10 microns), has placed an increased demand on the anode to provide structural support, yet allow sufficient fuel entry for sustained power generation. Concentration polarization, a condition where the fuel demand exceeds the supply, is evident in all commercial-based anode-supported cells, and it presents a significant roadblock to SOFC commercialization.

Sofie, Stephen W.↗
DOE OSTI2020

Keratin-derived functional carbon with superior charge storage and transport for high-performance supercapacitors

In this work, we report a scalable method to synthesize hierarchically porous, hetero-atom doped activated carbon nanosheet from waste biomass-human hair, and demonstrates the use of this carbon as an ultra-high performance electrode material for supercapacitor applications. Microscopic analyses reveal that sheet size ranges from 50 to 200 nm having a thickness of 15–27 nm. As-synthesized, carbon nanosheets possess a hierarchical porous structure having a specific surface area of 1548 m 2 g -1 . Heteroatom concentration (nitrogen, oxygen, and sulfur) of around 25% is confirmed from XPS analysis. Therefore, the novel interconnected hierarchical porous nanosheets structure enables fast adsorption and transportation of ions during electrochemical processes. Also, the abundant chemically available electroactive heteroatom species in the material enhance the wettability of ions and contribute to pseudocapacitance. The electrochemical analyses through cyclic voltammetry and galvanostatic charge-discharge measurements in 6 M KOH reveal the quasi-EDLC behavior of the activated carbons due to the presence of heteroatoms. A reprensentative KOH activated carbon shows an excellent specific capacitance value of 999 F g -1 at a current density of 1 A g -1 . Furthermore, the symmetrically assembled two-electrode device also delivers a maximum energy density of 32 W h Kg -1 at a power density of 325 W Kg -1 . In addition, excellent cyclic stability of 98% capacitance retention is observed after 10,000 continuous GCD cycles even at a high current density of 5 A g -1 . Symmetric flexible supercapacitor device using KOH-PVA-K3FeCN6 as redox gel polymer electrolyte shows a synergistic specific capacitance of 145 mF cm -1 at a current density of 0.8 mA cm -1 exhibiting very less deviation in bending mode. Therefore, this waste biomass derived heteroatom doped hierarchical porous carbon nanosheets can be a promising material for cost-effective high- performance supercapacitor.

42 ENGINEERING↗
NASA NTRS1992

Metals production

Existing procedures for design of electrochemical plants can be used for design of lunar processes taking into consideration the differences in environmental conditions. These differences include: 1/6 Earth gravity, high vacuum, solar electrical and heat source, space radiation heat sink, long days and nights, and different availability and economics of materials, energy, and labor. Techniques have already been developed for operation of relatively small scale hydrogen-oxygen fuel cell systems used in the U.S. lunar landing program. Design and operation of lunar aqueous electrolytic process plants appears to be within the state-of-the-art. Finding or developing compatible materials for construction and designing of fused-magma metal winning cells will present a real engineering challenge.

Beck, Theodore S.↗