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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 307 records · Page 17

A Lithium Feedstock Pathway: Coupled Electrochemical Saltwater Extraction and Direct Battery Materials Manufacturing

Lithium (Li) is one of the critical industrial materials and an indispensable component in manufacturing Li batteries. However, Li resource is limited and geographically uneven in earth’s crust and its mining is not sustainable due to the low efficiency and complicated separation and refining processes. In this work, we develop a one-step technology to electrochemically extract Li from low concentration solutions (brines, seawater or used Li-ion batteries) into a form to directly produce commercial battery materials, eliminating the costly Li separation/purification steps. By using this approach, Li was selectively extracted and converted into battery cathodes (e.g., spinel LiMn 2 O 4 and layered LiNi x Mn y Co z O 2 ) through heat treatment. With the importance of Li-ion batteries to the overall decarbonization strategy, the demonstration of a one-step Li-extraction to a ready-to-use material could expand the access to Li resources at a lower cost by eliminating processing steps.

25 ENERGY STORAGE↗

Corrosion Testing Of Additively Manufactured Stainless Steel 316H In Molten Salt Environments

The development of a new ASTM standard for evaluating the corrosion resistance of additive manufactured (AM) stainless steel (SS) 316H in chloride molten salts is critical for the use of these materials in extreme environments such as molten salt reactors (MSRs). This report pertains to a work package of the Advaned Materials and Manufacturing Technologies (AMMT) developing a systematic methodology to link changes in AM fabrication parameters, namely surface finishing, porosity, microstructure, and chemical heterogeneity, to corrosion performance in NaCl-MgCl2 salt, a proposed secondary coolant for MSRs. During Fiscal Year 2024, Idaho National Laboratory investigators in the AMMT program, utilized SS316H bars, fabricated with laser bed powder fusion at Los Alamos National Laboratory, to establish and optimize the workflow for evaluating these process-to-performance relationships. Standard practices for specimen preparation were established using these specimens, with particular focus on descaling and sectioning methods that align with ASTM guidelines. A comprehensive experimental design for static corrosion testing was developed, with pre- and post-exposure analysis utilizing optical microscopy and scanning electron microscopy. So far standard descaling techniques were optimized, one static corrosion test was conducted on the LANL AM SS316H specimens, and pre- and post-corrosion practices were established. In addition, the work package yielded a review paper on corrosion testing gaps for AM materials in nuclear applications and submitted a proposal for a rapid-turnaround experiment to the Nuclear Science User Facilities Program to investigate the combined effects of proton irradiation and corrosion on AM SS316H. This work package establishes a foundation for evaluating processing-to-performance relationships for AM SS316H in harsh conditions, contributing to the safe and efficient design of components for next-generation nuclear reactors. The creation of a standardized methodology and the generation of relevant publications and future research pathways represent significant strides towards integrating AM materials into critical applications where corrosion resistance is paramount.

36 MATERIALS SCIENCE↗

Draft Critical Minerals Evaluation Report: Advanced Materials and Manufacturing Technology

Future energy production by sustainable clean energy technologies will be influenced by the availability and projected supply risks of critical minerals. In this report we discuss this context from the perspective of a sustainable nuclear energy technology and the benefits from the deployment of advanced manufacturing. In the past, the demand of critical minerals in the energy sector was minor, but in recent years renewable energy systems do force a substantial increase in the requirements for critical minerals which further induces pressure on the supply of critical minerals such as chromium, cobalt, nickel, niobium, tantalum, titanium, tungsten, vanadium, and zirconium for nuclear energy technology. The demand of critical minerals for nuclear technology is, besides beryllium and hafnium, minor and less than 1 % of the world supply. This alleviates the negative impact as the nuclear industry may not be able to provide the most compelling priority for the suppliers and to other policymakers looking at the overall needs. In this draft report, detailed background information is provided on the mineralogy of the identified critical minerals, supply chain risks followed by the discussion of specific minerals applicable to material relevant to nuclear energy technology. Briefly, the impact of advanced manufacturing on savings of critical minerals and electric energy is discussed and its effect to nuclear energy technology evaluated. This report will be followed with a final report providing a strategic vision for executable actions to implement the savings through advanced manufacturing, which will be further explored in the upcoming months. The Gen-IV relevant critical minerals will also be evaluated in the context of the AMMT programs material priorities as identified in the material score cards, to determine priorities for future actions. Material savings will become even more substantial when commercial Gen-IV reactor technology becomes available because of their needs for structural materials with higher content in alloying elements for enhanced high-temperature properties and improved corrosion resistance. The requirement for critical minerals in nuclear technology (in kg/MWe) will therefore significantly increase by 2050, even though its contribution to the worldwide electric energy production capacity will remain at about 5 %. The share of nuclear on world’s electric energy production is, on grounds of high utilization and availability 10.2 % and is expected to increase to 12 % by 2050. Advanced manufacturing could aid the deployment of Gen-IV nuclear technology since critical materials savings of up to 30 % seems possible, promoting nuclear energy as a true sustainable clean energy technology together with hydroelectric power.

36 MATERIALS SCIENCE↗

Development of an immersion fiber optic Raman probe for real-time analysis of molten materials

This study presents an advancement in high-temperature Raman spectroscopy, specifically for analyzing molten materials. It introduces an approach by integrating a fiber-optic Raman probe with a copper block protection system designed to endure extreme thermal conditions. The copper block features an open port designed to accommodate an external telescope with a 3 cm focal length, enabling Raman spectra collection in challenging high-temperature environments. A built-in gas channel ensures a continuous flow of argon gas to prevent flux intrusion. The robust copper block acts as a reliable shield, safeguarding the fiber-optic Raman probe within molten materials. This enhancement maintains the probe's integrity and significantly improves its resilience, making it ideal for rigorous investigations of molten substances. This advancement is particularly relevant in metallurgy, where flux materials impact production quality and efficiency. The ability to acquire Raman signals under elevated thermal conditions offers opportunities for studying molecular dynamics, compositional changes, and chemical interactions within molten substances. This introduced direct immersion probing technique has implications, benefiting both scientific and industrial fields. It holds promise for advancing research and exploration in various contexts, from fundamental scientific inquiries to practical applications in metallurgical processes, where flux materials are critical for optimizing production quality and efficiency. Furthermore, this approach enhances the capabilities of high-temperature Raman spectroscopy, making it a valuable tool for investigating molten materials and their properties in diverse settings.

Argon↗

Using diglycolamides to improve rare-earth element separation

The family of 17 elements known as the “rare earth elements” are difficult to produce economically. Despite this, they are described as “critical raw materials” because of their unique properties and their various technological applications. This means their use is accelerating globally. Separation of these elements is a fundamental challenge, but this does not daunt Dr Santa Jansone-Popova and her team at Oak Ridge National Laboratory. In recovering praseodymium from neodymium using a variety of ligands known as diglycolamides, she has been demonstrating potentially game-changing advances in liquid-liquid separations that could realise more of these in-demand materials.

Jansone-Popova, Santa↗

Electrification and decarbonization of spent Li-ion batteries purification by using an electrochemical membrane reactor

The expanding electric vehicle market brings with it exponential growth in the use of lithium (Li)-ion batteries (LIB) for which a wave of spent LIB is expected to come within the next 5 to 10 years. Due to the economic and strategic value imbedded within the metals contained in LIB, different recycling technologies, including hydrometallurgy, pyrometallurgy and direct recycling, are under development. Being different from previous hydrometallurgical methods, which may have high chemical consumption and negative environmental impact, an electrochemical membrane reactor is designed and validated for the first time, to electrify and decarbonize the impurity removal process. This reactor electroplates copper (Cu) and electrochemically precipitates aluminum (Al) and iron (Fe) from simulated spent LIB leachates, by consuming only air, water, and electricity, and the impurities are reduced to <1 ppm. The purified leachate maintains 99.5 % of the nickel (Ni), 95.4 % of the cobalt (Co) and 99.14 % of manganese (Mn) from the original leachate solution, and then can be directly applied for cathode precursor synthesis. Additionally, the purification process doesn’t introduce extra impurity, and the reactor restoration process generates valuable by-product hydro sulfate (H2SO4). This electrochemical process can reduce the cost, because of the much less chemical consumption and the valuable by-product generation, and mitigates the waste emissions, because of no extra impurity introduced and no greenhouse gas (GHG) produced. In conclusion, the chemical precipitation method uses significant amount of NaOH, which induced GHG emission during the manufacturing process.

25 ENERGY STORAGE↗

Method for leaching rare earth elements and critical minerals from organically associated materials

A method for extracting rare earth elements and critical minerals including adding an acid to a mixture comprising organically bound rare earth elements. The mixture is maintained at a pH of 0.25 to 4 for a period of time, resulting in a liquor and a leached mixture. The liquor is removed from the leached mixture to form a dewatered cake. The dewatered cake is washed to form a washing liquid. The washing liquid is recycled to create a second slurry comprising organically bound rare earth elements.

Theaker, Nolan↗

Domestic Extremism (Executive Summary)

Domestic extremism (DE) has been a growing concern in the U.S. in recent months, as illustrated in multiple bulletins from the Department of Homeland Security (DHS) warning law enforcement partners of the heightened threat. As concerns about these actors grows, it is important that facilities in the U.S. and internationally that protect critical assets, such as sensitive information, hazardous materials, or critical infrastructure, have effective methods in place to secure those assets. DE has challenged security systems through the danger of insider attack and violence, creating a new threat to be countered. In this effort, therefore, we used a literature review and focus group discussions with experts in critical asset security and extremism to understand the nature of the domestic extremist threat, to identify best practices in securing assets, recognize potential gaps in security measures to be corrected, and recommend actions for the Office of Radiological Security (ORS) to address DE with its partners.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Renewable Energy Materials Properties Database: Summary

Renewable energy is providing a growing share of electricity generation in the United States, with generation from utility scale wind and solar increasing by 12% and 29%, respectively, in 2020 (EIA 2021). Installation of new renewable energy facilities requires material inputs that range from common construction materials to specialized, high-performance materials that may have limited availability. This report summarizes the Department of Energy (DOE) Wind Energy Technologies Office (WETO) and DOE Solar Energy Technologies Office (SETO) database of materials used in domestic wind and solar installations. The Energy Act of 2020 directs WETO and SETO to deliver a "comprehensive physical property database of materials for use in [wind and solar] energy technologies, which shall identify the type, quantity, country of origin, source, significant uses, projected availability, and physical properties of materials used in [wind and solar] energy technologies" by no later than September 1, 2022. This report is the summary and directions for use of the Renewable Energy Materials Property Database (REMPD), in response to that direction. The related full text of the Energy Act of 2020 is provided in Appendix A. The focus of the REMPD and this accompanying report is on quantifying the raw and processed materials used in renewable energy technologies. The database contains information on the amount of each material that goes into wind and solar power plants, descriptions of the relevant material properties, and the primary countries of origin for each material. Some materials go through several stages of processing and/or are incorporated into subcomponents that make up the completed energy generation facilities. This report does not analyze supply chains for the production of renewable energy plant components. The Department of Energy has carried out related analysis in response to Executive Order 14017, which directed production of "America's Supply Chains" reports for Wind and Solar. The supply chain reports can be found at https://www.energy.gov/sites/default/files/2022-02/Wind%20Supply%20Chain%20Report%20-%20Final%202.25.22.pdf (Wind) and https://www.energy.gov/sites/default/files/2022-02/Solar%20Energy%20Supply%20Chain%20Report%20-%20Final.pdf (Solar). Additional reports in this series that are relevant to wind, solar and hybrid plants include: Energy Storage at https://www.energy.gov/sites/default/files/2022-02/Energy%20Storage%20Supply%20Chain%20Report%20-%20final.pdf and Neodymium Magnets at https://www.energy.gov/sites/default/files/2022-02/Neodymium%20Magnets%20Supply%20Chain%20Report%20-%20Final.pdf.

14 SOLAR ENERGY↗

Domestic Extremism: Countering the Threat Posed to Critical Assets

Domestic extremism has been a growing concern in the United States in recent months, as illustrated in multiple bulletins from the Department of Homeland Security (DHS) warning law enforcement partners of the heightened threat. As concerns about these actors grows, it is important that facilities in the U.S. and internationally that protect critical assets, such as sensitive information, hazardous materials, or critical infrastructure, have effective methods in place to secure those assets. DE has challenged security systems through the threat of insider attack and violence, creating a new threat to be countered in the Office of Radiological Security’s radiological source security mission. In this effort, we used a literature review and focus group discussions with experts in critical asset security and extremism to understand the nature of the domestic extremist threat, to identify best practices in securing assets, recognize potential gaps in security measures to be corrected, and recommend actions and next steps. Twenty-two subject matter experts participated in a series of five focus group sessions. Questions focused on definitions of domestic extremism, potential changes in the threat, best practices in securing facilities, assets, and personnel, and any perceived gaps. Upon completion of the focus groups, notes were analyzed thematically to identify any recurring patterns in the results. In addition, a review of academic, industry, and government literature was conducted to understand the threat, describe the process of radicalization to extremism, and to identify empirically informed practices in prevention and response. Results of this project demonstrated that further work is needed to define domestic extremism in law, regulation, and policy, to help the U.S. develop a consistent response to the threat within organizations. This is especially important, as SMEs emphasized the need for early intervention in prevention efforts, noting that organizations need clear guidance on when and how to intervene. In addition, the need for social media monitoring was discussed, although challenges remain to do so with appropriate respect for privacy and civil liberties concerns.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Machine-learning-assisted deciphering of microstructural effects on ionic transport in composite materials: A case study of Li 7 La 3 Zr 2 O 12 -LiCoO 2

The effective diffusivity of ionic species in multiphase materials is critical for the design and function of composite materials for electrochemical energy storage. In practice, effective diffusivity depends sensitively not only on the intrinsic diffusivities of constituting materials but also on their topological arrangement; nevertheless, these coupled contributions are oversimplified in most analytical models. Here, we combine atomistically informed mesoscale modeling and machine learning (ML) analysis to unravel how such features affect effective diffusivity in two-phase composites. Using the Li 7 La 3 Zr 2 O 12 -LiCoO 2 composite solid-state battery cathode as a model system, we compute effective diffusivity for 600 distinct dense polycrystalline microstructures with different topological configurations of grains, grain boundaries, and heterointerfaces. We verify that in addition to atomic-scale variabilities, microstructural feature diversity can significantly impact effective transport properties. Across the ensemble of test microstructures, this often results in bimodal distributions of effective diffusivity that encompass two qualitatively distinct operating mechanisms, which we identify via flux analysis. An ML approach reveals that the most critical determining factors for effective diffusivity are the connectivity of bulk phases and their heterointerfaces. The role of ionic mobility at the heterointerfaces is also discussed. These insights highlight the combined importance of microstructure and interface engineering in tuning the transport properties of ionic species in composite materials. In conclusion, our framework can also be extended for understanding generic microstructure-property relationships in other complex multiphase materials.

25 ENERGY STORAGE↗

Immersive Analytics in Critical Spatial Domains: From Materials to Energy Systems

Immersive analytics (IA) leverages virtual reality, augmented reality, and mixed reality to transform how users interact with complex datasets across domains such as science, industry, and education. These immersive technologies offer spatial and multimodal environments that foster intuitive exploration, but they also introduce challenges related to cognitive load, interface design, and system performance. Here, this article presents a comprehensive review of visualization techniques, interaction models, and multimodal inputs utilized in IA. Drawing on case studies in scientific visualization, industrial training, and educational communication, we examine both the potential and limitations of current systems. Finally, we propose future research directions, focusing on real‐time collaboration, adaptive user interfaces, and scalable data exploration strategies to advance the field.

99 - GENERAL AND MISCELLANEOUS↗

Transforming E-Waste Into Strategic Resources: Techno-Economic Analysis of Gallium and By-products Recovery from LEDs via Bioleaching

The growing demand for gallium in optoelectronics and renewable energy applications raises concerns about supply security and production sustainability. This study evaluates the techno-economic feasibility of recovering gallium and by-products (copper and nickel) from waste GaN-based LEDs via bioleaching. A process flowsheet encompassing transportation, robotic disassembly, ball milling, bioleaching, solvent extraction/electrowinning, and refining was modeled. Based on mass balance analysis, more than 53 tons of LED waste are required annually to yield 1 kg of gallium alongside substantial copper and nickel co-products. Preliminary techno-economic analysis (TEA) shows an average total cost (ATC) of 6.84 USD/kg metal when costs are allocated by mass-weighted economic value (market price) fraction, corresponding to 6.75 USD/kg for copper, 15.91 USD/kg for nickel, and 470.95 USD/kg for gallium. For gallium, direct operational costs account for more than 70% of the cost. Monte Carlo simulations further quantify cost uncertainties under market price fluctuations. This work represents the first TEA of gallium recovery from GaN-based LEDs and highlights potential pathways for future cost reduction.

36 MATERIALS SCIENCE↗

Analysis of the dependence of critical electric field on semiconductor bandgap

Abstract Understanding of semiconductor breakdown under high electric fields is an important aspect of materials’ properties, particularly for the design of power devices. For decades, a power-law has been used to describe the dependence of material-specific critical electrical field ( $${\mathcal{E}}_{\text{crit}}$$ E crit ) at which the material breaks down and bandgap ( E g ) . The relationship is often used to gauge tradeoffs of emerging materials whose properties haven’t yet been determined. Unfortunately, the reported dependencies of $${\mathcal{E}}_{\text{crit}}$$ E crit on E g cover a surprisingly wide range in the literature. Moreover, $${\mathcal{E}}_{\text{crit}}$$ E crit is a function of material doping. Further, discrepancies arise in $${\mathcal{E}}_{\text{crit}}$$ E crit values owing to differences between punch-through and non-punch-through device structures. We report a new normalization procedure that enables comparison of critical electric field values across materials, doping, and different device types. An extensive examination of numerous references reveals that the dependence $${\mathcal{E}}_{\text{crit}}$$ E crit ∝ E g 1.83 best fits the most reliable and newest data for both direct and indirect semiconductors. Graphical abstract

36 MATERIALS SCIENCE↗

In Silico Versus In Situ: The Challenging Landscape of Nuclear Criticality Safety Training

Nuclear criticality safety grew out of the ranks of experimentalists studying the physics of chain-reacting systems at critical experiment facilities. Consequently, critical experiment facilities provide the best forum for conducting training in nuclear criticality safety. As the nuclear renaissance gains traction, there is an increased demand to train personnel in nuclear criticality safety (NCS). Strides have been made in both on-line and virtual reality based NCS training. While these are perhaps a necessary component of NCS training, hands-on training at critical experiments facilities remains the most effective means of developing competency for fissionable material handlers, managers of fissionable material operations, criticality safety analysts, and experimentalists. This paper explores the challenges of developing and maintaining workforce competency in nuclear criticality safety to support safe and efficient fissionable material operations.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

On the uncertainties in helium generation predictions for fission and fusion alloys

With ongoing advances in fusion and advanced fission reactors, quantifying irradiation effects in materials is critical. Transmutation-induced helium in cladding and structural materials can drive swelling and embrittlement, thereby reducing these components’ lifespans. Yet most studies ignore the considerable uncertainties in predicting helium generation rates. In this work, we created a code wrapper, F-SCATTER, that automatically performs simulations in FISPACT-II. We used this tool to investigate potential variance in helium generation rate, or He/dpa, calculations based on deviations in alloy composition, irradiating neutron flux spectrum, computational methodology, and nuclear data sources. We used 12 wt% Cr HT9 steel as the reference case and observed a 6.5%–98.3% He/dpa spread based on compositional variation within a single chemical specification, a 1.8%–11.5% He/dpa variation upon the incorporation of a 15% artificial uncertainty in flux at each energy, and a He/dpa difference as high as 231% when using ENDF/B-VIII.0 versus TENDL-2021 data libraries. Similar results were found for other prominent iron-based alloys, including Grade 91, castable nano-structured alloy, and 316H—where additional variations exist based on reactor type (e.g. thermal, fast, or fusion) and alloying elements such as carbon, nitrogen, and nickel. Based on the simulated results, we conclude that a significant part of the heat-to-heat variability in swelling responses of Fe-based alloys can be driven by impurity content in alloy compositions, and, therefore, chemical control should be a key element in supply chain design for advanced nuclear energy systems. Furthermore, we provide critical recommendations on best practices for evaluating and reporting helium production and lattice damage rates when computing predictions with multiphysics programs such as FISPACT-II.

FISPACT-II↗

IER 517: Molybdenum Critical Experiment Design [Slides]

In nuclear fuels, U-Mo metallic fuels are used in new space reactor designs and new research reactor fuels. MITR, MURR, and NBSR reactors plan on converting from different HEU fuels to a U-Mo HALEU fuel. In spend nuclear fuel, 95 Mo is one of the 15 main absorbing fission products in irradiated LWR fuel. This makes it important for criticality safety studies in transportation and reprocessing. In structural materials. Molybdenum is found commonly in alloys that make up the structural materials of nuclear reactors such as type 316 SS. Molybdenum helps to improve high temperature performance and corrosion resistance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗