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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Opportunities for Catalytic Reactions and Materials in Buildings

Residential and commercial buildings are responsible for over 30% of global final energy consumption and accounts for ~40% of annual direct and indirect greenhouse gas emissions. Energy efficient and sustainable technologies are necessary to not only lower the energy footprint but also lower the environmental burden. Many proven and emerging technologies are being pursued to meet the ever-increasing energy demand. Catalytic science has a significant new role to play in helping address sustainable energy challenges, particularly in buildings, compared to transportation and industrial sectors. Thermally driven heat pumps, dehumidification, cogeneration, thermal energy storage, carbon capture and utilization, emissions suppression, waste-to-energy conversion, and corrosion prevention technologies can tap into the advantages of catalytic science in realizing the full potential of such approaches, quickly, efficiently, and reliably. Catalysts can help increase energy conversion efficiency in building related technologies but must utilize low cost, easily available and easy-to-manufacture materials for large scale deployment. This entry presents a comprehensive overview of the impact of each building technology area on energy demand and environmental burden, state-of-the-art of catalytic solutions, research, and development opportunities for catalysis in building technologies, while identifying requirements, opportunities, and challenges.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Tuning crosslinking of hybrid preceramic polymers in vat photopolymerization toward controlled ceramic yields

Control of preceramic polymer crosslinking for UV-curable processing is essential for fine 3D printing with high ceramic conversion for sustainable polymer-derived ceramics (PDC) engineering. While various factors influencing ceramic yield have been studied, the systematic exploration of the relationship between crosslinking and ceramic yield, especially when crosslinking increases volatile elements, remains open for further investigation. This study addresses this gap by utilizing vat photopolymerization (VP) additive manufacturing (AM) as a versatile platform for controlling preceramic crosslinking and ceramic yield. By rationally designing and tuning the photochemical crosslinking through digital light processing (DLP), we demonstrate that the ceramic yield can be enhanced from 64% to over 86%, even with added volatile elements. We reveal that the post-pyrolysis ceramic yield can be closely correlated with the pre-pyrolysis crosslinking of the preceramic network represented by its stiffness. This correlation thereby suggests a fast, energy-efficient, non-destructive methodology to predict and improve ceramic yield. Combined with these findings, our one-pot thiol-ene hybridization of polycarbosilane and polycarbosiloxane via DLP offers an exemplary method to generate hybrid preceramic polymers with tailored material properties toward target applications, and potentially even higher ceramic yields. This study thus contributes to achieving better resource- and energy-efficient preceramic polymer and PDC processing routes toward sustainable, advanced organic–inorganic materials manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1982

Nonterrestrial utilization of materials: Automated space manufacturing facility

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility.

Source record↗
DOE OSTI2022

Enhancing Lifetime and Reducing Costs for Fish Diversion Netting Structures (Abstract)

This effort will focus on technology transfer and commercialization of antifouling coatings with an enthusiastic and engaged industrial team. Environmental requirements and operational demands call for a nontoxic coating/paint to prevent fouling on fish passage guidance netting at hydropower facilities. For example, one netting customer estimated the capital cost for compliance at $\$12$ million to $\$15$ million. This project will build partnerships between PNNL and private companies to optimize, demonstrate, mature, and commercialize a novel PNNL-developed technology that addresses this critical coating need of the hydropower industry. This effort will support modification of existing coatings for application to flexible netting structures. Industrial partners include commercial coating development specialist (Lorama), hydrophobic material manufacturer and paint developer (Dry Surface Technologies), aquatic applications specialists (Prometheus Innovations and River Connectivity Systems), and hydropower netting producer (Pacific Netting Products). Engagement with the U.S. Army Corps of Engineers (USACE) and Bureau of Reclamation (BOR), two hydropower operators, throughout the project will provide expertise and field test sites that will provide crucial proof of real-world performance data (additional details provided in Teaming section). Taylor Shellfish Farms will provide organisms and fouling expertise as well as a perspective of potential broader impacts for the blue economy. Sample netting will demonstrate performance in a range of environments for key hydropower applications. PNNL will work with industrial partners to overcome commercialization barriers as well as resolving any manufacturing or regulatory issues. This Phase 1 effort is focused on technology optimization for application to fish passage guidance netting and technology validation as verified by independent testing (through USACE, BOR, Taylor Shellfish and Prometheus Innovations). Through this effort, SLIC will be demonstrated for netting applications at technology readiness level (TRL) 5. The field test data will allow optimization of SLIC formulation and performance which is key to enabling technology transfer of a mature proven technology to industry and production of a viable commercial product specifically focused for hydropower needs.

13 HYDRO ENERGY↗
DOE OSTI2024

Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D) (Final Technical Report)

As the U.S clean energy transition hinges on the growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements to enable robust and cost-competitive wind turbines. The race to build larger and taller turbines rated 10 megawatts (MW) and beyond, has intensified pressure on OEMs in terms of logistics of handling and transporting large wind components, securing critical raw material as well as scaling up necessary domestic production infrastructure to meet the demand. There is increased interest in building lightweight, more efficient, and high-power dense drivetrains that will ease the burden on installation, minimize the raw material demand, increasing domestic sourceability. Despite good efficiency and reliability, existing drivetrain technologies such as direct-drive permanent magnet generators are heavy (> 300 tons), expensive, and often rely on large quantities of rare-earth permanent magnets (PMs), steel and copper.

17 WIND ENERGY↗
DOE OSTI2024

Hydrogen in energy and information sciences

Beyond its fascinating chemistry as the first element in the Periodic Table, hydrogen is of high societal importance in energy technologies and of growing importance in energy-efficient computing. In energy, hydrogen has reemerged as a potential solution to long-term energy storage and as a carbon-free input for materials manufacturing. Its utilization and production rely on the availability of proton-conducting electrolytes and mixed proton–electron conductors for the components in fuel cells and electrolyzers. In computing, proton mediation of electronic properties has garnered attention for electrochemically controlled energy-efficient neuromorphic computing. Incorporation of substitutional and interstitial hydride ions in oxides, though only recently established, enables tuning of electronic and magnetic properties, inviting a range of possible exotic applications. This article addresses common themes in the fundamental science of hydrogen incorporation and transport in oxides as relevant to pressing technological needs. The content covers (1) lattice (or bulk) mechanisms of hydrogen transport, primarily addressing proton transport, but also touching on hydride ion transport; (2) interfacial transport; (3) exploitation of extreme external drivers to achieve unusual response; and (4) advances in methods to probe the hydrogen environment and transport pathway. The snapshot of research activities in the field of hydrogen-laden materials described here underscores exciting recent breakthroughs, remaining open questions, and breathtaking experimental tools now available for unveiling the nature of hydrogen in solid-state matter.

08 HYDROGEN↗
DOE OSTI2026

Strong and recyclable bio-derived poly(ester amide) hot-melt adhesive

Bio-based adhesives offer inherent advantages over conventional petrochemical-derived systems, including renewable sourcing, reduced environmental impact and potential degradability. However, most bio-based adhesives suffer from poor adhesion strength, limited substrate compatibility and a lack of chemical recyclability. Here, in this work, we present a bio-derived multiblock poly(ester amide) adhesive that leverages microphase segregation between different segments to reconcile mechanical robustness with strong interfacial bonding. Notably, this multiblock architecture is accessed through a one-pot, selective acceptorless dehydrogenative polymerization, obviating the need for multistep synthesis. The materials exhibit excellent adhesion across a range of substrates including metals, glass and wet wood surpassing commercial benchmarks, while also demonstrating thermal stability, tunable mechanical properties and closed-loop chemical recyclability even in the presence of other commodity plastics. Furthermore, the adhesive strength of these materials could be tuned for various potential applications through control over the chemical composition of the polymer. By integrating renewable feedstocks, high-performance functionality and efficient chemical circularity within a single platform, this work provides a viable pathway toward more sustainable adhesive technologies and contributes to advancing circular materials manufacturing.

09 BIOMASS FUELS↗
NASA NTRS1971

Status and plans of NASA's Materials Science and Manufacturing in Space /MS-MS/ program.

Following two years of relatively low-level exploratory work, the Materials Science and Manufacturing in Space program is now in a phase of expansion toward higher levels of effort. The main thrust of this effort is toward initiation of a research and development program on the Space Shuttle missions that can prepare the way for possible commercial manufacturing operations on permanently orbiting space stations. Experiment capabilities currently being planned for the Space Shuttle will be based on an inventory of reusable general-purpose equipment that can be configured in many different ways to meet individual experiment requirements. It is expected that this approach can support very large numbers of experiments and make flight opportunities accessible to many potential experimenters who would not be prepared to involve themselves in the development of flight hardware.

Armstrong, W. O.↗
NASA NTRS1993

A widely adaptable habitat construction system utilizing space resources

This study suggests that the cost of providing accommodations for various manned activities in space may be reduced by the extensive use of resources that are commonly found throughout the solar system. Several concepts are proposed for converting these resources into simple products with many uses. Concrete is already being considered as a possible moonbase material. Manufacturing equipment should be as small and simple as possible, which leads to the idea of molding it into miniature modules that can be produced and assembled in large numbers to create any conceivable shape. Automated equipment could build up complex structures by laying down layer after layer in a process resembling stereolithography. These tiny concrete blocks handle compression loads and provide a barrier to harmful radiation. They are joined by a web of tension members that could be made of wire or fiber-reinforced plastic. The finished structure becomes air-tight with the addition of a flexible liner. Wire can be made from the iron modules found in lunar soil. In addition to its structural role, a relatively simple apparatus can bend and weld it into countless products like chairs and shelving that would otherwise need to be supplied from Earth. Wire woven into a loose blanket could be an effective micrometeoroid shield, tiny wire compression beams could be assembled into larger beams which in turn form larger beams to create very large space-frame structures. A technology developed with lunar materials could be applied to the moons of Mars or the asteroids. To illustrate its usefulness several designs for free-flying habitats are presented. They begin with a minimal self-contained living unit called the Cubicle. It may be multiplied into clusters called Condos. These are shown in a rotating tether configuration that provides a substitute for gravity. The miniature block proposal is compared with an alternate design based on larger triangular components and a tetrahedral geometry. The overall concept may be expanded to envision city-sized self-sufficient environments where humans could confortably live their entire lives. One such proposal is the Hive. It is configured around a unique sunlight collection system that could provide all its energy needs and that could be scaled up to compensate for the reduced solar intensity at greater distances from the sun. Its outer perimeter consists of a cylindrical section mated to two conical end walls that taper inwards toward a small aperture at the center of rotation. Light collected by two huge mirrors of unusual design enters the aperture and is redirected to the inside of the cylinder. The conical end walls are shielded from direct sunlight and are designed to radiate heat into space. They are lined with air ducts that passively recirculate the atmosphere while extracting moisture by condensation. Although there is no immediate demand for spacecraft on this scale, their consideration can influence even the earliest stages of the development process.

Wykes, Harry B.↗
DOE OSTI2026

Thermodynamic Control of Interface Directs MnO 2 Nucleation Chemistry for Dense and Conformal Electrodeposition

Manganese dioxide (MnO 2 ) is widely recognized as a promising material for high-energy-density energy storage systems due to its broad applicability and facile electrodeposition. However, achieving uniform, thin, and high-mass-loading MnO 2 coatings on high-surface-area electrodes remains a significant challenge. Conventional electrodeposition methods typically yield nonuniform, thick layers with poor conductivity and limited material utilization, restricting their practical use. Here, we uncover a thermodynamically engineered vanadyl/pervanadyl (VO 2+ /VO 2 + ) interface that fundamentally reshapes MnO 2 electrodeposition chemistry, enabling highly uniform and dense coatings. Here, combining in situ AFM measurement, Classical Nucleation Theory, and Johnson–Mehl–Avrami–Kolmogorov modeling, we show that this interface reduces early-stage detectable MnO 2 island size by 35-fold and shifts the MnO 2 growth from diffusion-limited to reaction-limited progressive nucleation. This thermodynamically controlled interface yields highly dense and conformal MnO 2 films with record-high mass loading of 241 mg cm –2 (1607 mg cm –3 ) on 3D-printed graphene aerogels, without compromising porosity or inducing thickness gradient. As a prototype demonstration, the resulting MnO 2 electrodes deliver record-setting volumetric performance in both capacitors (106 F cm –3 ) and Zn//MnO 2 pouch cells (162 mAh cm –3 ). Beyond energy storage, our findings demonstrate the significance of thermodynamic interface control in MnO 2 nucleation chemistry for achieving dense and uniform coatings on various substrates, with implications for electrocatalysis, semiconductor processing, and advanced materials manufacturing.

Batteries↗
DOE OSTI2023

Sustainable Materials Selection in Manufactured Products: A Framework for Design-Integrated Life Cycle Thinking with Case Studies

Materials selection can provide a major opportunity to improve the environmental performance of manufactured products. Substitution of conventional materials with eco-friendly options can lower a product's environmental impact while still meeting key application requirements. A prerequisite for sustainability-informed decision-making is that relevant data and information are available for all materials being considered. Here we outline examples of the types and sources of data needed; and we explore key considerations for sustainable materials selection through a series of practical, cross-sectoral case studies.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗
DOE OSTI2024

A Primer on Using Analysis to Guide Plastic Circularity

BOTTLE, funded by DOE's Advanced Materials & Manufacturing Technologies Office and Bioenergy Technologies Office (BETO), conducts analysis-guided R&D to change the way we recycle plastics. But what does analysis really mean? In this webinar, BOTTLE Analysis Co-Lead Dr. Taylor Uekert, a researcher with the National Renewable Energy Laboratory (NREL), will introduce key analysis techniques such as techno-economic analysis, life cycle assessment, and environmental justice evaluation. Relevant to both analysts and non-analysts, Dr. Uekert will cover the basics of analysis techniques and discuss how these methods are conducted and interpreted. She will provide examples from the BOTTLE portfolio demonstrating their use in benchmarking and optimizing the costs and environmental impacts of new innovations in plastic redesign and recycling. If you are working in the plastics recycling field - from experimental work to analysis to community-focused projects - you won't want to miss this talk. The webinar will end with a Q&A session.

analysis↗
DOE OSTI2024

Material selection and manufacturing for high‐temperature heat exchangers: Review of state‐of‐the‐art development, opportunities, and challenges

Abstract Many energy systems demand heat transfer at high temperatures to keep up with high demand for power, so high‐temperature material that can perform and last under these harsh conditions is needed for heat exchangers. The engineering requirements for these high‐temperature heat exchanger material call for high thermal conductivity, high resistance to fracture, high resistance to creep deformation, environmental stability in environments associated with the application, and high modulus of elasticity while maintaining low cost to make and maintain. Naturally, ceramics are a good solution for this endeavor. In the past, high‐temperature heat exchangers made from ceramics have been used. We provide examples of ceramics in relevant heat exchange applications and provide motivation where additive manufacturing (AM) can improve efficiency. AM for the relevant material is under development, and we provide insight on the AM of ceramic materials and examples of AM heat exchangers keeping cost in mind. The motivation of the review paper is to provide a framework for material and manufacturing selection for high‐temperature heat exchangers for AM to keep up with the demand for better efficiency, better material, better manufacturing, and cost moving forward with AM technology in high‐temperature ceramic heat exchangers.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Batteries Annual Progress Report (FY2019)

The Vehicle Technologies Office (VTO) of the Department of Energy (DOE) conducts research and development (R&D) on advanced transportation technologies that would reduce the nation’s use of imported oil and would also lead to reductions in harmful emissions. Technologies supported by VTO include electric drive components such as advanced energy storage devices (primarily batteries), power electronics and electric drive motors, advanced structural materials, energy efficient mobility systems, advanced combustion engines, and fuels. VTO is focused on funding early-stage high-reward/high-risk research to improve critical components needed for more fuel efficient (and cleaner-operating) vehicles. One of the major VTO objectives is to enable U.S. innovators to rapidly develop the next generation of technologies that achieve the cost, range, and charging infrastructure necessary for the widespread adoption of plug-in electric vehicles (PEVs). An important prerequisite for the electrification of the nation’s light duty transportation sector is development of more cost-effective, longer lasting, and more abuse-tolerant PEV batteries. One of the ultimate goals of this research, consistent with the current vehicle electrification trend, is an EV which can provide the full driving performance, convenience, and price of an internal combustion engine (ICE) vehicle. To achieve this, VTO has established the following overarching goal (Source: FY2021 Congressional Budget Justification1): …identify new battery chemistry and cell technologies with the potential to reduce the cost of electric vehicle battery packs by more than half, to less than $100/kWh (ultimate goal is $60/kWh battery cell cost), increase range to 300 miles, and decrease charge time to 15 minutes or less by 2028. VTO works with key U.S. automakers through the United States Council for Automotive Research (USCAR) – an umbrella organization for collaborative research consisting of Fiat Chrysler Automobiles (FCA), the Ford Motor Company, and General Motors. Collaboration with automakers through the partnership known as U.S. Driving Research and Innovation for Vehicle Efficiency and Energy Sustainability (U.S. DRIVE) attempts to enhance the relevance and the success potential of its research portfolio. VTO competitively selects projects for funding through funding opportunity announcements (FOAs). Directly-funded work at the national laboratories are awarded competitively through a lab-call process. During the past year, VTO continued R&D in support of PEVs. Stakeholders for VTO R&D include universities, national laboratories, other government agencies and industry (including automakers, battery manufacturers, material suppliers, component developers, private research firms, and small businesses). This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2019 (FY 2019).

25 ENERGY STORAGE↗
DOE OSTI2021

Catalysts by pyrolysis: Direct observation of chemical and morphological transformations leading to transition metal-nitrogen-carbon materials

Transition metal-nitrogen-carbon materials (M-N-C catalysts) are promising electrocatalysts in polymer electrolyte fuel cells (PEFCs) and electrolyzer applications. High temperature treatment in inert atmosphere (pyrolysis) is the essential, most common method for the synthesis of M-N-C catalysts and critical to achieve high electrocatalytic activity and electronic conductivity. To this day, despite many uses and successful implementations in materials manufacturing, pyrolysis has been an entirely empirical technology, with process control and optimization relying exclusively on “Edisonian” approach. The knowledge gap in the mechanism about how the precursor is being transformed into catalysts hinders further development of the M-N-C catalysts regardless of the precursor class and processing protocols. In this work, we probed the morphological evolution and chemical transformation of a nitrogen-containing charge transfer organic salt, mixed with transition metal (iron) salt and amorphous silica powder (precursor) during the pyrolysis process via a combination of in situ synchrotron and laboratory-based diagnostic techniques. The pyrolysis process is found to be divided into three stages. During a controlled temperature ramp, the selected organic N-C precursor (nicarbazin) began melting and decomposing just below 400 °C, forming a certain number of micrometer-scale pores and pathways. With increase in temperature from 400 °C to 900 °C, amorphous carbon domains started forming, and reduced (metallic) iron nanoclusters appeared, being dispersed uniformly throughout the carbonaceous matrix. When temperature advanced above 900 °C, graphitization of carbon commenced, associated with appearance and evolution of atomically dispersed metal-nitrogen moieties in the carbonaceous matrix. As the graphitization advanced further, a secondary process of agglomeration of metal nanoparticles occurred. Multi-analytical technique observations conducted here provide a base for rational design and optimization of M-N-C electrocatalysts via pyrolysis.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Grazer-induced changes in molecular signatures of cyanobacteria

Algal biomass production is an emerging renewable source of fuels, nutrients, manufacturing materials, and pharmaceuticals. Industrial-scale production is predominantly performed in open raceway ponds that are inexpensive to build, operate, and maintain compared to closed bioreactors. However, these open pond systems suffer from increased opportunities for biological contamination from predators, pathogens, and competitors, which result in reduced biomass quality and yields and often the complete destruction of the crop over a short period of time. Early detection of contaminants is a necessary step of integrated pest management for triggering and informing interventions to prevent crop losses. To develop a sensitive method of detection utilizing mass spectrometry (MS), we used three methods – imaging mass spectrometry (imaging MS), liquid chromatography MS/MS (LC-MS/MS) combined with molecular networking, and gas chromatography MS/MS (GC–MS/MS) – to observe and identify molecular signatures from a model predator-prey system of the heterolobosean amoeba HGG1 preying on the filamentous cyanobacterium Anabaena sp. PCC 7120. Imaging MS enabled the association of molecules with the crop, the predator, or the activity of protozoan grazing, while LC-MS/MS-based molecular networking identified a subset of the grazing-specific signals as the chlorophyll breakdown products pyropheophytin, pheophorbide A, and pyropheophorbide. Application of MS techniques to other amoebacyanobacterial predator-prey pairs allowed categorization of grazing signatures as universal or specific to the species of prey, predator, or the prey-predator pairing, indicating that MS-based techniques can distinguish crops from competitors and potentially identify predators. Finally, GCMS/MS was shown to be capable of monitoring novel volatile organic compounds (VOCs), including those predicted to be released through chlorophyll breakdown, in the headspace over algal cultures under predation. Furthermore, these results demonstrate that the combination of multiple MS technologies creates a predictive framework to identify and catalog relevant molecular signatures for informing crop protection strategies.

09 BIOMASS FUELS↗
DOE OSTI2021

Normal and anomalous self-healing mechanism of crystalline calcium silicate hydrates

The origin of different stability of crystalline calcium silicate hydrates was investigated. The tobermorite crystal has been used as an analog of cement hydrate that is being mostly manufactured material on earth. Normal tobermorite is thermally unstable and transforms to amorphous at low pressure. Meanwhile, anomalous tobermorite with high Al content does not significantly transform under high pressure or high temperature. Conducted X-ray absorption spectroscopy explains the weak stability of normal tobermorite which was originally hypothesized by the role of zeolitic Ca ions in the cavities of silicate chains. Atomic simulations reproduced the experimentally observed trend of pressure behavior once the ideal structures were modified to account for the Al content as well as the chain defects. The simulations also suggested that the stability of tobermorite under stress could be rationalized as a self-healing mechanism in which the structural instabilities were accommodated by a global sliding of the CaO layer.

36 MATERIALS SCIENCE↗