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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 OSTI2024

Liquid-like solid-state diffusion of lithium ions in super-halide-rich argyrodite

The development of solid electrolytes with high ionic conductivity is essential for advancing safer, high-energy-density solid-state batteries, where lithium site distribution in the sublattice strongly affects ion transport. Here, we report a super-halide-rich argyrodite, Li 5.3 PS 4.3 Cl 1.7 , with remarkable room-temperature ionic conductivity (11.4 ± 0.7 mS cm -1 ) due to population of two additional interstitial lithium sites induced by vacancy redistribution. Prominent lithium density between lithium sites and elevated atomic displacement parameters indicate liquid-like diffusive behavior resembling sublattice melting. Combining electrochemical impedance spectroscopy, pulsed-field gradient NMR, and T 1 relaxation methods, we demonstrate that the augmented conductivity partly arises from a low energy barrier (0.08 eV) at the local scale, attributed to a three-site lithium distribution that drives correlated lithium dynamics. This work advances our understanding of the structure-dynamics interplay in super-halide-rich argyrodites, and highlighting their potential as solid-state battery electrolytes in cells with a coated single-crystal NMC82 cathode that achieve 170 mAh/g capacity at a 0.2 C rate .

25 ENERGY STORAGE↗
DOE OSTI2023

PARFUME/BISON Fission Product Release Predictions versus AGR-3/4 Heating Test Measurements

The fuel performance modeling codes PARFUME (PARticle FUel ModEl) and BISON were used to predict the release of fission products silver, cesium, and strontium from as-irradiated fuel compacts containing tristructural isotropic (TRISO) coated particles during heating tests post irradiation. The AGR-3/4 fuel compacts were irradiated as part of the third and fourth series of planned experiments to support the Advanced Gas Reactor (AGR) program. The heating tests were conducted at temperatures between 1200°C and 1700°C to simulate reactor accident conditions. The measured fission product release fractions from the heating tests were compared to modeling predictions calculated by PARFUME and BISON to evaluate how the codes compare to experimental results. Comparisons between the experimental measured fission product release fractions from silver, cesium and strontium indicate that both modeling codes overpredict the fission product release fractions demonstrating that the diffusivities used in the codes are overestimated. This results in a conservative estimate predicted by the codes when evaluating the fission product release relative to experimental data as it pertains to silver, cesium, and strontium.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Understanding Environmental Barrier Coating Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. Here, the goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aeroturbine applications. To provide data for the lifetime model, laboratory testing used atmospheric plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air–steam environments and reaction kinetics were assessed from 700 °C to 1350 °C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

08 HYDROGEN↗
DOE OSTI2020

Vanadyl Phosphates A x VOPO 4 (A = Li, Na, K) as Multielectron Cathodes for Alkali-Ion Batteries

Vanadyl phosphates comprise a class of multielectron cathode materials capable of cycling two Li + , about 1.66 Na + , and some K + ions per redox center. In this review, structures, thermodynamic stabilities, and ion diffusion kinetics of various A x VOPO 4 (A = Li, Na, K, NH 4 ) polymorphs are discussed. Both the experimental data and first-principle calculations indicate kinetic limitations for alkali metal ions cycling, especially between for 0 ≤ x ≤ 1, and metastability of phases with x > 1. This creates challenges for multiple-ion cycling, as the slow kinetics call for nanosized particles, which being metastable and reactive with organic electrolytes are prone to side reactions. Thus, various synthesis approaches, surface coating, and transition metal ion substitution strategies are discussed here as possible ways to stabilize A x VOPO 4 structures and improve alkali metal ion diffusion. Finally, the role of advanced characterization techniques, such as X-ray absorption spectroscopy, diffraction, pair distribution function analysis and 7 Li and 31 P NMR, in understanding the reaction mechanism from both structural and electronic points of view is emphasized.

25 ENERGY STORAGE↗
DOE OSTI2023

Investigation of 3D printed lightweight hybrid composites via theoretical modeling and machine learning

Hybrid composites combine two or more different fillers to achieve multifunctional or advanced material properties, such as lightweight and enhanced mechanical properties. The properties of the composites significantly depend on their microstructures, which can be tailored via advanced 3D printing processes. Understanding the process-structure-property relationships is critical to enable the design and engineering of novel hybrid composites for applications in aerospace, automotive, and protective coatings. Here, for this work, we develop 3D printable and lightweight hybrid composites and leverage the conventional design of experiments, a theoretical hybrid model, and an image-driven machine learning (ML) method to investigate their mechanical behaviors. The hybrid composites are formulated with elastomer matrix, microfillers, and thin-shell particles, enabling a significant degree of design freedom of microstructures with densities and mechanical properties varying up to 70% and 91%, respectively. Our statistical analysis indicates that the 3D printing path direction and the microfibers fraction are dominating process parameters with contribution percentages of 45.3% and 57.7% on the specific stiffness and strength, respectively. A hybrid mechanics model is developed based on a simple Weibull distribution function and classical single-filler models to effectively capture the variations in mechanical properties, however, it overestimates the values due to its statistical constraints and idealization of experimental uncertainty. The image-driven ML model leverages the microscale images directly without losing the structural details, shows more accurate predictions with experimental data, and has 48.6% lower root mean square error than the theoretical model.

3D printing↗
DOE OSTI2023

Mechanical Actuation via Homeomorphic Transformations of Topological Solitons within Polymer Coatings

Abstract Topological solitons are currently under investigation for their exotic properties, especially in nonlinear physics, optics, and material sciences. However, challenges of robust generation and limited stability over time have hindered their practical uses. To address this issue, an approach is developed to form structured arrays of solitons in films of polymerizable liquid crystals. Their complex molecular architecture is preserved by in situ photopolymerization forming a stable liquid crystal network. Most excitingly, their properties are advanced to include responsiveness functions. When thermally actuated, these topological solitons mediate the reconfiguration of surface topographies. Complex shape changes occur depending on the intrinsic complex spatial distribution of the director, which may even lead to full shape inversion and topographical changes as high as ≈40% of the initial thickness. Conversely, the shape changes provide information on the initial director profile, which is consistent with the mathematical model. The soliton‐containing polymer coatings are applicable in multiple domains, ranging from tunable optics to haptics, and from shape‐coupled sensing systems to temperature‐coupled heat management.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Atmospheric Cold Plasma Jet Coating and Surface Treatment for Improved Adhesive Bonding Performance of Dissimilar Material Joints Subject to Harsh Environmental Exposure

The program goal was the development and demonstration of a novel material coating system using an innovative atmospheric cold microwave plasma jet to enable surface functionalization for corrosion protection, wear resistance and improved bonding strength. The technical approach was directed towards proof-of-concept demonstration of advanced point-of-manufacturing material bonding to improve adhesive joint performance subject to harsh environmental exposure. The assembled team, consisting of the researchers at the University of Illinois, end-users at General Motors and small business manufacturer Starfire Industries, successfully demonstrated a single, cost-effective, high-volume production process that meets the requirements of multi-material combinations relevant to the energy-intensive transportation industry (e.g. Al-steel, Mg-steel, Al-Mg and Al-CFRP joints for body-in-white structures) while eliminating offline pretreatment for Al and Mg alloy substrates that are energy intensive, have chemical waste disposal issues, and add cost. Technical demonstration of dissimilar material joining while maintaining bonding strength and cohesion after long-duration environmental exposure was accomplished for all materials of interest. This novel approach has broad applicability for manufacturing in automotive, aerospace, marine, railcar, and specialty consumer goods, etc.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Facile Dual-Protection Layer and Advanced Electrolyte Enhancing Performances of Cobalt-free/Nickel-rich Cathodes in Lithium-Ion Batteries

Despite cobalt (Co)-free/nickel (Ni)-rich layered oxides being considered as one of the promising cathode materials due to their high specific capacity, their highly reactive surface is one of the shortcomings that still hinder their practical usages in high-energy-density batteries. Herein, a polyimide/polyvinylpyrrolidone (PI/PVP, denoted as PP) coating layer is demonstrated as dual-protection for LiNi 0.96 Mg 0.02 Ti 0.02 O 2 (NMT) cathode material to suppress surface contamination against moisty air and to prevent unwanted side reactions between cathode and electrolyte during electrochemical cycling. The optimal PP-coated NMT (PP@NMT) preserves a clean surface without generation of lithium (Li) residues, structural degradation, and gas evolution after exposure to air with ~30% humidity for 2 weeks. Contrarily, the exposed bare NMT shows severe contamination, structural shrinkage due to Li loss, and increased gas release during charging. In addition, the exposed PP@NMT significantly enhances the electrochemical performance of graphite (Gr)||NMT cells by decreasing byproducts and maintaining structural stability. Moreover, the exposed PP@NMT achieves a high capacity retention of 86.7% after 500 cycles in Gr||NMT cells using an advanced localized high-concentration electrolyte. Furthermore, this work demonstrates a promising facile approach to the protection of Co-free/Ni-rich layered cathodes for their practical applications even after exposure to moisty air.

25 ENERGY STORAGE↗
DOE OSTI2025

Facile synthesis of co-doped Carbon nanofibers for supercapacitor applications

Here, in this study, the synthesis and electrochemical performance of carbon nanofibers (CNFs) co-doped with aluminum (Al) and nitrogen (N) and decorated with zinc oxide (ZnO) nanoparticles are investigated. After electrospinning polyacrylonitrile (PAN) nanofibers, the nanofiber mats are coated with Al and ZnO precursors by the dip coating method and converted into carbon nanofibers by thermal treatments at 850 °C. Co-doping and nanoparticle decoration affect the efficacy of carbon nanofibers as supercapacitors. With a maximal specific capacitance of 206.28 Fg -1 , it is believed that our produced carbon nanofibers, which can effectively store the renewable energy resources required to meet the rising energy demand, offer superior electrochemical properties compared to traditional supercapacitor materials. The effective incorporation of Al, N, and ZnO into the CNF structure, in conjunction with enhanced electrochemical performance, represents a significant advancement in the development of functional carbon nanofibers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Interface Coating Design for Dynamic Voltage Stability of Solid‐State Batteries

Abstract Intrinsic or interface thermodynamic voltage windows of solid electrolytes are often narrower than the operational voltage range needed by a full battery, thus various interface decomposition reactions can happen in a practical solid‐state battery. Experimentally, it is found that a proper battery design utilizing the reactions can lead to a dynamic evolution from interface instability to stability, giving the so‐called dynamic voltage stability for advanced battery performance. Here, first the state‐of‐the‐art understanding is articulated about how the dynamic voltage stability should be interpreted in physical picture and treated in computation, emphasizing the potential importance of nonequilibrium reaction pathways. The constrained ensemble computational approach is further applied across most types of solid‐state electrolytes to systematically evaluate and compare their dynamic stability voltage windows in response to the mechanical constriction effect. High‐throughput calculations are used to search for coating materials for different interfaces between sulfide, halide, and oxide electrolytes and typical cathode materials with enhanced dynamic voltage stability. A comparison with experiment is given to highlight the value of these computational predictions.

Wang, Yichao↗
DOE OSTI2021

Upgrade of the Materials Analysis Particle Probe (MAPP-U) to decipher the impact of lithium-based surfaces on NSTX-U plasma behavior

Understanding the plasma wall interaction (PWI) remains a critical issue for the feasibility of thermonuclear magnetic fusion energy solutions. Key issues with PWI mechanisms in fusion tokamak reactors include: evolution of surface chemistry and its role on hydrogen retention. In particular how low-Z coatings such as lithium can impact the behavior of plasma at the edge and in the core. PMI (plasma-material interactions) are particularly important for strategies that involve low-recycling regimes and the use of lithium PFS (plasma-facing surfaces) to attain them, as in the case of NSTX-U. Recent reports have indicated the importance of access to the evolving plasma-facing surface during and in-between plasma discharges. Changes in surface chemistry and morphology due to ion bombardment and the difficulty of diagnosing plasma-facing surfaces, especially reactive surfaces, complicate the development of a predictive understanding of the wall and its interaction with the plasma. Consequently, this impairs the ability to design advanced PFC materials for future plasma-burning fusion reactors and appropriate PMI code validation. The Materials Analysis Particle Probe (MAPP) is an established and on-going PMI probe diagnostic system compatible with the highly chemically reactive system of lithium and boron coatings adopted by the NSTX-U research program. MAPP is the first PMI diagnostic to capture the surface physics and chemistry in-vacuo in a fusion tokamak system and correlate this data to controlled plasma shots. Currently MAPP captures this information at a fixed radial location at the NSTX-U outboard divertor region. The MAPP diagnostic has enabled understanding of the near-surface and surface chemistry of complex evolving lithiated and borated carbon-based PFC surfaces retention and transport of hydrogen. Coupled to atomistic simulations in collaboration with P. Krstic of Stony Brook U. MAPP has been very successful in achieving high-impact scientific research in its current grant period evidenced by two invited review articles and over 20 peer-reviewed manuscripts and over 40 contributed and invited presentations at both national and international conferences.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Enhanced Laser-Induced Graphene Microfluidic Integrated Sensors (LIGMIS) for On-Site Biomedical and Environmental Monitoring

The convergence of microfluidic and electrochemical biosensor technologies offers significant potential for rapid, in-field diagnostics in biomedical and environmental applications. Traditional systems face challenges in cost, scalability, and operational complexity, especially in remote settings. Addressing these issues, laser-induced graphene microfluidic integrated sensors (LIGMIS) are presented as an innovative platform that integrates microfluidics and electrochemical sensors both comprised of laser-induced graphene. This study advances the LIGMIS concept by resolving issues of uneven fluid transport, increased hydrophobicity during storage, and sensor biofunctionalization challenges. Key innovations include Y-shaped reservoirs for consistent fluid flow, hydrophilic polyethyleneimine coatings to maintain wettability, and separable microfluidic and electrochemical components enabling isolated electrode nanoparticle metallization and biofunctionalization. Multiplexed electrochemical detection of the neonicotinoid imidacloprid and nitrate ions in environmental water samples yields detection limits of 707 nm and 10 -5.4 m with wide sensing ranges of 5–100 µm and 10 -5 –10 -1 m, respectively. Similarly, uric acid and calcium ions are detected in saliva, demonstrating detection limits of 217 nm and 10 -5.3 m with sensing ranges of 10–50 µm, and 10 -5 –10 -2.5 m, respectively. Overall, this biosensing demonstrates the capability of the LIGMIS platform for multiplexed detection in biologically complex solutions, with applications in environmental water quality monitoring and oral cancer screening.

environmental monitoring↗
DOE OSTI2025

Surface modification of cathode material enhances electrochemical performance in dry-processed Li-ion battery electrodes

The transition to electric vehicles (EVs) is pivotal for achieving energy security and integrating grid stability, with lithium-ion batteries (LIBs) playing a central role in this transformation. However, the conventional wet electrode manufacturing relying on N-methyl-2-pyrrolidone (NMP) solvent is energy intensive and costly. Dry processing (DP) has emerged as a promising alternative, eliminating solvents and using polytetrafluoroethylene (PTFE) binder for electrode fabrications. Despite its advantages, DP faces a critical challenge: poor interfacial adhesion between the hydrophobic PTFE binder and the hydrophilic cathode active material (CAM), particularly LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811), which undermines electrode performance. Here, to address this, we introduced a novel vapor-phase trimethoxymethylsilane (TMMS) coating to hydrophobize the CAM surface, enhancing compatibility with PTFE. This surface modification significantly enhances binder – CAM interactions, enabling uniform mixing and robust electrode integrity without damaging the CAM particles. Our findings advance the feasibility of environmentally sustainable and cost-effective dry processing, representing a significant step toward sustainable battery manufacturing.

Choi, Junbin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2025

Sn-InAs Nanowire Shadow-Defined Josephson Junctions

Hybrid superconductor–semiconductor platforms are foundational to advancing quantum information technologies, motivating the integration of materials with clean interfaces, robust superconductivity, and scalable architectures. Here, in this work, we report the synthesis and analysis of inclined InAs nanowires, conformally coated with β-Sn shells. These nanowires extend in opposite in-plane directions, forming a self-aligned, criss-cross network. This enables the deterministic formation of nanowire-shadow Josephson junctions through angle-controlled, low-temperature Sn deposition. Structural characterization shows uniform polycrystalline β-Sn shells forming a sharp, diffusion-free interface with InAs. Low-temperature transport measurements reveal a hard induced superconducting gap ≈ 600 μeV, switching currents up to ≈ 500 nA, and parallel magnetic field resilience beyond 1T. These results establish β-Sn/InAs nanowire networks as a promising platform for superconducting qubits, low-noise microwave devices, and the exploration of exotic superconducting phases including triplet pairing and topological superconductivity.

B-Sn↗
DOE OSTI2020

Advanced Accelerator Technology (Final Report)

Superconducting radio-frequency (SRF) acceleration, together with high precision RF field control and high precision beam instrumentation and control, is a key technology for future next generation accelerators. In the past 10 years, significant progress on these technologies has been made jointly at KEK and US laboratories. The research progress summarized here is Cornell University’s contribution to a continued US-Japan collaborative accelerator research effort. The combined objectives of this collaboration were to solve critical technical issues related to SRF acceleration technology, related to low emittance beam generation, and related to reducing the vertical beam size of the ATF2 final focus beam line. These joint efforts significantly advance current accelerator technologies. The specific objective of the Cornell University part of this collaboration was to develop, in close connection with KEK and FNAL, new SRF cavity Nb3Sn thin-film coating technologies for transformational cavity performance. Cornell is a world leader in the synthesis of Nb3Sn for SRF application, and has produced the first-ever next-generation non-niobium (i.e., Nb 3 Sn) prototype SRF accelerator cavities with cryogenic efficiency exceeding that of traditional niobium cavities. These next-generation Nb 3 Sn SRF cavities strongly reduce AC power consumption of SRF based accelerators, and also enable using greatly simplified cryogenic cooling infrastructure, thereby making SRF technology available to a much wider range of accelerator applications. During this project, Cornell has designed and started fabrication of a new Nb 3 Sn coating setup, which will be large enough to coat full-scale (i.e., multi-cell) SRF accelerator cavities. In addition, Cornell University has participated in other collaborative activities at KEK and partner US laboratories.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Engineering Approaches to Dendrite free Lithium Anodes

This is the Final Technical Report of the work that was completed related to development of dendrite free anodes for Li-metal batteries. The report contains full details of all the strategies that were employed to overcome this pernicious problems of dendrite formation of lithium metal during cycling of Li-metal and Li-ion batteries. Various approaches were developed to understand the formation of dendrites and mitigation strategies were then developed to overcome this severe problem. In doing so novel multi-component alloys as well as structurally isomorphous alloys have been developed. In addition coating strategies were also developed to overcome the formation of dendrites. The novel approaches related to development of novel alloys using economic cost effective and scalable approaches. The new approaches will easily advance the science of lithium metal alloys and dendrite free anodes including current collectors. Development of this new technology will have immense benefit to providing new high energy density batteries of tremendous benefit to the public since cost effective and safe high energy density batteries will be possible with this new technology.

25 ENERGY STORAGE↗
DOE OSTI2024

Report on RIA Relevant Modified Burst Testing of ATF Cladding Materials

The mechanical performance of accident-tolerant fuel (ATF) cladding candidates in light-water reactors (LWRs) must be similar to or better than that of current conventional nuclear fuel claddings to reduce dose to the public and ensure a that the core coolable geometry is maintained during a postulated reactivity-initiated accident (RIA) in light-water reactors (LWRs). During an RIA event, the rapid thermal expansion of nuclear fuel can deform the cladding once the fuel–cladding gap closes. In some cases, the pellet–cladding mechanical interaction (PCMI) can induce mechanical failure in ATF candidates. Thus, the mechanical response of ATF cladding must be investigated by mimicking the conditions of RIA and potentially performing Transient Reactor Test (TREAT) experiments to establish or verify the safety envelope. The work presented in this report investigated the failure behavior of as-received, hydrided, and chromium-coated (Cr-coated) Zircaloy-4 (Zry-4) cladding tube under strain-driven mechanical conditions, mimicking postulated RIA loading conditions. Mechanical testing was performed at 300°C via modified burst test (MBT) equipment with pulse width control previously developed under the Department of Energy’s (DOE’s) Advanced Fuel Campaign (AFC). The mechanical strains were determined using 2D digital image correlation (DIC) techniques. The base Zry-4 acquired by Cameco Inc. was in stress-relieved annealed (SRA) condition. Because of the observed large deformation of the cladding tubes, the failure strain definition was updated for the MBT, which can also be applied to other tube tests where significant bulging (out-of-plane deformation) is present. The failure strain was determined to be affected by the speed of the test or the RIA event. As the RIA-like event duration decreased from 75 to 15 ms, the failure strain decreased 5, 7 and 1% for as-received, hydrided, and Cr-coated specimens, respectively. Fractography on the Cr-coated specimens indicated the presence of two failure mechanisms: (i) crenulation at the outer surface of the coating due to the tensile tractional forces along with coatings grain microstructure and (ii) formation of critical defect at the coating/cladding interface that initiated coating rupture after severe plastic deformation of the Zry- 4 substrate. Based on the MBT results and fractography observations, performing mechanical property testing at high strain rates—in particular on Cr-coated tubes—and semi-integral TREAT experiments are required future efforts to ensure ATF cladding performance during transients. The testing recommended would also inform the development of long-term generalized cladding technologies.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗