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This report highlights some of our overarching successes and quantifies the impacts achieved by this program over five years and two presidential administrations. We are proud to say that American-Made has come a long way since its inception, but there is more work to be done. We hope you will not only celebrate our shared successes, but also join us to lay the groundwork for the next stages of the clean energy revolution.
To evaluate the potential of Sonic Wafering(TM), a new manufacturing method that may lower the cost of high-efficiency photovoltaic materials. This work is to be conducted in support of the Department of Energy’s American Made Challenges Solar Prize.
Hydrothermal liquefaction (HTL) has potential for converting abundant wet organic wastes into renewable fuels. Because HTL consists of a complex reaction network, deterministic, physics-based prediction of its biocrude yield is prohibitively difficult. Data-driven methods provide an alternative to the physics-based approach; however, rigorous testing must be performed to ensure the accuracy of predictions made by data-driven methods. To this end, a data set was assembled consisting of 570 data points appearing in the open literature. The data set was divided into training, validation, and test sub-sets and used for evaluating different machine learning regression approaches to predict biocrude yield. Among the tested algorithms, Random Forest and eXtreme Gradient Boosting (XGBoost) predicted biocrude yields in a test set that had not been used for training with the greatest accuracy, with root mean square errors (RMSE) of 8.34 and 8.57, respectively. Further refinement of the Random Forest model reduced its RMSE to 8.07. In comparison, predictions of a series of literature models resulted in RMSE ranging from 9.16 in the most accurate case to 27.6 in the least accurate; most literature models yielded RMSE values > 10. Using biocrude yield predictions from the most accurate Random Forest model and a probabilistic economic analysis found that the model accuracy is sufficient to prioritize allocation of resources based on projected minimum fuel selling price. In our report the models and analysis represent a major advance in the ability to use readily available data to predict biocrude yields on new feedstocks that have not previously been studied.
The Hygroscopic Tandem Differential Mobility Analyzer (H-TDMA) measures the hygroscopicity of atmospheric particles, and many atmospheric processes that change this hygroscopicity also change the atmospheric size distribution. Two assumptions made during H-TDMA inversion create spurious hygroscopic trends as a function of the changing inlet size distribution. These two assumptions—that the particles exiting the first Differential Mobility Analyzer (DMA1) are singly charged and that the inlet size distribution has a slope of zero (flat)— generate Multi-Charge Dispersion (MCD) bias and Slope bias, respectively. First, we use a model, named TAO, to show that the inlet size distribution could theoretically change the measured ammonium sulfate hygroscopicity by 10%–20% as a function of diameter or experimental time with no change in relative humidity. Secondly, we show experimentally that aerosol emitted from the flaming combustion of grass creates MCD bias. Here, in this experiment, we measure the CPC response of the first three charges and invert these responses using a new routine named Junior. Junior's inversion of each charge shows that one growth factor distribution describes all measured diameters (no growth dependence on diameter). As in the modeling study above, previous publications of this aerosol system, using traditional inversion assumptions, report a decrease in hygroscopicity as DMA1 diameter increases. Unlike traditional inversions, Junior's inversion does not assume the particles are singly charged nor does it make the flat inlet size distribution assumption. Instead, both the inlet size distribution and each charge's CPC response are measured quantities. Thus, the discrepancy between our inversion results and previous publications is likely due to the traditional inversion routine assumptions. This underscores the importance for accounting for Slope and MCD bias during inversions. Experimental results should be carefully analyzed when reporting hygroscopic trends with respect to diameter or experimental time when using the traditional inversion assumptions.
Structural materials used in the next generation nuclear reactors or other advanced energy systems are often required to withstand higher operating temperatures for a longer service life. Alloy 709 (A709), a Nb-containing and N-stabilized Fe-25Ni-20Cr austenitic stainless steel, has been recommended for high-temperature reactor constructions due to the better performance over the baseline Type 316H stainless steel. Here, in the current manuscript, for the first time, the microstructure evolution and tensile behavior of an A709 made by laser powder bed fusion (LPBF) is discussed. The as deposited and heat treated LPBF alloys are compared with a reference wrought alloy. Owing to the chemical segregation and a higher number of dislocations, the LPBF materials show a significantly higher density of precipitates formed during high temperature treatments when compared to the wrought samples. This is reflected when looking at the tensile properties, both at room and elevated temperatures, where LPBF samples show higher strengths compared to wrought materials.
The polymer brush architecture of the end-tethered polymer molecules is one of the most widely used efficient methods to regulate interfacial interactions in colloidal systems found in live matter and manufactured materials. Emerging applications of polymer brush structures require solutions to new tasks in the control of interfacial interactions. The rapid development of live cell manufacturing relies on scalable and efficient cell harvesting methods. Stimuli-responsive surfaces made of surface-grafted poly(N-isopropylacrylamide) (PNIPAM) can bind and detach the adherent cell upon changes in temperature and have been used for cell growth and harvesting. The applications are limited by the requirement to satisfy a range of PNIPAM coating characteristics that depend on the dimensions of the integrin complex in the cell membrane and the basal surface. The analysis of the microstructured surfaces, when adhesive and disjoining functions of the microdomains are decoupled, shows that many limitations of PNIPAM one-component coatings can be avoided by using a much broader range of structural characteristics of the microstructured interfaces composed of alternating disjoining PNIPAM domains and adhesive polymeric domains with cell-affinity functional groups. Temperature-controlled reversible adhesion to such microstructured interfaces is studied here experimentally with model systems of solid spherical particles and by employing simulations for solid and soft membranes interacting with the microstructured surfaces to mimic interactions with soft and solid disk-like particles.
Two-dimensional monolayer structures of transition metal dichalogenides (TMDs) have been shown to allow many higher-order excitonic bound states, including trions (charged excitons), biexcitons (excitonic molecules), and charged biexcitons. Here, we report here experimental evidence and the theoretical basis for a new bound excitonic complex, consisting of two free carriers bound to an exciton in a bilayer structure. Our experimental measurements on structures made using two different materials show a new spectral line at the predicted energy with two different TMD materials (MoSe 2 and WSe 2 ) with both n- and p-doping, if and only if all the required theoretical conditions for this complex are fulfilled, in particular, only in the presence of a parallel metal layer that significantly screens the repulsive interaction between the like-charge carriers. Because these four-carrier bound states are charged bosons, they could eventually be the basis for a new path to superconductivity without Cooper pairing.
Perovskite nanocrystals are exceptional candidates for light-emitting diodes (LEDs). However, they are unstable in the solid film and tend to degrade back to the bulk phase, which undermines their potential for LEDs. Here we demonstrate that perovskite nanocrystals stabilized in metal–organic framework (MOF) thin films make bright and stable LEDs. The perovskite nanocrystals in MOF thin films can maintain the photoluminescence and electroluminescence against continuous ultraviolet irradiation, heat and electrical stress. As revealed by optical and X-ray spectroscopy, the strong emission originates from localized carrier recombination. Bright LEDs made from perovskite-MOF nanocrystals are demonstrated with a maximum external quantum efficiency of over 15% and a high brightness of over 10 5 cd m -2 after the device reaches stabilization. During LED operation, the nanocrystals can be well preserved, free of ion migration or crystal merging through protection by the MOF matrix, leading to a stable performance over 50 hours.
A slight deformation of a double gyroid structure of a cubic Ia 3̄ d phase results in the formation of a phase with an orthorhombic Pcab symmetry. The phase seems to be an intermediate state towards a columnar phase made of helical pillars.
A very low thermal conductivity and moisture stable composite made of hollow silica particles and cellulose fibers.
The effect of oxygen partial pressure on the structure, morphology, chemical bonding, and optical properties of Ga–W–O films made by pulsed laser deposition is evaluated. Conditions were optimized to realize materials for deep UV-photodetectors.
We present a combined Brillouin light scattering (BLS) and micromagnetic simulation investigation of the magnetic-field-dependent spin-wave spectra in a hybrid structure made of permalloy (NiFe) artificial spin-ice (ASI) systems, composed of stadium-shaped nanoislands, deposited on the top of an unpatterned permalloy film with a nonmagnetic spacer layer. The thermal spin-wave spectra were recorded by BLS as a function of the magnetic field applied along the symmetry direction of the ASI sample. Magneto-optic Kerr effect magnetometry was used to measure the hysteresis loops in the same orientation as the BLS measurements. Here, the frequency and the intensity of several spin-wave modes detected by BLS were measured as a function of the applied magnetic field. Micromagnetic simulations enabled us to identify the modes in terms of their frequency and spatial symmetry and to extract information about the existence and strength of the dynamic coupling, relevant only to a few modes of a given hybrid system. Using this approach, we suggest a way to understand if the dynamic coupling between ASI and film modes is present or not, with interesting implications for the development of future three-dimensional magnonic applications and devices.
Significance Reaction centers (RCs) are critical to photosynthetic energy conversion. RCs in all characterized photosynthetic organisms contain two symmetrically arranged branches of chromophores and enable light-induced electron transfer with high yield. We fine-tune the properties of a key bacterial RC symmetry-breaking tyrosine via its replacement with noncanonical tyrosine analogs and determine kinetic outcomes. Results are interpreted through energetic characterization made possible by resonance Stark spectroscopy. Analysis indicates this tyrosine modulates the mechanism of the initial light-induced electron transfer, affording an alternative functional pathway that maintains the RC’s robust electron transfer. Modern molecular biology, ultrafast spectroscopy, crystallography, and energetic characterization enable the mechanistic model we describe. Our results deepen understanding of RC function and may have implications for other photocatalysts and enzymes.
REBa 2 Cu 3 O 7-δ (REBCO, RE = rare earth) tapes with high critical current can be very impactful in high magnetic field applications at low temperatures and power applications at high temperatures. A pilot-scale Advanced Metal Organic Chemical Vapor Deposition (MOCVD) method was used to fabricate 50-m-long, 4+μm-thick REBCO tape in a single pass. Critical currents 3.3x that of commercial HTS tapes were achieved at 20 K, 12 T in these 50-m-long tapes. An in-line 2D X-ray Diffraction (XRD) system has been used to assess the quality of the long tapes in real-time, during manufacturing. The key peaks of REBCO, REO, and BZO phases were identified and utilized for tape quality analysis. Furthermore, a 20-m tape made by Advanced MOCVD was tested over its entire length by reel-to-reel (R2R) scanning Hall-probe microscopy (SHPM) at 65 K, 0.25 T, 2 T, and 4 T. 4-mm-wide strands of Advanced MOCVD tapes showed mean critical currents at 65 K of 530 A, 200 A, and 104 A at 0.25 T, 2 T, and 4 T respectively. The combined use of in-line and offline characterization techniques provides a reliable approach for assessing long REBCO tapes during manufacturing, serving as an effective feedback source for quality control in scaled-up REBCO tape deposition processes. This advancement contributes to the production of longer and more uniform high-performance REBCO tapes for large-scale, high-field superconducting applications
Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. Here, in this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed.
Currently, fine grain niobium (Nb) (grain size ~ 50 um) and large grain Nb (grain size of a few cm) are being used for the fabrication of superconducting radio frequency (SRF) cavities. Medium grain forged ingot with grain size of a few hundred um may be beneficial for cost-effectiveness as well as providing better performance for future SRF-based accelerators. Forged ingot Nb with medium grain size is a novel production method to obtain Nb discs used for the fabrication of superconducting radio frequency cavities. We have fabricated two 1.5 GHz single cell cavities made from forged Nb ingot with a residual resistivity ratio of ~100. The cavities were chemically and mechanically polished and heat-treated in the temperature range of 650-1000 C before the rf test. One of the cavities reached an accelerating gradient of 34 MV/m with a quality factor Q > 1e10, while the second cavity was limited at 14 MV/m, likely due to a weld defect at the equator.
Trapped residual magnetic field during the cool down of superconducting radio frequency (SRF) cavities is one of the primary sources of RF residual losses leading to lower quality factor. Historically, SRF cavities have been fabricated from high purity fine grain niobium with grain size ~50 to 100 µm as well as large grain with grain size of the order of few centimeters. Non-uniform recrystallization of fine-grain Nb cavities after the post fabrication heat treatment leads to higher flux trapping during the cool down, and hence the lower quality factor. We fabricated two 1.3 GHz single cell cavities from cold-worked niobium from different vendors and processed along with cavities made from SRF grade Nb. The flux expulsion and flux trapping sensitivity were measured after successive heat treatments in the range 800 to 1000°C. The flux expulsion from cold-worked fine-grain Nb cavities improves after 800°C/3h heat treatments and it becomes similar to that of standard fine-grain Nb cavities when the heat treatment temperature is higher than 900°C.
This report documents the technical assistance provided to Orison as part of the American-Made Challenges Round 2 Voucher: Orison Enables Solar project. A testbed was developed and used to demonstrate, using modeling and simulation, the capability of controlled behind-the-meter energy storage to (1) reduce net load variability caused by appliances and distributed generation and (2) enable customers to respond to the time-of-use pricing. We demonstrate that load leveling can shave peak loads or limit solar photovoltaic export and that load shifting enables customers to reduce load during “peak” pricing intervals. In the scenarios that we simulated, load leveling was effective up to the charging and discharging limits of the storage systems and the effectiveness of load shifting was a function of the energy capacity of the storage systems. This report describes the co-simulation testbed and the scenarios simulated, including controller setup and simulation results. Considerations for a multi-objective controller are also discussed.