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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Flexural Fatigue Testing and Qualification of Hybrid PAN-pitch Composite Materials with High Through-Thickness Thermal Conductivity

Carbon-fiber-reinforced polymers (CFRPs) considered for motor components within future electric vertical takeoff and landing (eVTOL) vehicles require not only a high strength-to-weight ratio but also a high through-thickness thermal conductivity (TC) to dissipate heat. Previously, CFRPs incorporating pitch CF interleaves demonstrated an increased through-thickness TC relative to the baseline composite, but the effect on flexural fatigue life was not evaluated. For this work, T700S/TC275–1 braided carbon fiber/epoxy prepreg baseline (no interleave), YSH–60A pitch interleave, and YS–80A pitch interleave configurations were tested for fatigue life. A combination of ASTM International Standards D7264 and D3479 were used to develop a reliable testing method. An Instron® (Illinois Tool Works Inc.) 8501 servohydraulic system with a fatigue test fixture was set up with a 16:1 span:thickness ratio, load ratio R set to 0.1, and frequency of 4 Hz. High-cycle fatigue testing was completed, and it was found that YSH–60A interleave performed slightly better than YS–80A below 100,000 cycles but showed no differences above 100,000 cycles. In all cases, the baseline CFRP had superior fatigue life performance both in terms of stress handled and total cycles to failure. These fatigue testing data will inform future use of hybrid CFRP materials by highlighting the tradeoff between increased through-thickness TC and fatigue life. Testing guidelines, equipment, and parameters for static and fatigue tests were successfully outlined for CFRPs.

composites↗
DOE OSTI2022

16.52% Efficiency All-Polymer Solar Cells with High Tolerance of the Photoactive Layer Thickness

All-polymer solar cells (all-PSCs) have drawn growing attention and achieved tremendous progress recently, but their power conversion efficiency (PCE) still lags behind small-molecule-acceptor (SMA)-based PSCs due to the relative difficulty on morphology control of polymer photoactive blends. Here, in this work, low-cost PTQ10 is introduced as a second polymer donor (a third component) into the PM6:PY-IT blend to finely tune the energy-level matching and microscopic morphology of the polymer blend photoactive layer. The addition of PTQ10 decreases the π–π stacking distance, and increases the π–π stacking coherence length and the ordered face-on molecular packing orientation, which improves the charge separation and transport in the photoactive layer. Moreover, the deeper highest occupied molecular orbital energy level of the PTQ10 polymer donor than PM6 leads to higher open-circuit voltage of the ternary all-PSCs. As a result, a PCE of 16.52% is achieved for ternary all-PSCs, which is one of the highest PCEs for all-PSCs. In addition, the ternary devices exhibit a high tolerance of the photoactive layer thickness with high PCEs of 15.27% and 13.91% at photoactive layer thickness of ≈205 and ≈306 nm, respectively, which are the highest PCEs so far for all-PSCs with a thick photoactive layer.

14 SOLAR ENERGY↗
DOE OSTI2020

Modeling of deformation of battery cells using thick shell element formulation

Here, we describe a new approach for modeling nonlinear deformation and stress distribution of battery cells using a new thick shell finite element formulation with a through-thickness calculation of stresses and strains that satisfy equilibrium conditions. Battery cells are transversely layered materials that contain numerous thin layers in a repeating sequence. The layers are made of materials with significantly different mechanical responses. Explicit discretization of the layers is computationally impractical except for very small domains, while homogenized material models cannot account for stress and strain variations and partition through the thickness. The new formulation allows for calculation of the transverse and interlayer stresses based on the material properties of the individual cell layers. The application to problems where the transverse stresses have strong influence is also possible.

25 ENERGY STORAGE↗
DOE OSTI2022

Coupling of multiscale imaging analysis and computational modeling for understanding thick cathode degradation mechanisms

Here, using a thick NMC811 (LiNi 0.8 Mn 0.1 Co 0.1 O 2 ) electrode as an example, we present a macro- to nanoscale 2D and 3D imaging analysis approach coupled with 4D (space + time) computational modeling to probe its degradation mechanism in a lithium-ion battery cell. Particle cracking increases and contact loss between particles and carbon-binder domain are observed to correlate with the cell degradation. This study unravels that the reaction heterogeneity within the thick cathode caused by the unbalanced electron conduction is the main cause of the battery degradation over cycling. The increased heterogeneity in the system will entail more cathode regions where the degree of active material utilization is uneven, leading to higher probabilities of particle cracking. These findings shed light on the crucial role of the electronic and ionic transportation networks in the performance deterioration of the thick cathode. They also provide guidance for cathode architecture optimization and performance improvement.

25 ENERGY STORAGE↗
DOE OSTI2021

Impact of electrode porosity architecture on electrochemical performances of 1 mm-thick LiFePO4 binder-free Li-ion electrodes fabricated by Spark Plasma Sintering

Thick electrodes with high active material loadings have been intensively studied over the last couple of decades in pursuit of achieving high energy density systems. To optimize and enhance the electrochemical performance of such electrodes, one has to control the pore morphology by, for example, varying the pore size and shape, and the level of porosity. In the present work, the fabrication of thick binder-free LiFePO4 (LFP) electrodes with two different pore sizes (12 and 20 mu m) and porosities (21 vol% and 44 vol%) using Spark Plasma Sintering (SPS) and templating approach is reported. The well-controlled porous architecture inside the thick electrodes is realized by fine-tuning experimental parameters. The impact of porosity architecture on electrochemical performance is quantified and correlated with the 3D tortuosity values determined from both micro-computed tomography and electrochemical impedance-based experimental methods. Based on the micro-computed tomography data analysis, estimated tortuosity values along X, Y, and Z axes reveal an anisotropic effect perpendicularly to the SPS compression axis (Z-direction). This is particularly profoundly observed in the samples with larger pores (20 mu m). The correlation between morphological properties and the rate capability performance is established indicating that the capacity loss happens mainly due to the Li-ion diffusion limitations.

Cathode material↗
DOE OSTI2021

Impact of secondary particle size and two-layer architectures on the high-rate performance of thick electrodes in lithium-ion battery pouch cells

Increasing lithium-ion battery gravimetric energy density to > 300 Wh/kg, while simultaneously meeting a cost target of $80/kWh, is of paramount importance to increasing the driving range and affordability of electric vehicles. One way to address this goal is to reduce inactive components by increasing electrode areal capacities, but conventional thick electrode designs typically perform poorly at high discharge rates due to Li + mass transport limitations. Here we compare the rate capability and cycle life of NMC 532/graphite pouch cells made with five different thick cathode and anode designs paired together in 25 combinations. We find that using different particle sizes to structure both the cathode and anode architectures in two-layer configurations results in a 2X capacity improvement over the worst-performing combination at high discharge rates (97 vs. 46 mAh/g at 2C). These different cathode/anode designs also translate to different cycle life performance, with many cells cycled at C/2 achieving ~80% capacity retention after 1000 cycles, and cells cycled at 2C showing different degrees of capacity fade. Altogether, these results demonstrate that simple, scalable changes in electrode design can significantly improve the performance of thick electrodes for high energy density batteries.

25 ENERGY STORAGE↗
DOE OSTI2023

High-speed friction stir butt welding of 25.4 mm thick 7175-T79 aluminum alloy

This presents the first experimental demonstration of friction stir butt welding of 25.4 mm thick high-strength, precipitate-strengthened 7XXX aluminum alloy at a welding speed above 500 mm/min and penetration depth greater than 10 mm. Tool pin threads that terminate away from the shoulder region, helped mitigate nearby stress concentration during tool traversing, enabling a higher welding speed while avoiding pin fracture near shoulder. Two kinds of welds—one-sided with full penetration of the plate thickness and double-sided with partial penetration of the plate thickness—were conducted. Significant grain refinement (grain size 1.3 ± 0.8 µm) was evident at the junction of double-sided friction stir welding (FSW) compared to other regions of weld-nugget or base material. Cross-weld tensile testing with digital image correlation revealed high local strains at the junction of double-sided FSW before macro-yield. This strain concentration impeded the typical early necking on advancing/retreating sides of FSW joints, improving the yield strength of as-welded double-sided FSW by 20–24% over slow- to medium-speed one-sided FSW. In conclusion, the joint efficiency of as-welded, double-sided high-speed FSW was about 76% with respect to the base material’s ultimate tensile strength.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Spatiotemporal Imaging of Thickness-Induced Band-Bending Junctions

van der Waals materials exhibit naturally passivated surfaces and an ability to form versatile heterostructures to enable an examination of carrier transport mechanisms not seen in traditional materials. Here, we report a new type of homojunction termed a "band-bending junction" whose potential landscape depends solely on the difference in thickness between the two sides of the junction. Using MoS 2 on Au as a prototypical example, we find that surface potential differences can arise from the degree of vertical band bending in thin and thick regions. Furthermore, by using scanning ultrafast electron microscopy, we examine the spatiotemporal dynamics of charge carriers generated at this junction and find that lateral carrier separation is enabled by differences in the band bending in the vertical direction, which we verify with simulations. As a result, band-bending junctions may therefore enable new optoelectronic devices that rely solely on band bending arising from thickness variations to separate charge carriers.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Thickness-Dependent Interlayer Charge Transfer in MoSe 2 /MoS 2 Heterostructures Studied by Femtosecond Transient Absorption Measurements

We report observations of a strong thickness dependence for charge transfer (CT) from MoSe 2 to MoS 2 , as evidenced by transient absorption measurements. By time-resolving CT from MoSe 2 monolayers (1Ls) to MoS 2 flakes of varying thicknesses, including 1L, bilayer (2L), and trilayer (3L), we find that the CT time is several picoseconds in the 1L-MoSe 2 /3L-MoS 2 heterostructure, which is much longer than that of 1L-MoSe 2 /1L-MoS 2 and 1L-MoSe 2 /2L-MoS 2 heterostructures. In addition, the recombination lifetime of the interlayer excitons in the 1L/3L heterostructure is several times longer than that of 1L/1L and 1L/2L heterostructures, reaching 800 ps. Furthermore, we show that a prepulse can reduce the CT time and enhance the interlayer exciton recombination in the 1L/3L heterostructure. Furthermore, these findings illustrate that layer thickness can be an important parameter to control the CT property of van der Waals heterostructures. These experimental results also provide important information for further refining the understanding of the physical mechanisms of CT in van der Waals heterostructures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Evidence That Sharp Interfaces Suppress Recombination in Thick Organic Solar Cells

Commercialization and scale-up of organic solar cells (OSCs) using industrial solution printing requires maintaining maximum performance at active-layer thicknesses >400 nm – a characteristic still not generally achieved in non-fullerene acceptor OSCs. NT812:PC71BM is a rare system whose performance increases up to these thicknesses due to highly suppressed charge recombination relative to the classic Langevin model. The suppression in this system, however, uniquely depends on device processing, pointing towards the role of nano-morphology. We investigate the morphological origins of this suppressed recombination by combining results from a suite of X-ray techniques. We are surprised to find that while all investigated devices are composed of pure, similarly aggregated nanodomains, Langevin reduction factors can still be tuned from ~2 to >1000. This indicates that pure aggregated phases are insufficient for non-Langevin (reduced) recombination. Instead, we find that large well-ordered conduits and, in particular, sharp interfaces between domains appear to help to keep opposite charges separated and percolation pathways clear for enhanced charge collection in thick active layers. To our knowledge, this is the first quantitative study to isolate donor/acceptor interfacial width correlated to non-Langevin charge recombination. Furthermore, this new structure-property relationship will be key to successful commercialization of printed OSCs at scale.

14 SOLAR ENERGY↗
DOE OSTI2022

Soil thickness map at two hillslopes near the pumphouse in the east river watershed, Colorado

The soil thickness maps were created by using a hybrid model-data approach. Field sampling and remote sensing data of the spatial distribution of two hillslopes in the Pump House area in the East River Watershed in the CO., the U.S. The data package includes the geospatial data of the soil thickness maps at two hillslopes near the pumphouse, and the associated remote sensing data, including lidar DEM and a shape file of the boundary of the study area. The data can be viewed in GIS software such as QGIS or ArcGIS desktop. The geospatial data can also be viewed in Python or Matlab. The data were generated for the purpose of modeling surface hydrology and near-surface chemistry. This work shows how to combine sampling data and a process-based model to predict one of the highest uncertainty in the land surface process, the soil thickness.

2D Geospatial Maps↗
NASA NTRS2013

Sea Ice Thickness, Freeboard, and Snow Depth products from Operation IceBridge Airborne Data

The study of sea ice using airborne remote sensing platforms provides unique capabilities to measure a wide variety of sea ice properties. These measurements are useful for a variety of topics including model evaluation and improvement, assessment of satellite retrievals, and incorporation into climate data records for analysis of interannual variability and long-term trends in sea ice properties. In this paper we describe methods for the retrieval of sea ice thickness, freeboard, and snow depth using data from a multisensor suite of instruments on NASA's Operation IceBridge airborne campaign. We assess the consistency of the results through comparison with independent data sets that demonstrate that the IceBridge products are capable of providing a reliable record of snow depth and sea ice thickness. We explore the impact of inter-campaign instrument changes and associated algorithm adaptations as well as the applicability of the adapted algorithms to the ongoing IceBridge mission. The uncertainties associated with the retrieval methods are determined and placed in the context of their impact on the retrieved sea ice thickness. Lastly, we present results for the 2009 and 2010 IceBridge campaigns, which are currently available in product form via the National Snow and Ice Data Center

sea ice thickness↗
DOE OSTI2020

Erosion-Corrosion Detection in Carbon Steel Pipe Loops using SRNLs Thickness and Mass Loss Measurement Coupons - 20464

Structural health of waste transfer infrastructure is of utmost importance to DOE and communities surrounding their active sites. A Fitness-for-Service (FFS) program for the Waste Transfer System has been implemented by the US Department of Energy (DOE) for the purposes of evaluating and quantifying the degradation of critical components. Currently, the method of approach is to section and evaluate pipelines that have been removed at end service. In order to augment data collection methods applied to making lifespan estimates of waste transfer system components, Florida International University (FIU) has been investigating new-technology based strategies for quantifying the rate of degradation. Present research considers the option of a coupon system installed on a section of pipe at points of interest that will provide easy access to high resolution measurements of erosion/corrosion rates during operation. Researchers at Savannah River National Laboratory (SRNL) have developed this novel solution for in situ erosion and corrosion measurements in many applicable locations such as tanks, pipes, ducts, and injection points. The coupons are approximately 12.7 mm (1/2 inch) in diameter and 25.4 mm (1 inch) in length and can be placed in the pipe sections using Swagelok compression fittings. The coupon design allows for monitoring of the total degradation resulting from corrosion and erosion. High-resolution Ultrasonic Thickness (UT) testing allows in-situ monitoring of both degradation mechanisms. When removed from the system mass loss resulting from corrosion and erosion may also be evaluated. Experimental testing at FIU implemented the SRNL coupon system in a 6.10 meter (20 foot) pipe loop system comprised of 50.8 mm (2 inch) and 76.2 mm (3 inch) pipe sections in order to replicate expected use cases at the sites. Operational conditions were emulated by pumping abrasive materials through the pipeline at full capacity and collecting measurements from the SRNL coupons. Initial testing was conducted by circulating water followed by a mixture of sand and water for uniform wear rates. Thickness changes and mass loss were measured, and the surface exposed to the process fluid was observed for visual evidence of characteristic wear patterns resulting from an erosive environment. The test matrix consisted of several hours of operation and using fine, medium and coarse grain sands. Test results were analyzed to check for all three parameters (mass loss/gain, thickness change and surface patters) which could provide estimates of the remaining useful life of the pipe sections. Thus, the research presents the findings of this evaluation of the SRNL coupons as a means for conducting high accuracy, cost effective in-situ analysis of pipeline and waste transfer systems for erosion and corrosion susceptibility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Growth of Crystallographically Aligned PbSe Films of Controlled Thickness on Amorphous Substrates

Lead selenide (PbSe) has extensively been investigated due to its thermoelectric and photoconductive properties. More recently, predictions of emergent properties have focused synthetic efforts on preparing ultra-smooth layers of crystallographically aligned PbSe layers with a thickness equal to an integer number of monolayers. While rough films are typically formed through Volmer-Weber growth on heated substrates, we report the data presented herein indicates that a crystallographically aligned, ultrathin layer with a defined number of PbSe layers forms on mostly amorphous Mo-Se and V-Se coated Si substrates during nominally room temperature deposition. Since the films are uniform in thickness, the number of PbSe bilayers formed depends on the amount of Pb (or Se) deposited. If the amount of Pb deposited is close to that required for an integral number of unit cells and there is sufficient Se, Laue oscillations are present in the as-deposited samples. The Laue oscillations reflect the quality and uniformity of the crystalline PbSe domains. This study demonstrates that the substrate does not need to be crystalline to form uniform, crystallographically aligned, integer monolayer thick PbSe films. These results suggest that tuning the strength of interactions be-tween substrate and growing film is necessary to form smooth, crystallographically aligned layers. The substrate does not need to be crystalline for these interactions to be strong enough to enable growth of crystallographically aligned films.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thickness threshold study of polyaniline-based lightning strike protection coating for carbon/glass fiber reinforced polymer composites

Different polyaniline (PANI) based lightning strike protection (LSP) coating thicknesses were tested against simulated lightning strike tests to evaluate the threshold thickness of the coating. A series of lightning strike tests were performed on carbon/glass fiber reinforced polymer (CFRP/GFRP) composites subjected to simulated lightning currents ranging from 40 to 100 kA. Five LSP-coated specimens were considered herein: two CFRP and three GFRP composites. A minimum of ~ 345 μm thick PANI-based LSP coating on CFRP and GFRP composites under a 40 kA peak current retained 83 % and 100 % residual strength, respectively. Additionally, GFRP specimens tested against 60 and 100 kA peak currents exhibited 100 % residual strength. Finally, this study proposes that a PANI-based LSP coating is suitable for protecting GFRP composites, while the careful design is necessary for CFRP composites to avoid any catastrophic failure.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A New Simultaneous Membrane Thickness and Catalyst Loading Measurement for Fuel Cell Proton-Exchange Assemblies by $\mathrm{IR}$ Transmission

Here, we present a study of mid-infrared (mid-IR) transmission through typical proton-exchange fuel cell and water electrolyzer catalyst-coated membrane materials, and the determination of membrane layer thickness, and catalyst layer loading, from the power of the transmitted beam. Measured membrane thicknesses lay in the range of 25-125 um, and catalyst areal loadings range from 0.05 to 0.35 mg/cm 2 . We show that the transmission spectrum correlated to membrane thickness and catalyst loading values separately, and also used a mathematical model to calculate both quantities simultaneously, from a single measurement of transmission. Measurements were carried out using a Fourier-transform infrared (FTIR) spectrometer, in specular transmission mode, in the wavelength range of 3-13 um (3333-770 cm -1 ). We discuss the potential application of this method to the development of roll-to-roll manufacturing full-area-scanning quality inspection of catalyst-coated membrane (CCM) materials.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Determination of film thicknesses of metal oxides prepared by atomic layer deposition on SBA-15

ZrO 2 and CeO 2 films were grown in SBA-15 by Atomic Layer Deposition (ALD) to loadings of 0.92 g oxide/g SBA-15. Scanning Transmission Electron Microscopy (STEM) with Energy Dispersive Spectra (EDS) showed that the oxides grew uniformly inside the mesopores. Film thicknesses were then analyzed as a function of the number of ALD cycles using three methods: 1) mass changes assuming bulk densities for the films; 2) changes in pore size from Barret-Joyner-Halenda (BJH) analysis with N 2 adsorption isotherms; and 3) small-angle X-ray scattering (SAXS). Film thicknesses assuming bulk densities were between 6 and 8 times smaller than those obtained from BJH analysis. SAXS analysis gave film thicknesses that were approximately twice that obtained from bulk densities. Here, possible explanations of the discrepancies between these methods are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Stress evolution and thickness change of a lithium-ion pouch cell under various cycling conditions

We report to design large-sized lithium-ion battery modules for the application of electric vehicles and grid-level energy storage, it is of important significance to understand how stress and dimension of a single pouch cell fluctuate during charge/discharge cycles. In this study, stress evolution under the constant-thickness condition and thickness change under the constant-stress condition are measured for in-house fabricated pouch cells, respectively. The results of stress measurements show that the stress increase percentage generally decreases when the charge/discharge current increases, regardless of the value of the initial compressive stress. With the same current density, the stress increase percentage generally increases when the upper cutoff voltage increases. With the same current density and upper cutoff voltage, the stress increase percentage decreases when the initial compressive stress increases. The results of thickness measurements show that the volume expansion percentage generally increases when the current density increases, regardless of the value of the constant compressive stress. With the same current density, the volume expansion percentage generally increases when the upper cutoff voltage increases. With the same current density and upper cutoff voltage, the volume expansion decreases when the constant compressive stress increases. The results provide important insights into the design principles of battery packs.

25 ENERGY STORAGE↗