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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
DOE OSTI2023

Baltimore Ecosystem Study: Stream chemistry for core sites in Gwynns Falls

In the Baltimore urban long-term ecological research (LTER) project, (Baltimore Ecosystem Study, BES) we use the watershed approach to evaluate integrated ecosystem function. The LTER research is centered on the Gwynns Falls watershed, a 17,150 ha catchment that traverses a gradient from the urban core of Baltimore, through older urban residential (1900 - 1950) and suburban (1950- 1980) zones, rapidly suburbanizing areas and a rural/suburban fringe. Our long-term sampling network includes four longitudinal sampling sites along the Gwynns Falls as well as several small (40 - 100 ha) watersheds located within or near to the Gwynns Falls. The longitudinal sites provide data on water and nutrient fluxes in the different land use zones of the watershed (rural/suburban, rapidly suburbanizing, old suburban, urban core) and the small watersheds provide more focused data on specific land use areas (forest, agriculture, rural/suburban, urban). Each of the gaging sites is continuously monitored for discharge and is sampled weekly for chemistry. Additional chemical sampling is carried out in a supplemental set of sites to provide a greater range of land use. Weekly analyses includes nitrate, phosphate, total nitrogen, total phosphorus, chloride and sulfate, turbidity, fecal coliforms, temperature, dissolved oxygen and pH. Cations, dissolved organic carbon and nitrogen and metals are measured on selected samples. Streamflow data for this site are posted at: http://waterdata.usgs.gov/md/nwis/nwisman?site_no=015835701

Groffman, Peter M (ORCID:0000000183716255)↗
NASA NTRS2015

Representing Matrix Cracks Through Decomposition of the Deformation Gradient Tensor in Continuum Damage Mechanics Methods

A method is presented to represent the large-deformation kinematics of intraply matrix cracks and delaminations in continuum damage mechanics (CDM) constitutive material models. The method involves the additive decomposition of the deformation gradient tensor into 'crack' and 'bulk material' components. The response of the intact bulk material is represented by a reduced deformation gradient tensor, and the opening of an embedded cohesive interface is represented by a normalized cohesive displacement-jump vector. The rotation of the embedded interface is tracked as the material deforms and as the crack opens. The distribution of the total local deformation between the bulk material and the cohesive interface components is determined by minimizing the difference between the cohesive stress and the bulk material stress projected onto the cohesive interface. The improvements to the accuracy of CDM models that incorporate the presented method over existing approaches are demonstrated for a single element subjected to simple shear deformation and for a finite element model of a unidirectional open-hole tension specimen. The material model is implemented as a VUMAT user subroutine for the Abaqus/Explicit finite element software. The presented deformation gradient decomposition method reduces the artificial load transfer across matrix cracks subjected to large shearing deformations, and avoids the spurious secondary failure modes that often occur in analyses based on conventional progressive damage models.

Leone, Frank A., Jr.↗
DOE OSTI2025

CRCNS22 Learning Rules in the Hippocampus and their Mapping to Neuromorphic Systems (Final Technical Report)

Large scale biologically-realistic computational models are key to investigating the interplay between structure and function in nervous systems, thus paving the way to new clinical methods and neuro-inspired computing solutions. This project focuses on the hippocampus, in particular the CA3-CA1 regions, due to their role in associative learning and memory, pattern separation and completion, and spatial navigation. Investigations into the neuronal organization and learning rule(s) of this circuit can shed light into how declarative memories are formed, stored, recalled and forgotten and inform computational, experimental and clinical neuroscience work. Our project aims at developing a novel data-driven methodology supported by a broad heterogeneous base of neuroscience experimental knowledge and inspired from advances in computer science and engineering. Specifically, this work will benchmark existing and new learning rules within a full-scale spiking neural network simulation of the CA3-CA1 region. The model will be based on an open-source repository, called the Hippocampome, which contains neuronal morphologies, firing patterns, synapse probabilities, and most other required parameters for all known neuron types in the rodent hippocampal formation. The model will be first trained in a supervised fashion for associative memory tasks using backpropagation through time traditionally used in computer science, enhanced with a new technique called the surrogate gradient method. This optimization method will be used to obtain a global loss minimization, but it is not biologically inspired as it assumes the use of data not locally available to the synapses. However, we propose its use as a benchmarking tool, to compare the training performance of local biologically plausible and hardware-mappable learning rules at scale. New rules or combinations will be proposed and tested as needed, based on the obtained results. Progress in this area will also drive the development of novel hardware-mappable algorithms for continual lifelong learning and categorization of new events from few presented examples. This project goes beyond the existing state-of-the-art by looking at large scale realistic neuronal circuits as networks trainable via global optimization methods such as surrogate gradient descent. The objective function of the brain that supports learning is largely unknown, but it is likely that it operates through local learning rules. Studying network trajectories around local minima as proposed in this work represents a useful strategy for understanding whether a network is training by using a specific (set of) learning rule(s). Starting from a completely untrained network is a challenging test since it is difficult to determine how the learning rule affects the trajectory of the network. This interdisciplinary project will help understand what rule governs learning in these regions or if multiple learning rules are involved. The work will develop a robust methodology to measure if the network is converging to the target solution, oscillating around it, or diverging away.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

A Subspace-Inclusive Sampling Method for the Computational Design of Compositionally Graded Alloys

Abstract Compositionally graded alloys, a subclass of functionally graded materials (FGMs), utilize localized variations in composition with a single metal part to achieve higher performance than traditional single material parts. In previous work [Kirk, T., Galvan, E., Malak, R., and Arroyave, R., 2018, “Computational Design of Gradient Paths in Additively Manufactured Functionally Graded Materials,” J. Mech. Des., 140, p. 111410. 10.1115/1.4040816], the authors presented a computational design methodology that avoids common issues which limit a gradient alloy’s feasibility, such as deleterious phases, and optimizes for performance objectives. However, the previous methodology only samples the interior of a composition space, meaning designed gradients must include all elements in the space throughout the gradient. Because even small amounts of additional alloying elements can introduce new deleterious phases, this characteristic often neglects potentially simpler solutions to otherwise unsolvable problems and, consequently, discourages the addition of new elements to the state space. The present work improves upon the previous methodology by introducing a sampling method that includes subspaces with fewer elements in the design search. The new method samples within an artificially expanded form of the state space and projects samples outside the true region to the nearest true subspace. This method is evaluated first by observing the sample distribution in each subspace of a 3D, 4D, and 5D state space. Next, a parametric study in a synthetic 3D problem compares the performance of the new sampling scheme to the previous methodology. Lastly, the updated methodology is applied to design a gradient from stainless steel to equiatomic NiTi that has practical uses such as embedded shape memory actuation and for which the previous methodology fails to find a feasible path.

Engineering↗
DOE OSTI2021

Carbon aerogels with integrated engineered macroporous architectures for improved mass transport

Carbon aerogels (CAs) combine unique properties including ultra-high surface area, high electrical conductivity, corrosion resistance, and robust mechanical properties making them ideal materials for electrochemical applications. Traditional CA synthesis results in isotropic, random nanoporous networks that work well for applications relying on diffusional mass transport. However, many applications would benefit from integration of engineered macroporous network structures that enable directed pressure-gradient-driven mass transport. In this study, we report on using 3D-printed sacrificial polymeric templates to generate templated CAs (t-CAs) with integrated engineered nonrandom macroporous network structures. Specifically, we used projection micro-stereo-lithography (PμSL) and two-photon polymerization direct laser writing (2PP-DLW) to fabricate millimeter-to-centimeter-sized 3D sacrificial polymeric templates with features ranging from tens of microns (PμSL) to 100s of nanometers (2PP-DLW). T-CAs were fabricated by infiltrating the templates with resorcinol-formaldehyde (RF) precursor solution, followed by carbonization at 1050 °C to simultaneously convert the RF gel to a CA and decompose the 3D-printed template, leaving an embedded templated macroporous network structure behind. X-ray computer tomography confirms integration of the macroporous architecture defined by the template. The templated macroporous architecture improves mass transport in t-CAs compared to traditional bulk CA as demonstrated by more uniform activation and their response in electrochemical cyclic voltammetry and galvanostatic charge-discharge tests.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Electropolishing parameters study for surface smoothening of low-$\beta$650 MHz five-cell niobium superconducting radio frequency cavity

Electropolishing (EP) is applied to niobium (Nb) superconducting radio frequency (SRF) cavities, which are used in particle accelerators for their surface treatment. The EP process for 1.3 GHz cavities has been extensively studied earlier. In this work, a parametric study on EP of low-β (0.61) 650 MHz Nb SRF cavities (LB650), which will be used in pre-production cryomodule for proton improvement plan-II (PIP-II) linear accelerator, was conducted to determine adequate EP conditions for attaining a smooth surface of the cavities. EP performed with the standard parameters and an initial cathode (cathode-I) having a cathode surface area of ~5% of the cavity surface area yielded a rough equator surface of the cavity. The grain step height on the equator weld position was measured to be ~ 32 μm. The rough surface was attributed to preferential grain etching confirmed by a polarization curve showing a linear relationship between the EP current and voltage and the absence of the current plateau region. The cathode was modified to make its surface area twice that of cathode-I. The modified cathode (cathode-M) provided a current plateau region in the corresponding I-V curves measured at different cavity temperatures. The onset voltage for the plateau was found to be higher at higher cavity temperatures. Here this study revealed that even with cathode-M, the standard 18 V was low for EP of such large-sized cavities when the cavity temperature was 18 °C. EP performed at a higher voltage of 22–24.5 V with cathode-M yielded a smooth surface with a grain step height of only 0.6 μm. The applied EP conditions also improved removal uniformity along the cavity length. In contrast to the cavity treated with cathode-I, the cavities treated with cathode-M achieved a significantly higher accelerating gradient (E acc ) in vertical tests conducted in a cryostat at 2 K. The modified EP was found efficient to produce the cavities that achieved E acc of 22.4 MV/m, required by PIP II project in the baseline RF tests, to qualify for further surface processing used to enhance their quality factors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Numerical Experiments and Identification of Areas for Further Consideration (B639388 Subcontract Quarter II Report)

The second quarter of the project was spent carrying out numerical experiments on a variety of test matrices, using a combination of precisions, with the intent to study the numerical properties (namely, accuracy and convergence behavior) of the Conjugate Gradient (CG) method. We summarize our findings in the remainder of the document. Other activities include attending biweekly xSDK meetings. We are also currently collaborating with Steven Thomas (NREL) on the numerical stability analysis of “low-synch” Gram-Schmidt routines, for potential application within high-performance GMRES variants. This work is in progress. The subsequent quarter will be spent delving into the numerical analysis in order to provide theoretical explanation for the behavior observed in our experiments.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Comparing measurements of the mixing layer height to modeled values

The mixing layer height (MLH) is the top layer of turbulent mixing within the lower atmosphere, above the Earth’s surface. Estimates of the mixing layer height allow us to determine the volume available for the dispersion of pollutants throughout the atmosphere. Our goal is to identify the most suitable mixing layer height input for our dispersion modeling tool (AERMOD). For this project we evaluated two different methods of estimating the local mixing layer height. First, we use 3 estimates of the mixing layer height obtained from a ceilometer, each height estimate corresponds to a different gradient in aerosol backscatter which is used as a proxy for mixing layer height identification. Second, we use AERMET, our AERMOD modeling system preprocessor for meteorological data, which estimates the mixing layer height using several equations combined with measured meteorological data. We evaluate the ceilometer and AERMET estimates over a 5-year period (2015-2019) to see how well aligned the estimated mixing layer heights are. Our results suggest that our model, AERMET, is on average, aligned with ceilometer estimates during the daytime hours. However, daily maximum MLH estimates by AERMET occur earlier in the day than those estimated by the ceilometer. We believe that the ceilometer struggles with accurately measuring the MLH during nighttime hours as a result of sensor limitations.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1992

Search for subgrid scale parameterization by projection pursuit regression

The dependence of subgrid-scale stresses on variables of the resolved field is studied using direct numerical simulations of isotropic turbulence, homogeneous shear flow, and channel flow. The projection pursuit algorithm, a promising new regression tool for high-dimensional data, is used to systematically search through a large collection of resolved variables, such as components of the strain rate, vorticity, velocity gradients at neighboring grid points, etc. For the case of isotropic turbulence, the search algorithm recovers the linear dependence on the rate of strain (which is necessary to transfer energy to subgrid scales) but is unable to determine any other more complex relationship. For shear flows, however, new systematic relations beyond eddy viscosity are found. For the homogeneous shear flow, the results suggest that products of the mean rotation rate tensor with both the fluctuating strain rate and fluctuating rotation rate tensors are important quantities in parameterizing the subgrid-scale stresses. A model incorporating these terms is proposed. When evaluated with direct numerical simulation data, this model significantly increases the correlation between the modeled and exact stresses, as compared with the Smagorinsky model. In the case of channel flow, the stresses are found to correlate with products of the fluctuating strain and rotation rate tensors. The mean rates of rotation or strain do not appear to be important in this case, and the model determined for homogeneous shear flow does not perform well when tested with channel flow data. Many questions remain about the physical mechanisms underlying these findings, about possible Reynolds number dependence, and, given the low level of correlations, about their impact on modeling. Nevertheless, demonstration of the existence of causal relations between sgs stresses and large-scale characteristics of turbulent shear flows, in addition to those necessary for energy transfer, provides important insight into the relation between scales in turbulent flows.

Meneveau, C.↗
NASA NTRSDate not supplied

Feasibility of Self Powered Actuation for Flow, Separation and Vibration Control

Gas turbine engines are anywhere from 40-50% efficient with a large amount of waste heat production. The primary focus of this work was to evaluate the feasibility of harvesting energy from sections of an imaginary but representative gas turbine engine that has large thermal gradients using thermoelectric generators (TEGs) and using the harvested energy locally for flow control using either plasma actuators or piezoelectric actuators. This work is a summary of a two- year NASA Center Innovation Fund Project from 2010 to 2012. The trade-off between thermoelectric harvesting and turbine blade surface temperature was studied to ensure that blade durability is not adversely impacted by embedding a low thermal conductivity TEG. Calculations show that at least 2-3 Watts can be harvested per blade depending on flow conditions and on the thermoelectric material chosen while maintaining metal temperatures below critical limits. BiTe and SiGe were considered as TEG materials although higher ZT materials are now in development. A circuit to convert the DC power output of the TEG to AC input for plasma actuation was fabricated and tested. Several novel plasma actuator configurations were also tested.

Thermoelectric↗
NASA NTRS1981

Implications of natural sources for the latitudinal gradients of NO/y/ in the unpolluted troposphere

The latitudinal distributions of tropospheric odd nitrogen (NO/y/) due to lightning discharges and stratospheric injection are studied by estimating latitude dependences of the sources and the rainout sink from data obtained in August-September, 1977, and May-June, 1978, during project GAMETAG. A one-dimensional (latitude dependent) model is developed for the annually, zonally, and vertically averaged concentration of trace species, NO(y) being treated as a single species, which decouples the NO(y) calculation from the rest of the model since NO(y) has no chemical sources or sinks in the troposphere. The equation governing the NO(y) distribution is solved using finite differences with 33 uniformly spaced grid points in the micron range of -1 to 1. The distribution due to the stratospheric source has a minimum in the tropics, and there are broad maxima centered in the 25-30 degree region in both hemispheres. The calculated NO(y) due to lightning has a maximum near 15 degrees S, and it decreases to nearly a fourth of the maximum value near the poles. The drop off from the maximum is sharper in the Southern Hemisphere in comparison with the Northern Hemisphere.

Hameed, S.↗
NASA NTRS2015

Lightning Protection and Structural Bonding for the B2 Test Stand

With the privatization of the space industry, NASA has entered a new era. To explore deeper parts of the solar system, NASA is developing a new spacecraft, the Space Launch System (SLS), capable of reaching these destinations, such as an asteroid or Mars. However, the test stand that is capable of testing the stage has been unused for many years. In addition to the updating/repair of the stand, more steel is being added to fully support the SLS. With all these modifications, the lightning protection system must be brought up to code to assure the protection of all personnel and assets. Structural bonding is a part of the lightning protection system. The focus of this project was to assure proper structural bonding. To begin, all relevant technical standards and the construction specifications were reviewed. This included both the specifications for the lightning protection and for general construction. The drawings were reviewed as well. From the drawings, bolted structural joints were reviewed to determine whether bonding was necessary. Several bolted joints were determined to need bonding according to the notes in the drawings. This exceeds the industry standards. The bolted joints are an electrically continuous joint. During tests, the stand experiences heavy vibration that may weaken the continuity of the bolted joint. Therefore, the secondary bonding is implemented to ensure that the structural joint has low resistance. If the structural joint has a high resistance because of corrosion, a potential gradient can occur that can cause a side flash. Damage, injury, or death can occur from a side flash so they are to be prevented. A list of the identified structural joints was compiled and sent to the contractor to be bonded. That covers the scope of this project.

Kinard, Brandon↗
DOE OSTI2023

Assessment of radial transport induced by Alfvénic resonances in tokamaks and stellarators

In a symmetric plasma confinement device, a perturbation such as an Alfvén mode produces a resonance island which flattens the local energy gradient due to induced rotation about the elliptic points of the resonance. The location of the resonance is mode frequency and particle energy dependent, and particles away from the resonance are not affected. Here, a projection onto the Poincaré subspace allows the evaluation of resonance widths and internal rotation rates. In a stellarator without symmetry because of the toroidal dependence of the equilibrium magnetic field, a mode instead produces chaos in all orbits passing where the amplitude is large and is, thus, much more effective in producing radial transport and loss. The mode growth rate and saturation are also affected by the local chaos.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2016

Scientific and Technical Assistance for the Deployment of a Flexible Airborne Spectrometer System During C-MAPExp and COMEX: COMEX Version - 1.9T

The COMEX (CO2 and MEthane eXperiment) campaign supports the mission definition of CarbonSat and HyspIRI (Hyperspectral Infrared Imager) by providing representative airborne remote sensing data ‐ MAMAP (Methane Airborne MAPper) for CarbonSat; the Airborne Visual InfraRed Imaging Spectrometer (Classic & Next Generation) AVIRIS‐C/AVIRIS‐NG for HyspIRI ‐ as well as ground-based and airborne in‐situ data. The objectives of the COMEX campaign activities are (see Campaign Implementation Plan (RD‐4)): 1. Investigate spatial/spectral resolution trade‐offs for CH4 anomaly detection and flux inversion by comparison of MAMAP‐derived emission estimates with AVIRIS/AVIRIS‐NG derived data. 2. Evaluate sun‐glint observation geometry on CH4 retrievals for marine sources. 3. Characterize the effect of Surface Spectral Reflectance (SSR) heterogeneity on trace gas retrievals of CO2 and CH4 for medium and low‐resolution spectrometry. 4. Identify benefits from joint SWIR/TIR (ShortWave InfraRed/Thermal InfraRed ) data for trace gas detection and retrieval by comparison of MAMAP and AVIRIS/AVIRIS‐NG NIR/SWIR data with MAKO (Aerospace Corp.)TIR data. The ability to derive emission source strength for a range of strong emitting targets by remote sensing will be evaluated from combined AVIRIS‐NG and MAMAP data, adding significant value to the HyspIRI campaign AVIRIS‐NG dataset. The data will be used to quantify anomalies in atmospheric CO2 and CH4 from strong local greenhouse gas sources e.g. localized industrial complexes, landfills, etc. and to derive CO2 and CH4 emissions estimates from atmospheric gradient measurements. The original campaign concept was developed by University of Bremen and BRI. The COMEX campaign is funded bilaterally by NASA and ESA (European Space Agency). Whereas NASA funds the US part of the project via a contract with Dr. Ira Leifer, BRI (Bubbleology Research International), the contribution of MAMAP to the COMEX campaign is funded by ESA within the COMEX‐E project and NASA with respect to a 50 percent contribution to the flight-related costs of flying MAMAP on a US aircraft. The Data Acquisition Report (RD‐9) describes the instrumentation used, the measurements made by the team during the COMEX campaign in May/June 2014 and August/September 2014 in California, and an initial assessment of the data quality.

Point Sources↗
DOE OSTI2020

The Largest Accelerators and Colliders of Their Time

The Study Group for a GeV-scale Proton Synchrotron was launched in 1952 at CERN. Initially, an up-scaled version of the 3 GeV Cosmotron was considered but soon a new design based on the newly discovered alternating-gradient principle and promising a proton energy of 30 GeV was adopted by the CERN Council in the same year. In order to limit cost the energy was subsequently limited to 25 GeV and the project led by J.B. Adams was approved in 1953. The final parameters were fixed in 1954 and construction started in 1955. The CPS [1] became operational towards the end of 1959 reaching an energy of 28 GeV [2, 3]. It has turned out to be an extremely versatile facility [4] (Table 10.1).

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Gradient-based constrained optimization using a database of linear reduced-order models

A methodology grounded in model reduction is presented for accelerating the gradient-based solution of a family of linear or nonlinear constrained optimization problems where the constraints include at least one linear Partial Differential Equation (PDE). A key component of this methodology is the construction, during an offline phase, of a database of pointwise, linear, Projection-based Reduced-Order Models (PROM)s associated with a design parameter space and the linear PDE(s). A parameter sampling procedure based on an appropriate saturation assumption is proposed to maximize the efficiency of such a database of PROMs. A real-time method is also presented for interpolating at any queried but unsampled parameter vector in the design parameter space the relevant sensitivities of a PROM. The practical feasibility, computational advantages, and performance of the proposed methodology are demonstrated for several realistic, nonlinear, aerodynamic shape optimization problems governed by linear aeroelastic constraints.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Thermopile Energy Harvesting for Subsurface Wellbore Sensors (Final Report)

Robust in situ power harvesting underlies all efforts to enable downhole autonomous sensors for real-time and long-term monitoring of CO 2 plume movement and permeance, wellbore health, and induced seismicity. This project evaluated the potential use of downhole thermopile arrays, known as thermoelectric generators (TEGs), as power sources to charge sensors for in situ real-time, long-term data capture and transmission. Real-time downhole monitoring will enable “Big Data” techniques and machine learning, using massive amounts of continuous data from embedded sensors, to quantify short- and long-term stability and safety of enhanced oil recovery and/or commercial-scale geologic CO 2 storage. This project evaluated possible placement of the TEGs at two different wellbore locations: on the outside of the casing; or on the production tubing. TEGs convert heat flux to electrical power, and in the borehole environment, would convert heat flux into or out of the borehole into power for downhole sensors. Such heat flux would be driven by pumping of cold or hot fluids into the borehole—for instance, injecting supercritical CO 2 —creating a thermal pulse that could power the downhole sensors. Hence, wireless power generation could be accomplished with in situ TEG energy harvesting. This final report summarizes the project’s efforts that accomplished the creation of a fully operational thermopile field unit, including selection of materials, laboratory benchtop experiments and thermal-hydrologic modeling for design and optimization of the field-scale power generation test unit. Finally, the report describes the field unit that has been built and presents results of performance and survivability testing. The performance and survivability testing evaluated the following: 1) downhole power generation in response to a thermal gradient produced by pumping a heated fluid down a borehole and through the field unit; and 2) component survivability and operation at elevated temperature and pressure conditions representative of field conditions. The performance and survivability testing show that TEG arrays are viable for generating ample energy to power downhole sensors, although it is important to note that developing or connecting to sensors was beyond the scope of this project. This project’s accomplishments thus traversed from a low Technical Readiness Level (TRL) on fundamental concepts of the application and modeling to TRL-5 via testing of the fully integrated field unit for power generation in relevant environments. A fully issued United States Patent covers the wellbore power harvesting technology and applications developed by this project.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

VTO_2021_APR_LLNL_Ye

Traditional batteries are composed of two-dimensional films that are stacked and/or rolled. Thin film batteries display high power density while their thick film counterparts show good energy density, but it has proven difficult to concurrently achieve both within these planar form factors. In addition, conventional Li-ion batteries based on liquid organic electrolytes or gel polymer electrolytes have raised severe safety concerns due to the intrinsic flammable properties of the organic electrolytes. They are also not ideal for the use of high energy density metallic lithium (Li) anodes due to Li dendrite growth, or sulfur cathodes due to shuttling effects that result in fast capacity fade. There is an urgent need to develop safe, high-performance solid-state batteries (SSBs) with advanced electrolyte and separator technologies. Although in recent years a series of superionic conductors have been developed for electrolytes and separators, their performance does not satisfy demanding criteria due to large impedance from poor solid electrolyte-electrode contact and questionable electrochemical and mechanical stability. Unlike the well-established roll-to-roll fabrication of conventional Li-ion batteries, the processing of SSBs is unique due to the brittleness of solid-state electrolytes (SSEs). The commercially available or lab-developed SSE discs are usually very thick (hundreds of micrometers to millimeters) to overcome their brittle nature, which unfortunately increases the cell impedance and accounts for the majority of the overall cell weight and volume, leading to dramatically decreased power and energy densities. In this project, we will investigate 3D printing techniques to overcome safety, fabrication, mechanical, and electrochemical issues in SSBs. 3D printing builds complex structures in a layer-by-layer fashion, which allows rapid production of hierarchical architectures, gradient and multi-material structures, and multi-component assemblies. 3D printing is an emerging area that could fundamentally transform energy storage devices. For example, 3D printing can produce batteries with arbitrary form factors to fit a product’s specific volume requirements and can create interwoven electrode arrangements over a wide range of length scales to improve transport and increase power density for a given energy density. For SSBs, 3D printing may dramatically reduce the separator thickness from ~1 mm (by hydraulic pressing) to tens of micrometers or less. In addition, the interfacial contact area between the electrolyte and the electrode may be increased via 3D interdigitated designs. Hence, we expect a significant reduction of the overall cell impedance and enhancement of both energy and power densities of SSBs by harnessing an array of 3D printing technologies being developed at Lawrence Livermore National Laboratory (LLNL).

25 ENERGY STORAGE↗