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DOE OSTI2023

The Eighteenth Data Release of the Sloan Digital Sky Surveys: Targeting and First Spectra from SDSS-V

The eighteenth data release (DR18) of the Sloan Digital Sky Survey (SDSS) is the first one for SDSS-V, the fifth generation of the survey. SDSS-V comprises three primary scientific programs or “Mappers”: the Milky Way Mapper (MWM), the Black Hole Mapper (BHM), and the Local Volume Mapper. This data release contains extensive targeting information for the two multiobject spectroscopy programs (MWM and BHM), including input catalogs and selection functions for their numerous scientific objectives. We describe the production of the targeting databases and their calibration and scientifically focused components. DR18 also includes ~25,000 new SDSS spectra and supplemental information for X-ray sources identified by eROSITA in its eFEDS field. We present updates to some of the SDSS software pipelines and preview changes anticipated for DR19. We also describe three value-added catalogs (VACs) based on SDSS-IV data that have been published since DR17, and one VAC based on the SDSS-V data in the eFEDS field.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Measuring spin correlation between quarks during QCD confinement

The vacuum is now understood to have a rich and complex structure, characterized by fluctuating energy fields and a condensate of virtual quark–antiquark pairs. The spontaneous breaking of the approximate chiral symmetry, signalled by the nonvanishing quark condensate $\langle$$q\bar{q}$$\rangle$, is dynamically generated through topologically nontrivial gauge configurations such as instantons. The precise mechanism linking the chiral symmetry breaking to the mass generation associated with quark confinement remains a profound open question in quantum chromodynamics (QCD)—the fundamental theory of strong interaction. High-energy proton–proton collisions could liberate virtual quark–antiquark pairs from the vacuum that subsequently undergo confinement to form hadrons, whose properties could serve as probes into QCD confinement and the quark condensate. Here we report evidence of spin correlations in $Λ\bar{Λ}$ hyperon pairs inherited from spin-correlated strange quark–antiquark virtual pairs. Measurements by the STAR experiment at the Relativistic Heavy Ion Collider (RHIC) at Brookhaven National Laboratory reveal a relative polarization signal of (18 ± 4)% that links the virtual spin-correlated quark pairs from the QCD vacuum to their final-state hadron counterparts. Crucially, this correlation vanishes when the hyperon pairs are widely separated in angle, consistent with the decoherence of the quantum system. Our findings provide a new experimental model for exploring the dynamics and interplay of quark confinement and entanglement.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

DESI 2024 V: Full-Shape galaxy clustering from galaxies and quasars

We present the measurements and cosmological implications of the galaxy two-point clustering using over 4.7 million unique galaxy and quasar redshifts in the range 0.1 < z < 2.1 divided into six redshift bins over a ∼ 7,500 square degree footprint, from the first year of observations with the Dark Energy Spectroscopic Instrument (DESI Data Release 1). By fitting the full power spectrum, we extend previous DESI DR1 baryon acoustic oscillation (BAO) measurements to include redshift-space distortions and signals from the matter-radiation equality scale. For the first time, this Full-Shape analysis is blinded at the catalogue-level to avoid confirmation bias and the systematic errors are accounted for at the two-point clustering level, which automatically propagates them into any cosmological parameter. When analyzing the data in terms of compressed model-agnostic variables, we obtain a combined precision of 4.7% on the amplitude of the redshift space distortion (RSD) signal reaching a similar precision with just one year of DESI data than with twenty years of observation from the previous generation survey. We also analyze the data to directly constrain the cosmological parameters within the ΛCDM model using perturbation theory and combine this information with the reconstructed DESI DR1 galaxy BAO. Using a Big Bang Nucleosynthesis Gaussian prior on the baryon density parameter, ω b , and a weak Gaussian prior on the spectral index, n s , we constrain the matter density is Ω m = 0.296±0.010 and the Hubble constant H 0 = (68.63 ± 0.79)[km s -1 Mpc -1 ]. Additionally, we measure the amplitude of clustering σ 8 = 0.841±0.034. The DESI DR1 galaxy clustering results are in agreement with the ΛCDM model based on general relativity with parameters consistent with those from Planck. The cosmological interpretation of these results in combination with DESI DR1 Ly-α forest data and external datasets are presented in the companion paper [1].

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Search for High-energy Neutrino Emission from Galactic X-Ray Binaries with IceCube

We present the first comprehensive search for high-energy neutrino emission from high- and low-mass X-ray binaries conducted by IceCube. Galactic X-ray binaries are long-standing candidates for the source of Galactic hadronic cosmic rays and neutrinos. The compact object in these systems can be the site of cosmic-ray acceleration, and neutrinos can be produced by interactions of cosmic rays with radiation or gas, in the jet of a microquasar, in the stellar wind, or in the atmosphere of the companion star. We study X-ray binaries using 7.5 yr of IceCube data with three separate analyses. In the first, we search for periodic neutrino emission from 55 binaries in the Northern Sky with known orbital periods. In the second, the X-ray light curves of 102 binaries across the entire sky are used as templates to search for time-dependent neutrino emission. Finally, we search for time-integrated emission of neutrinos for a list of 4 notable binaries identified as microquasars. In the absence of a significant excess, we place upper limits on the neutrino flux for each hypothesis and compare our results with theoretical predictions for several binaries. In addition, we evaluate the sensitivity of the next generation neutrino telescope at the South Pole, IceCube-Gen2, and demonstrate its power to identify potential neutrino emission from these binary sources in the Galaxy.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2021

Roadmap for Advanced Power System Measurements

Conditions in the electric power grid are changing rapidly. Changes are driven, in particular, by the increased penetration of renewable resources in the generation mix. Part of the solution to dealing with the changing conditions is the better use of measurement systems, taking advantage of the better understanding of measurements that was heralded by digital technology. Another part of the solution is the communication of samples of the directly observable voltages and currents by means of continuous point-on-wave values. The increased bandwidth capability of such a system allows more complicated measurement models to be built at the point of use. Additional measurements and analyses can then be performed. This Roadmap hinges on these two aspects of measuring: improved measurements supported by high-bandwidth (raw data) communications. Following an introduction to the overall subject, the report explores the impact of what can be thought of as the digital revolution in measurement. In essence, that revolution has served to clarify ideas about measurement and is continuing to lead to improved processes. An extensive survey of the relevant literature was performed . Webinars were held to learn from the wider community of practitioners. Based on this information, a number of gaps were identified whose continued existence would hamper the solution of the challenges now facing measurement and communication in the power grid. The underlying value propositions are interoperability (presently not very satisfactory in many measurements); greater (and less challenging) adoption of distributed energy resources; and improved international competitiveness. Underlying all that, of course, is progress toward a more reliable and resilient power system. The identified gaps were addressed in four major thrusts: technology deployment and demonstration, education, instrumentation testing and standards, and analytical methods. For each of the thrusts, multiple goals are defined to guide the implementation. The thrusts were designed to close gaps and unlock high-value use cases. After discussing the literature review, gap analysis, high-value use cases, and research thrusts in chapters 2-5, the report culminates in chapter 6 with a roadmap that links each aspect together to form a unified plan. Developing a research portfolio aligned with this plan will ensure that advanced measurement systems are in place to support reliable operation of the power system as it modernizes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

3D nanolithography with metalens arrays and spatially adaptive illumination

The growing demand for advanced materials, miniaturized devices and integrated microsystems calls for the reliable fabrication of complex, multiscale, three-dimensional (3D) architectures, a need increasingly addressed through light-based and laser-based processes. However, owing to the field-of-view (FOV) limitations of conventional imaging optics, existing 3D laser nanofabrication techniques face fundamental challenges in throughput, proximity error and stitching defects on the path to scaling. Here, in this study, we present a scalable 3D nanofabrication platform that uses a metalens-generated focal spot array to parallelize two-photon lithography (TPL) beyond centimetre-scale write field areas. Metalenses are ideally suited for producing submicron-scale focal spots for high-throughput nanolithography, as they uniquely feature large numerical apertures (NAs), immersion media compatibility and large-scale manufacturability. We experimentally demonstrate a printing system that uses a 12-cm 2 metalens array to produce more than 120,000 cooperative focal spots, corresponding to a throughput exceeding 10 8 voxels s −1 . By programmatically patterning the focal spot array using a spatial light modulator (SLM), an adaptive parallel printing strategy is developed for precise greyscale linewidth modulation and choreographed printing of semiperiodic and fully aperiodic 3D geometries. We demonstrate parallel printing of replicated microstructures (>50 M microparticles per day), centimetre-scale 3D architectures with feature sizes down to 113 nm, and photonic and mechanical metamaterials. This work demonstrates the potential of 3D nanolithography towards wafer-scale production, showing how TPL could be used at scale for applications in microelectronics, biomedicine, quantum technology and high-energy laser targets.

Materials science↗
DOE OSTI2025

The Spectroscopic Stage-5 Experiment

The existence, properties, and dynamics of the dark sectors of our universe pose fundamental challenges to our current model of physics, and large-scale astronomical surveys may be our only hope to unravel these long-standing mysteries. In this white paper, we describe the science motivation, instrumentation, and survey plan for the next-generation spectroscopic observatory, the Stage-5 Spectroscopic Experiment (Spec-S5). Spec-S5 is a new all-sky spectroscopic instrument optimized to efficiently carry out cosmological surveys of unprecedented scale and precision. The baseline plan for Spec-S5 involves upgrading two existing 4-m telescopes to new 6-m wide-field facilities, each with a highly multiplexed spectroscopic instrument capable of simultaneously measuring the spectra of 13,000 astronomical targets. Spec-S5, which builds and improves on the hardware used for previous cosmology experiments, represents a cost-effective and rapid approach to realizing a more than 10$\times$ gain in spectroscopic capability compared to the current state-of-the-art represented by the Dark Energy Spectroscopic Instrument project (DESI). Spec-S5 will provide a critical scientific capability in the post-Rubin and post-DESI era for advancing cosmology, fundamental physics, and astrophysics in the 2030s.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Observation of seasonal variations of the flux of high-energy atmospheric neutrinos with IceCube

Atmospheric muon neutrinos are produced by meson decays in cosmic-ray-induced air showers. The flux depends on meteorological quantities such as the air temperature, which affects the density of air. Competition between decay and re-interaction of those mesons in the first particle production generations gives rise to a higher neutrino flux when the air density in the stratosphere is lower, corresponding to a higher temperature. A measurement of a temperature dependence of the atmospheric νμ flux provides a novel method for constraining hadronic interaction models of air showers. It is particularly sensitive to the production of kaons. Studying this temperature dependence for the first time requires a large sample of high-energy neutrinos as well as a detailed understanding of atmospheric properties. We report the significant (> 10 σ) observation of a correlation between the rate of more than 260,000 neutrinos, detected by IceCube between 2012 and 2018, and atmospheric tem peratures of the stratosphere, measured by the Atmospheric Infrared Sounder (AIRS) instrument aboard NASA’s AQUA satellite. For the observed 10% seasonal change of effective atmospheric temperature we measure a 3.5(3)% change in the muon neutrino flux. This observed correlation deviates by about 2-3 standard deviations from the expected correla tion of 4.3% as obtained from theoretical predictions under the assumption of various hadronic interaction models.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

The LUX-ZEPLIN (LZ) radioactivity and cleanliness control programs

LUX-ZEPLIN (LZ) is a second-generation direct dark matter experiment with spin-independent WIMP-nucleon scattering sensitivity above 1.4×10 –48 cm 2 for a WIMP mass of 40GeV/c 2 and a 1000 days exposure. LZ achieves this sensitivity through a combination of a large 5.6 t fiducial volume, active inner and outer veto systems, and radio-pure construction using materials with inherently low radioactivity content. The LZ collaboration performed an extensive radioassay campaign over a period of six years to inform material selection for construction and provide an input to the experimental background model against which any possible signal excess may be evaluated. The campaign and its results are described in this paper. We present assays of dust and radon daughters depositing on the surface of components as well as cleanliness controls necessary to maintain background expectations through detector construction and assembly. Finally, examples from the campaign to highlight fixed contaminant radioassays for the LZ photomultiplier tubes, quality control and quality assurance procedures through fabrication, radon emanation measurements of major sub-systems, and bespoke detector systems to assay scintillator are presented.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Erratum to: The LUX-ZEPLIN (LZ) radioactivity and cleanliness control programs

LUX-ZEPLIN (LZ) is a second-generation direct dark matter experiment with spin-independent WIMP-nucleon scattering sensitivity above 1.4 × 10 -48 cm 2 for a WIMP mass of 40 GeV/c 2 and a 1000 d exposure. LZ achieves this sensitivity through a combination of a large 5.6 t fiducial volume, active inner and outer veto systems, and radio-pure construction using materials with inherently low radioactivity content. The LZ collaboration performed an extensive radioassay campaign over a period of six years to inform material selection for construction and provide an input to the experimental background model against which any possible signal excess may be evaluated. The campaign and its results are described in this paper. We present assays of dust and radon daughters depositing on the surface of components as well as cleanliness controls necessary to maintain background expectations through detector construction and assembly. Finally, examples from the campaign to highlight fixed contaminant radioassays for the LZ photomultiplier tubes, quality control and quality assurance procedures through fabrication, radon emanation measurements of major sub-systems, and be spoke detector systems to assay scintillator are presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

The Evolving Solar Energy Innovation Ecosystem in Puerto Rico

This report presents initial findings from the research project, “Developing socially and economically generative, resilient PV-energy systems for low- and moderate-income communities: Applications for Puerto Rico.” This material is based upon work supported primarily by the US Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technology Office Fiscal Year 2018 Funding Program award number DE-EE0008570 and in part by the National Science Foundation (NSF) and the Department of Energy (DOE) under NSF CA No. EEC-1041895. This project is a joint effort of Arizona State University’s Center for Energy and Society; the University of Puerto Rico-Mayaguez’s Center for Hemispheric Cooperation in Research and Education in Engineering and Applied Science, Sustainable Energy Center, and National Institute for Energy and Island Sustainability; and the National Renewable Energy Laboratory. The project seeks to understand the place of energy in low-income communities in Puerto Rico, the opportunities for solar energy to provide solutions to the energy challenges facing these communities, and the capacity of the solar energy innovation ecosystem in Puerto Rico to deliver relevant solar solutions for these communities. We define the solar energy innovation ecosystem as the diverse actors and stakeholders whose collective networks and actions—and the flows among them of ideas, knowledge, data, influence, money, and equipment, as well as the rules that govern those flows—are essential to the success of renewable energy markets and projects. This report presents results from the first year of the project’s research, which has concentrated on several key goals: (1) characterizing the trajectory of solar energy development in Puerto Rico in the three years since Hurricane María; (2) mapping and characterizing the current solar energy innovation ecosystem in Puerto Rico, including the technical potential for solar energy in Puerto Rico, and the business and policy landscape shaping solar developments; and (3) beginning to characterize the broad landscape of community energy initiatives underway in Puerto Rico. To pursue these goals, we engaged in a systematic review of solar energy developments in Puerto Rico and conducted interviews with over 100 members of the solar energy innovation, including policy, business, finance, research, and civil society leaders, as well as solar users. Solar technical potential data for Puerto Rico was developed by the National Renewable Energy Laboratory (NREL) and is publicly available at: https://data.nrel.gov/submissions/144. The documentation for the NREL dataset is included as Appendix A.

14 SOLAR ENERGY↗
DOE OSTI2025

Lithography-Defined Semiconductor Moirés with Anomalous In-Gap Quantum Hall States

Quantum materials and phenomena have attracted great interest for their potential applications in next-generation microelectronics and quantum-information technologies. In one especially interesting class of quantum materials, moiré superlattices (MSLs) formed by twisted bilayers of 2D materials, a wide range of novel phenomena are observed. However, there exist daunting challenges such as reproducibility and scalability of utilizing 2D MSLs for microelectronics and quantum technologies due to their exfoliate-tear-stack method. Here, we propose lithography-defined semiconductor MSLs, in which three fundamental parameters electron−electron interaction, spin−orbit coupling, and band topology are designable. We experimentally investigate quantum-transport properties in a moiré specimen made in an InAs quantum well. Strong anomalous in-gap states are observed within the same integer quantum Hall state. Our work opens up new horizons for studying 2D quantum-materials phenomena in semiconductors featuring superior industry-level quality and state-of-the-art technologies, and they may potentially enable new quantum-information and microelectronics technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2025

New physics search at the CEPC: a general perspective

A next generation, high-intensity electron-positron collider “Higgs factory”, such as the Circular Electron-Positron Collider (CEPC), is among the highest priority for the global high energy collider physics community. The CEPC can provide unprecedented opportunities for making fundamental discoveries and providing decisive insights in the quest for a “New Standard Model (SM)” of nature’s fundamental interactions. The CEPC could: 1) Identify the origin of matter, especially the mechanism related to the first-order phase transition in the early Universe, which could produce a detectable gravitational wave signal. 2) Discover dark matter, particularly dark matter particles with a mass between one tenth and 100 times the proton mass. 3) Observe an array of new physics smoking guns, with sensitivities orders of magnitude better than those of existing facilities. The SM of Particle Physics is a triumph of the past half a century, as it predicts and interprets almost all the phenomena observed in experiments from the highest energies with colliders to low energy “tabletop” studies. On the other hand, deep mysteries exist concerning the most fundamental interactions of matter and the space-time fabric of the Universe, including the nature of dark matter, the origin of “visible” matter, the vast hierarchy of elementary particle masses, the quantum nature of gravity, and the mechanism of inflation. These mysteries challenge us to look for “new physics” beyond the SM and General Relativity. Indeed, physicists believe that the SM is simply a low-energy effective theory that reflects aspects of the more profound theory that answers the aforementioned mysteries. Uncovering this “New SM”, the profound theory who supports the SM is the primary mission for particle physics in the post-Higgs boson era.

Ai 艾, Xiaocong 小聪 [Zhengzhou University (China); e↗
DOE OSTI2024

Bench-scale Development of a Transformational Graphene Oxide-based Membrane Process for Post-combustion CO 2 Capture

Graphene-based materials, such as graphene and graphene oxide (GO), have been considered as next-generation membrane materials. GTI Energy and The State University of New York at Buffalo (UB) have been developing a transformational GO-based membrane process (designated as GO2) that integrates a high CO 2 /N 2 selectivity membrane (GO-1) and a high CO 2 flux membrane (GO-2) for post-combustion CO 2 capture. An innovative membrane structure, consisting of GO nanochannels intercalated by single-walled carbon nanotube (SWCNT), was developed. The membrane prepared on hollow fiber substrate showed CO 2 permeance as high as 1,300 GPU with CO 2 /N 2 selectivity >200. The membranes were successfully scaled up to effective area of 50-100 cm 2 . The 50-100 cm 2 membranes showed CO 2 /N 2 selectivity ≥200 and CO 2 permeance ≥1,000 GPU for the GO-1 type, and CO 2 /N 2 selectivity ≥20 and CO 2 permeance ≥2,500 GPU for the GO-2 type. The CO 2 capture performance of the GO-based membranes was tested using a simulated flue gas. The testing results indicate that the GO-based membranes are stable in the presence of flue gas contaminants. The GO-based membranes were then further scaled up to a surface area of 1,000 cm 2 . Good stability was achieved during an integrated testing with GO-1 and GO-2 membranes using simulated flue gas. A bench-scale system was designed, constructed, and tested at the National Carbon Capture Center (NCCC). Good stability was achieved during testing of a single-stage process with >10 shutdowns/startups at NCCC. During the integrated testing, the membranes showed good stability at 50°C and 57°C. 70-90% CO 2 removal efficiencies and ≥95% CO 2 purity were validated during the steady state operation at NCCC. Techno-economic analysis indicates the GO2 membrane-based process technology provides a reduction in both the levelized cost of electricity (LCOE) and cost of capture when compared to the reference B12B case presented in the Cost and Performance Baseline for Fossil Energy Plants Volume 1: Bituminous Coal and Natural Gas to Electricity study prepared by the National Energy Technology Laboratory (NETL), before considering any system optimization or improvement opportunities. The benefits are primarily driven by a reduction in the equipment costs of the CO 2 capture process vs. the solvent-based reference process in NETL Case B12B as well as a decrease in the base plant size.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Identification and denoising of radio signals from cosmic-ray air showers using convolutional neural networks

Radio pulses generated by cosmic-ray air showers can be used to reconstruct key properties like the energy and depth of the electromagnetic component of cosmic-ray air showers. Radio detection threshold, influenced by natural and anthropogenic radio background, can be reduced through various techniques. In this work, we demonstrate that convolutional neural networks (CNNs) are an effective way to lower the threshold. We developed two CNNs: a classifier to distinguish radio signal waveforms from background noise and a denoiser to clean contaminated radio signals. Following the training and testing phases, we applied the networks to air-shower data triggered by scintillation detectors of the prototype station for the enhancement of IceTop, IceCube’s surface array at the South Pole. Over a four-month period, we identified 554 cosmic-ray events in coincidence with IceTop, approximately five times more compared to a reference method based on a cut on the signal-to-noise ratio. Comparisons with IceTop measurements of the same air showers confirmed that the CNNs reliably identified cosmic-ray radio pulses and outperformed the reference method. Additionally, we find that CNNs reduce the false-positive rate of air-shower candidates and effectively denoise radio waveforms, thereby improving the accuracy of the power and arrival time reconstruction of radio pulses.

Abbasi, R↗
DOE OSTI2026

Time-integrated Southern-sky Neutrino Source Searches with 10 yr of IceCube Starting-track Events at Energies Down to 1 TeV

In the IceCube Neutrino Observatory, a signal of astrophysical neutrinos is obscured by backgrounds from atmospheric neutrinos and muons produced in cosmic-ray interactions. IceCube event selections used to isolate the astrophysical neutrino signal often focus on the morphology of the light patterns recorded by the detector. The analyses presented here use the new IceCube Enhanced Starting Track Event Selection (ESTES), which identifies events likely generated by muon–neutrino interactions within the detector geometry, focusing on neutrino energies of 1–500 TeV with a median angular resolution of 1.4°. Selecting for starting-track events filters out not only the atmospheric-muon background but also the atmospheric-neutrino background in the southern sky. This improves IceCube’s muon–neutrino sensitivity to southern-sky neutrino sources, especially for Galactic sources that are not expected to produce a substantial flux of neutrinos above 100 TeV. In this work, the ESTES sample was applied for the first time to search for astrophysical sources of neutrinos, including a search for diffuse neutrino emission from the Galactic plane. No significant excesses were identified from any of the analyses; however, constraining limits are set on the hadronic emission from TeV gamma-ray Galactic plane objects and models of the diffuse Galactic plane neutrino flux.

Abbasi, R. [Loyola University, Chicago, IL (United↗
DOE OSTI2020

Batteries Annual Progress Report (FY2019)

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

25 ENERGY STORAGE↗
DOE OSTI2020

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗