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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Challenges, Technological Pathways and Trade-Offs of Perovskite Solar Modules for Long-Term Operation

Perovskite solar modules (PSMs) have emerged as a promising photovoltaic technology due to their high efficiency, low fabrication cost and compatibility with lightweight and flexible applications. However, ensuring long-term reliable performance under real-world conditions remains a critical barrier to commercialization. PSMs degrade through mechanisms that differ substantially from those affecting established technologies such as silicon, particularly under environmental stressors like ultraviolet light, oxygen, temperature cycling and reverse bias. Here we provide an analysis of the degradation pathways specific to perovskite modules and discuss why standard accelerated tests often fail to predict outdoor performance. We conceptualize challenges across material, device and module levels and evaluate strategies to mitigate ion migration, interfacial breakdown and encapsulation failure. By highlighting the need for realistic testing protocols and durable materials, we propose a framework highlighting key challenges, technological pathways and the trade-offs required to extend perovskite module lifetimes towards long-term operation, aiming to guide the development of PSMs capable of a 30-year operational lifetime.

14 SOLAR ENERGY↗
DOE OSTI2025

Acetolysis for Epoxy-Amine Carbon Fibre-Reinforced Polymer Recycling

Carbon fibre-reinforced polymers (CFRPs) are used in many applications in the global energy transition, including for lightweighting aircraft and vehicles and in wind turbine blades, shipping containers and gas storage vessels1,2,3,4. Given the high cost and energy-intensive manufacture of CFRPs5,6,7, recycling strategies are needed that recover intact carbon fibres and the epoxy-amine resin components. Here we show that acetic acid efficiently depolymerizes both aliphatic and aromatic epoxy-amine thermosets used in CFRPs to recoverable monomers, yielding pristine carbon fibres. Deconstruction of materials from multiple sectors demonstrates the broad applicability of this approach, providing clean fibres from 2 h reactions. The optimal conditions were scaled to 80.0 g of post-consumer CFRPs, and demonstrative composites were fabricated from the recycled carbon fibres, which were recycled two more times, maintaining their strength throughout. Process modelling and techno-economic analysis, with feedstock cost informed by wind turbine blade waste generation8, indicates this method is cost effective, with a minimum selling price of US$1.50 per kg for recycled carbon fibres whereas life cycle assessment shows process greenhouse gas emissions around 99% lower than virgin carbon fibre production. Overall, this approach could enable recycling of industrial CFRPs as it provides clean, mechanically viable recycled carbon fibres and recoverable resin monomers from the thermoset.

09 BIOMASS FUELS↗
DOE OSTI2020

A new magnesium sheet alloy with high tensile properties and room-temperature formability

Lightweight sheet alloys with superior mechanical performance such as high strength, ductility and formability at room temperature (RT) are desirable for high volume automotive applications. However, ductility or formability of metallic alloys at RT are generally inversely related to strength, thereby making it difficult to optimize all three simultaneously. Here we design a new magnesium sheet alloy-ZAXME11100 (Mg-1.0Zn-1.0Al-0.5Ca-0.4Mn-0.2Ce, wt. pct.) via CALPHAD (CALculation of PHAse Diagram) modeling and experimental validation. This new sheet alloy offers an excellent RT formability with a high Index Erichsen (I.E.) value of 7.8 mm in a solution-treated condition (T4), due to its weak and split basal texture and fine grain structure. The new ZAXME 11100 alloy also shows a rapid age-hardening response during post-forming artificial aging treatment at 210 °C for 1hour (T6), resulting in a significant increase of yield strength from 159 MPa (T4) to 270 MPa (T6). The excellent combination of T4 ductility (31%), T4 formability (7.8 mm) and T6 yield strength (270 MPa) in this new magnesium alloy is comparable to that of common 6xxx series aluminum sheet alloys. Thus, this new magnesium sheet alloy is highly attractive for sheet applications in automotive and other industries.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Golden ratio in venation patterns of dragonfly wings

Abstract The vein pattern in insect wings allows this lightweight structure to carry multiple biological functions. Here, an investigation of the angular distribution of the vein struts in dragonfly wings revealed that the golden angle or golden ratio dominates the venation patterns. We find that the golden angle dominates the intervein angles in regions where thin veins and membranes demand strength reinforcement. A golden ratio partition method has thus been developed that explains a set of preferred intervein angles in distorted polygon-shaped venation cells throughout the venation pattern in dragonfly wings. These observations provide new evidence that the wing structure is spatially optimized, by the golden rule in nature, for supporting biomechanical functions of dragonfly wings.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Achieving strength-ductility synergy in hierarchical aluminum metal matrix composites via friction extrusion

We report the fabrication of aluminum metal matrix composites (Al-MMCs) with hierarchical architectures via friction extrusion (FE), a scalable, single-step, solid-phase processing technique. Precursor pucks containing 0–15 vol% Al₂O₃ particles were extruded into fully dense AA6061-based composite rods. The FE induced a tree-ring-like architecture of concentric particle-rich and particle-lean bands, yielding refined grains in particle-rich regions and coarser grains elsewhere. At the nanoscale, magnesium in AA6061 selectively reacted with Al₂O₃ particles to form virus-like nodes, improving particle–matrix bonding. This multi-scale design strategy, combining mesoscale architecture, microscale grain refinement, and nanoscale interface engineering overcome the conventional strength–ductility trade-off. Tensile testing showed substantial increases in yield and ultimate tensile strengths while retaining high ductility ( > 20%). Enhanced strain hardening, driven by the accumulation of geometrically necessary dislocations at interfaces, contributed to the performance. The hierarchical microstructure produced by FE demonstrates a promising pathway for scalable fabrication of lightweight MMCs for structural applications requiring a combined high strength and ductility.

Kalsar, Rajib [Pacific Northwest National Laborato↗
DOE OSTI2024

Analyses of circular solutions for advanced plastics waste recycling

A circular plastics economy can leverage the lightweight, strong and durable characteristics of macromolecular materials, while simultaneously reducing the negative environmental impacts associated with polymer waste. Advanced recycling technologies provide an opportunity to valorize plastics waste and extend the lifespan of these materials by converting waste into new monomers, polymers or specialty chemicals. Although many advanced technologies appear promising, assessments of economic and environmental sustainability are often not conducted in a standardized fashion and neglect factors such as plastics waste transportation, sorting and pretreatment. These shortcomings can lead to inaccurate or misleading predictions, reduce opportunities for optimization and limit industrial relevance. In this Review, we highlight select industrial case studies to underscore the notable consequences of underestimating the complexity of real-life consumer plastics waste. In addition, the current challenges associated with the assessment of the industrial viability of laboratory-scale processes are explored. Here, by discussing relevant analysis frameworks and system boundaries, along with potential analytical pitfalls, future research will be guided beyond chemical considerations and toward impactful circular solutions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Toward a circular economy: zero-waste manufacturing of carbon fiber-reinforced thermoplastic composites

Fiber-reinforced composites are becoming ubiquitous as a way of lightweighting in the wind, aerospace, and automotive industries, but current recycling technologies fall short of a circular economy. In this work, fiber-reinforced composites made of recycled carbon fiber and polyphenylene sulfide were recycled and remanufactured using common processing technologies such as compression and injection molding. An industrially viable size-exclusive sieving technique was used to retain fiber length and reduce variability in the mechanical properties of the remanufactured composites. Fiber length reduction alone could not explain the strength reductions apparent in the composites, which we propose are due to microstructural inhomogeneity as defined by poor dispersion of the fibers. Future recycling efforts must focus on fiber length retention and good dispersion to make composite remanufacturing a viable path toward a circular economy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

An end-to-end workflow for executing a classically bootstrapped variational quantum algorithm on an academic quantum computer

Academic quantum computing platforms often face unique challenges in executing quantum workloads due to fragmented software environments and limited engineering support. Unlike commercial ecosystems, academic devices typically evolve without full-stack integration in mind, making it difficult to run complex applications—such as variational quantum algorithms (VQA)—reliably and efficiently. Issues such as incompatible software layers and lack of automated job management significantly increase the overhead of theory-experiment collaboration. To address these challenges, we develop a modular, end-to-end workflow that decouples application-layer code from low-level hardware control, automates circuit submission and result collection, and supports fine-grained circuit-level job scheduling and recovery. The architecture employs a dual-end application programming interface (API) design, enabling robust operation across unstable or resource-constrained hardware backends. For practical use, the framework is lightweight and user-friendly, allowing rapid prototyping of full-stack workflows using basic Python tools. We validate this workflow on a high-fidelity trapped-ion quantum computer by demonstrating a variational quantum eigensolver (VQE) experiment with a classically bootstrapped ansatz initialization technique. The system successfully executed over 60,000 circuits across multiple molecular test cases with minimal human intervention, highlighting the framework’s effectiveness in enabling reproducible, resilient quantum experimentation in academic settings.

Clifford↗
DOE OSTI2021

Bio-inspired strategies for next-generation perovskite solar mobile power sources

Smart electronic devices are becoming ubiquitous due to many appealing attributes including portability, long operational time, rechargeability and compatibility with the user-desired form factor. Integration of mobile power sources (MPS) based on photovoltaic technologies with smart electronics will continue to drive improved sustainability and independence. With high efficiency, low cost, flexibility and lightweight features, halide perovskite photovoltaics have become promising candidates for MPS. Realization of these photovoltaic MPS (PV-MPS) with unconventionally extraordinary attributes requires new ‘out-of-box’ designs. Natural materials have provided promising designing solutions to engineer properties under a broad range of boundary conditions, ranging from molecules, proteins, cells, tissues, apparatus to systems in animals, plants, and humans optimized through billions of years of evolution. Applying bio-inspired strategies in PV-MPS could be biomolecular modification on crystallization at the atomic/meso-scale, bio-structural duplication at the device/system level and bio-mimicking at the functional level to render efficient charge delivery, energy transport/utilization, as well as stronger resistance against environmental stimuli (e.g., self-healing and self-cleaning). In this paper, we discuss the bio-inspired/-mimetic structures, experimental models, and working principles, with the goal of revealing physics and bio-microstructures relevant for PV-MPS. Here the emphasis is on identifying the strategies and material designs towards improvement of the performance of emerging halide perovskite PVs and strategizing their bridge to future MPS.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Cost estimates of production scale semitransparent organic photovoltaic modules for building integrated photovoltaics

Building integrated photovoltaics (BIPVs) are attached to commercial and residential structures to enable solar energy harvesting. While conventional Si photovoltaics (PVs) are dominant in the current market, second and third generation thin film solar cells based on amorphous Si, CdTe, CIGS, perovskites or organic photovoltaics (OPVs) are often considered as an alternative for BIPV applications since they may offer reduced costs compared to Si PVs. Indeed, recent advances in performance suggest that lightweight, flexible and visibly transparent OPVs can potentially be integrated into windows or other applications to which Si PVs are less well suited. Here, we estimate the cost of high efficiency, semitransparent OPVs (ST-OPVs) based on solution processing in a roll-to-roll (R2R) manufacturing line. Assuming modules with 10% power conversion efficiency (PCE), a 70% geometric fill factor (GFF), and 95% inverter efficiency, we anticipate a %1.6 per Wp module manufacturing cost that includes the cost of the microinverter to condition the OPV dc output to be compatible with the ac line voltage of the building. The materials and inverter cost comprise ~90% of the total module cost. Hence, with simplified material synthesis and a lower inverter cost, including marginally improved PCE and GFF, we expect the cost can be as low as $0.47 per Wp. Here, while the module costs ~60% of the average (uninstalled) double-pane window, we expect the payback period can be as short as 2 to 6 years, suggesting that OPVs can be an economic and attractive candidate for BIPV applications.

14 SOLAR ENERGY↗
DOE OSTI2020

A macromolecular assembly directed ceramic aerogel monolith material

Ceramic aerogels exhibit remarkable thermal insulation for energy efficient building applications, while it is indispensable to understand their nanoporous structure evolution to control their thermal regulation performance. In this study, we design and synthesize a lightweight porous silica aerogel monolithic material, and demonstrate its thermal insulation performance regulated by the morphology of porous nanostructures controlled by surfactant induced self-assembly. The micelle networks and in situ gas bubble formation guide the formation of uniform pores in the as-synthesized monolith, which shows superior thermal and acoustic insulation and robust mechanical stability with a thermal conductivity of 0.032 W m –1 K –1 , a soundproof performance improvement by 17% at a frequency of 800 Hz, and a 1.3 MPa compressive strength with a Young's modulus of 15 MPa. Lastly, these findings provide a new route to manufacture low-cost aerogel monolithic insulation materials for energy efficient building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational investigations of Dienes defect- and vacancy-induced changes in the electronic and vibrational properties of carbon fiber structural units

Carbon fiber (CF) is a promising lightweight alternative to steel and is of significant interest for energy applications. As CF continues to find new uses and is exposed to new external conditions, a noninvasive method of monitoring its structural integrity is critical. Raman spectroscopy is a commonly used method for this monitoring; however, it is highly inferential, and the interpretation of the data is not always straightforward. In this work, we perform density functional theory (DFT) calculations to investigate changes in the vibrational properties of CF structural units (i.e., graphene and graphite) caused by monovacancy and Dienes defects as a foundation for modeling more complex defects that move our model toward that of realistic CF. Using large computational supercells, we can understand how these defects change the electronic structure and vibrational properties of graphene and graphite for interdefect distances near those of the lower experimental limit. The monovacancy opens an electronic bandgap at the K point. Although no such electronic gap is opened by the Dienes defect, both defects introduce flat defect bands near the Fermi energy. The Dienes defect creates long-range deviations of the phonons, leading to substantial broadening of the highest frequency optical modes in the band structure compared to that of the pristine material. In contrast, the phonon changes caused by the monovacancy are short range, and only minor changes in the band structure or phonon density of states were observed. These findings can assist in the interpretation of experimental results by providing atomic-scale insight into key electronic and vibrational features.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

High-performance carbon nanotube electronic ratchets

The rapid advancements in low-power portable/wearable electronic devices require concurrent development of technologies that can provide power without the need for bulky, heavy battery storage. Electronic ratchets, asymmetric transistor-based devices that can convert AC signals or electronic noise into DC power, have been proposed as one solution to this growing need. Here, the recent demonstration of conjugated polymer-based electronic ratchets offers a route toward lightweight, flexible power sources for portable applications. Here we demonstrate the fabrication of the first electronic ratchets where the active channel component consists of semiconducting single-walled carbon nanotubes (s-SWCNTs), which can transform electronic noise or AC signals to a stable DC current with higher output power (up to ca. 14 mW for a chemically doped device) than their polymer-based analogs. We also show that patterning of the dopant profile in the s-SWCNT channel enables reasonable power conversion performance (ca. 3.5 mW) with improved stability relative to homogeneously doped devices. Our findings demonstrate the promise for s-SWCNT electronic ratchets as energy harvesting devices for portable, low-power applications.

ENGINEERING,MATERIALS SCIENCE,NANOSCIENCE AND NANO↗
DOE OSTI2022

Covalently integrated silica nanoparticles in poly(ethylene glycol)-based acrylate resins: thermomechanical, swelling, and morphological behavior

Nanocomposites integrate functional nanofillers into viscoelastic matrices for electronics, lightweight structural materials, and tissue engineering. Herein, the effect of methacrylate-functionalized (MA-SiO 2 ) and vinyl-functionalized (V-SiO 2 ) silica nanoparticles on the thermal, mechanical, physical, and morphological characteristics of poly(ethylene glycol) (PEG) nanocomposites was investigated. The gel fraction of V-SiO 2 composites decreases upon addition of 3.8 wt% but increases with further addition (>7.4 wt%) until it reaches a plateau at 10.7 wt%. The MA-SiO 2 induced no significant changes in gel fraction and both V-SiO 2 and MA-SiO 2 nanoparticles had a negligible impact on the nanocomposite glass transition temperature and water absorption. The Young's modulus and ultimate compressive stress increased with increasing nanoparticle concentration for both nanoparticles. Due to the higher crosslink density, MA-SiO 2 composites reached a maximum mechanical stress at a concentration of 7.4 wt%, while V-SiO 2 composites reached a maximum at a concentration of 10.7 wt%. Scanning electron microscopy, transmission electron microscopy, and small-angle X-ray scattering revealed a bimodal size distribution for V-SiO 2 and a monomodal size distribution for MA-SiO 2 . Although aggregates were observed for both nanoparticle surface treatments, V-SiO 2 dispersion was poor while MA-SiO 2 were generally well-dispersed. Finally, these findings lay the framework for silica nanofillers in PEG-based nanocomposites for advanced manufacturing applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Curiosity driven exploration to optimize structure–property learning in microscopy

Rapidly determining structure–property correlations in materials is an important challenge in better understanding fundamental mechanisms and greatly assists in materials design. In microscopy, imaging data provides a direct measurement of the local structure, while spectroscopic measurements provide relevant functional property information. Deep kernel active learning approaches have been utilized to rapidly map local structure to functional properties in microscopy experiments, but are computationally expensive for multi-dimensional and correlated output spaces. Here, we present an alternative lightweight curiosity algorithm which actively samples regions with unexplored structure–property relations, utilizing a deep-learning based surrogate model for error prediction. We show that the algorithm outperforms random sampling for predicting properties from structures, and provides a convenient tool for efficient mapping of structure–property relationships in materials science.

36 MATERIALS SCIENCE↗
DOE OSTI2025

X-ray and neutron diffraction patterns of the AlCrTiV high-entropy alloy and quaternary Heusler structures

The quaternary alloy AlCrTiV has been proposed as both a lightweight high-entropy alloy and also a functional spin filter material based on the Heusler structure. Experimental investigations to-date, based on X-ray diffraction, offer conflicting interpretations of the structure. Here we simulate diffraction patterns of the various proposed structures to show that neutron diffraction, in particular, can reveal the nature of long-range chemical order and discriminate among distributions of the refractory transition metals. Magnetic contributions to the neutron diffraction are also discussed.

Kalliney, Nedjma [Carnegie Mellon Univ., Pittsburg↗
DOE OSTI2025

Controlling N speciation in solution synthesis of N-doped carbon materials

Carbon-based materials, such as graphite and its functionalized/doped derivatives, are promising lightweight layered materials for hydrogen activation and storage. Their propensity to control the thermodynamics of hydrogen binding and the kinetics of hydrogen mobility strongly depends on the speciation and the arrangement of dopants. In this study, we demonstrate precise control over dopant speciation and clustering in nitrogen-containing layered carbon materials during hydrothermal synthesis. Through extensive spectroscopic characterization and first principles simulations, we demonstrate that the formation of N-motifs can be controlled by the choice of precursor and synthesis temperature. The distinct three-dimensional architecture and porosity in graphene oxide and carbon nitride-derived materials furnish a synthetic pathway for precise control over the local and global structure of nitrogen-doped carbon materials and their activity toward the activation of molecular hydrogen.

Byun, Mi Yeon [Pacific Northwest National Laborato↗
DOE OSTI2025

Elucidating the impact of fiber source on polypropylene/hemp composite performance for the automotive industry

Given their high strength-to-weight ratio, there is an ever-increasing volume of plastics being used in the automotive industry as plastics aid in the charge to lightweight vehicles for improved fuel efficiency. However, these plastics are often landfilled at their end-of-life, which has given rise to the demand for sustainable materials and waste management alternatives compared to purely synthetic systems. Natural fiber composites have been explored as a viable material option to reduce the environmental impact of plastic use in automobiles while simultaneously ensuring the part performance is not sacrificed. Herein, we explored the use of hemp/polypropylene (PP) composites in which US-sourced hemp is compared to internationally sourced and industrially available hemp. There appears to be a minimal impact on the composite properties regardless of fiber sourcing, and the addition of a natural filler to the PP matrix results in up to a 367% increase in Young's modulus, 126% increase in heat deflection temperature, and comparable water uptake performance. It should be noted that the natural filler addition does increase density by up to 13% due to the higher density of natural fibers compared to the low-density PP matrix. A modified rule of mixtures calculation revealed that the composite materials produced in this study demonstrated good agreement with analytical modeling. Finally, a screening analysis was performed exploring the transportation of hemp fibers, and the results build a strong case for regionalized manufacturing of automotive parts.

Hubbard, Amber M. [Oak Ridge National Laboratory (↗