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DOE OSTI2021

Epitaxial nanotwinned metals and alloys: synthesis-twin structure–property relations

Extensive studies have been performed to understand the structure–property relationship in nanotwinned (NT) metals, where the average twin thickness or twin spacing is less than 100 nm. NT metals may have high strength, ductility, good electrical conductivity and corrosion resistance and have promising applications in microelectronics, structural materials and coatings for gas and oil industry. Most prior studies focus on the computational and experimental investigations of NT metals with low stacking fault energy (SFE) and often in polycrystalline forms. In this highlight, we review recent findings on epitaxial growth of NT metals and alloys with low and high SFEs deposited on single crystal substrates, and focus primarily on advancing our comprehension towards tailoring the microstructures and properties of NT metals via extrinsic factors, including the synthesis technique, parametric control and growth template, and intrinsic factors, such as SFE and thermodynamic, kinetic alloying effects. The review intends to illuminate how to synthesize and design epitaxial NT structures to achieve desirable properties.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Chelation-directed interface engineering of in-place self-cleaning membranes

Water–energy sustainability will depend upon the rapid development of advanced pressure-driven separation membranes. Although energy-efficient, water-treatment membranes are constrained by ubiquitous fouling, which may be alleviated by engineering self-cleaning membrane interfaces. In this study, a metal-polyphenol network was designed to direct the armorization of catalytic nanofilms (ca. 18 nm) on inert polymeric membranes. The chelation-directed mineralized coating exhibits high polarity, superhydrophilicity, and ultralow adhesion to crude oil, enabling cyclable crude oil-in-water emulsion separation. The in-place flux recovery rate exceeded 99.9%, alleviating the need for traditional ex situ cleaning. The chelation-directed nanoarmored membrane exhibited 48-fold and 6.8-fold figures of merit for in-place self-cleaning regeneration compared to the control membrane and simple hydraulic cleaning, respectively. Precursor interaction mechanisms were identified by density functional theory calculations. Here, chelation-directed armorization offers promise for sustainable applications in catalysis, biomedicine, environmental remediation, and beyond.

42 ENGINEERING↗

DOE OSTI2025

Demonstration of $E$ acc = 10 MV m −1 with Nb 3 Sn cavities in a cryomodule

Accelerating cryomodules with superconducting cavities are key components for particle accelerators. The efficiency, energy gain and operating temperature of cavities drive the operating and capital costs; hence, advances in these areas enable future accelerators. While superconducting cavities are currently made from Nb, Nb 3 Sn, with a superconducting transition temperature and superheating field approximately twice that of Nb, is poised to substantially improve the efficiency and energy gain. We present results from the first cryomodule with two five-cell 1.5 GHz superconducting radiofrequency Nb cavities coated with Nb 3 Sn, which attained an accelerating gradient of ⩾10 MV m −1 with low cryogenic loss at 4.4 K.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Formulation via Resonant Acoustic Mixing at LANL

Discussions in the middle of 2014 led researchers at LANL to seek an alternate formulation method for making PBX based explosives. We began looking into the use of Resonant Acoustic Mixers (RAM) to formulate explosives and mocks. Acoustic mixing had been used in pharmaceutical plants for mixing medicines and coating materials, so we envisioned transitioning that same technology to the energetics world. Up until this time only the wet slurry formulation method that had been used was from the 1940’s. This wet slurry method had been and still was the standard for all explosive formulations. The possibility of an alternate method needed to be looked at to advance the process by expanding solvent choices, substrates, and reducing costs. Acoustic mixing had been shown to mix powders, slurries, pastes or even liquids. A Resodyn LabRAM was purchased in late 2014 to explore these possible applications to energetics. This LabRAM was in a remote configuration that met our need for explosive operations.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hybrid nanocapsules for in situ TEM imaging of gas evolution reactions in confined liquids

Liquid cell transmission electron microscopy (TEM) enables the direct observation of dynamic physical and chemical processes in liquids at the nanoscale. Quantitative investigations into reactions with fast kinetics and/or multiple reagents will benefit from further advances in liquid cell design that facilitate rapid in situ mixing and precise control over reagent volumes and concentrations. This work reports the development of inorganic–organic nanocapsules for high-resolution TEM imaging of nanoscale reactions in liquids with well-defined zeptoliter volumes. These hybrid nanocapsules, with 48 nm average diameter, consist of a thin layer of gold coating a lipid vesicle. As a model reaction, the nucleation, growth, and diffusion of nanobubbles generated by the radiolysis of water is investigated inside the nanocapsules. When the nanobubbles are sufficiently small (10–25 nm diameter), they are mobile in the nanocapsules, but their movement deviates from Brownian motion, which may result from geometric confinement by the nanocapsules. Gases and fluids can be transported between two nanocapsules when they fuse, demonstrating in situ mixing without using complex microfluidic schemes. The ability to synthesize nanocapsules with controlled sizes and to monitor dynamics simultaneously inside multiple nanocapsules provides opportunities to investigate nanoscale processes such as single nanoparticle synthesis in confined volumes and biological processes such as biomineralization and membrane dynamics.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Are Contact Angle Measurements Useful for Oxide-Coated Liquid Metals?

This work establishes that static contact angles for gallium-based liquid metals have no utility despite the continued and common use of such angles in the literature. In the presence of oxygen, these metals rapidly form a thin (~1–3 nm) surface oxide “skin” that adheres to many surfaces and mechanically impedes its flow. This property is problematic for contact angle measurements, which presume the ability of liquids to flow freely to adopt shapes that minimize the interfacial energy. We show here that advancing angles for a metal are always high (>140°)—even on substrates to which it adheres—because the solid native oxide must rupture in tension to advance the contact line. The advancing angle for the metal depends subtly on the substrate surface chemistry but does not vary strongly with hydrophobicity of the substrate. During receding measurements, the metal droplet initially sags as the liquid withdraws from the “sac” formed by the skin and thus the contact area with the substrate initially increases despite its volumetric recession. Furthermore, the oxide pins at the perimeter of the deflated “sac” on all the surfaces are tested, except for certain rough surfaces. With additional withdrawal of the liquid metal, the pinned angle gets smaller until eventually the oxide “sac” collapses. Thus, static contact angles can be manipulated mechanically from 0° to >140° due to hysteresis and are therefore uninformative. We also provide recommendations and best practices for wetting experiments, which may find use in applications that use these alloys such as soft electronics, composites, and microfluidics.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Solid-to-plasma transition of polystyrene induced by a nanosecond laser pulse within the context of inertial confinement fusion

Laser Direct Drive (LDD) Inertial Confinement Fusion (ICF) involves irradiating a spherical target of thermonuclear fuel coated with an ablator, usually made of polystyrene. Laser energy absorption near the target surface leads to matter ablation, hydrodynamic shocks, and ultimately capsule implosion. The conservation of spherical symmetry is crucial for implosion efficiency, yet spatial modulations in laser intensity can induce nonuniformities, causing the laser imprint phenomenon. Understanding laser imprint, especially considering the initial solid state, is essential for advancing LDD ICF. A first microscopic model of solid-to-plasma transition was built in 2019, accounting for laser absorption in the solid state with a band structure based ionization model. This model has been improved to include chemical fragmentation and a more accurate description of electron collision frequency in various matter states. The latest development involves assessing the model reliability by comparing theoretical predictions with experimental observations. Despite the success of this approach, questions remain, leading to further investigations and observations under different irradiation conditions. This work presents an experiment with a nanosecond pulse, taking into account hydrodynamic effects, and measures transmission dynamics over the entire laser beam area to observe two-dimensional effects. As a result, the objective is to adapt the theoretical model, couple it with a hydrodynamic code, and observe additional effects related to the initial solid state.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

High-Temperature Compatibility of Structural Alloys with Supercritical and Subcritical CO 2

In searching for new working fluids for power generation, supercritical CO 2 (sCO 2 ) offers some attractive features for efficient cycles. However, compatibility with structural alloys is a concern. NiCr-based alloys have excellent compatibility at 600°-800°C at 20-30 MPa sCO 2 . However, conventional steels have restrictions in temperature because of carburization and accelerated oxidation in sCO 2 , similar to observations in CO 2 . To assess the impact of carburization on steel mechanical properties, small (25mm long) dogbone tensile bars are being exposed and tested after exposure at 450°-650°C. Only highly alloyed advanced austenitic steels are resistant to carburization at 650°-750°C, suggesting that Crrich oxide scales are good barriers to C ingress. Above 800°C, it is only possible to conduct subcritical evaluations at this time, but initial results suggest most conventional high-temperature Fe- and Ni-based alloys are more rapidly degraded by CO 2 at higher temperatures. Coatings are a potential solution that require more study.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Graphene-assisted spontaneous relaxation towards dislocation-free heteroepitaxy

While conventional homoepitaxy forms high-quality epitaxial layers, the limited set of material systems for commercially available wafers restricts the range of materials that can be grown homoepitaxially. At the same time, conventional heteroepitaxy of lattice-mismatched systems produces dislocations above a critical strain energy to release the accumulated strain energy as the film thickness increases. The formation of dislocations, which severely degrade electronic/photonic device performances, is fundamentally unavoidable in highly lattice-mismatched epitaxy. Herein, we introduce a unique mechanism of relaxing misfit strain in heteroepitaxial films that can enable effective lattice engineering. We have observed that heteroepitaxy on graphene-coated substrates allows for spontaneous relaxation of misfit strain owing to the slippery graphene surface while achieving single-crystalline films by reading the atomic potential from the substrate. This spontaneous relaxation technique could transform the monolithic integration of largely lattice-mismatched systems by covering a wide range of the misfit spectrum to enhance and broaden the functionality of semiconductor devices for advanced electronics and photonics.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2022

Performance of Different Water-Based Binder Formulations for Ni-Rich Cathodes Evaluated in LiNi 0.8 Mn 0.1 Co 0.1 O 2 //Graphite Pouch Cells

Water-based processing for lithium-ion battery electrodes is attractive due to its lower manufacturing cost and smaller environmental impact. However, multiple challenges associated with aqueous cathode processing have hindered commercial adoption. Polymer binders are an important component of the electrode, and thus the choice of binders can alter electrode cycling performance significantly. In this work, four different water-based binder combinations are investigated for Ni-rich LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811)-based cathodes, with a focus on the long-term electrochemical performance in practical-format full pouch cells. No additional pH-modulating additives were added to the aqueous cathode slurries, and no protective coatings were present on the cathode or aluminum current collector. Results are compared with the standard PVDF/NMP-based binder/solvent combination, used as a baseline. The influence of water-based binder type on slurry rheology and electrode microstructure are also discussed. All cells made by water-processing had worse rate performance compared to the baseline. However, the cell discharge capacity after 1000 U.S. Advanced Battery Consortium (USABC) cycles at C/3 charge/discharge rate was comparable to the baseline for two of the water-based cathode formulations (CMC & JSR, and LiPAA), demonstrating the potential viability of aqueous-processed Ni-rich cathodes at a commercial scale.

25 ENERGY STORAGE↗

DOE OSTI2023

High-Strength, High-Ductility, High Entropy Alloys with High-Efficiency Native Oxide Solar Absorbers for Concentrating Solar Power Systems

This EPSCoR Project has been investigating the synergy between the excellent high-temperature mechanical behavior of FeMnNiAlCr high entropy alloys (HEA) and the high solar absorptance of their native oxides for high efficiency concentrated solar thermal power (CSP) systems working at >700°C. While HEAs have attracted substantial interest in recent years, most investigations have focused on their applications as structural materials rather than functional materials. This EPSCoR project discovered that FeMnNiAlCr HEAs can potentially be applied synergistically as both a structural and functional material for high-efficiency concentrating solar thermal power (CSP) systems working at >700°C. The HEA itself would be used in high-temperature tubing to carry molten salts or supercritical CO 2 , while its surface oxide would act as a high-efficiency solar thermal absorber. With Fe and Mn being the major components in these HEAs (adding up to ~70 at.% of the alloy), these materials are much more cost-effective than the Ni-based superalloys currently being investigated for high-temperature CSP systems. Through this research, these Fe-Mn based HEAs have demonstrated yield strengths 2-3x greater than that of stainless steel at 700°C and a creep lifetime >800 h at 700ºC under a typical CSP tubing mechanical load of 35 MPa. Their Mn-rich surface oxides maintain a high optical-to-thermal conversion efficiency of ~87% under 1000x solar concentration ratio for 20 simulated day-night thermal cycles between 750ºC and room temperature. In preliminary corrosion studies, these HEAs have sustained immersion in unpurified bromide molten salts for 14 days at 750°C with <2% weight loss, in contrast to 70% weight loss from a 316 stainless steel reference. The simultaneous achievement of promising mechanical, optical, and thermochemical properties in this FeMnNiAlCr system opens the door to new applications of HEAs in solar energy harvesting. Partnerships with Ames Laboratory and Oak Ridge National Laboratory (ORNL) also advanced our understanding of the fundamental structure-property relationships through atomic scale material characterization and first-principles computational modeling. The key research results in this project can potentially be extended to other HEAs and their native oxides. In terms of applications, the proposed FeMnNiAlCr HEA/native oxide system could potentially exceed the mechanical and the optical performance of existing tubing and solar coating materials under EERE’s CSP program at lower cost, which also aligns well with the EPSCoR Science and Technology strategies of New Hampshire in boosting the deployment of renewable energy.

14 SOLAR ENERGY↗

DOE OSTI2025

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Scale-invariant machine-learning model accelerates the discovery of quaternary chalcogenides with ultralow lattice thermal conductivity

We design an advanced machine-learning (ML) model based on crystal graph convolutional neural network that is insensitive to volumes (i.e., scale) of the input crystal structures to discover novel quaternary chalcogenides, AMM'Q 3 (A/M/M' = alkali, alkaline earth, post-transition metals, lanthanides, and Q = chalcogens). These compounds are shown to possess ultralow lattice thermal conductivity (κ l ), a desired requirement for thermal-barrier coatings and thermoelectrics. Upon screening the thermodynamic stability of ~1 million compounds using the ML model iteratively and performing density-functional theory (DFT) calculations for a small fraction of compounds, we discover 99 compounds that are validated to be stable in DFT. Taking several DFT-stable compounds, we calculate their κ l using Peierls–Boltzmann transport equation, which reveals ultralow κ l (<2 Wm -1 K -1 at room temperature) due to their soft elasticity and strong phonon anharmonicity. Our work demonstrates the high efficiency of scale-invariant ML model in predicting novel compounds and presents experimental-research opportunities with these new compounds.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Understanding EBC Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. The goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aero-turbine applications. To provide data for the lifetime model, laboratory testing used plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air-steam environments and reaction kinetics were assessed from 700°-1350°C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

Ridley, Mackenzie↗

DOE OSTI2024

Advancements in Manufacturing of High-Performance Perovskite Solar Cells and Modules Using Printing Technologies

Perovskite photovoltaic technology carries immense opportunity for the solar industries because of its remarkable efficiency and prospect for cost-effective production. However, the successful deployment of perovskite solar modules (PSMs) in the solar market necessitates tackling stability-based obstacles, scalability, and environmental considerations. This paper unveils a comprehensive examination of the cutting-edge advancements in the manufacturing of perovskite solar cells (PSCs) and modules, with an emphasis on high-speed, large-area printing. The paper underscores the substantial progress achieved in printed PSCs and PSMs, demonstrating promising electrical performance and long-term device durability. This review paper categorizes printing techniques compatible with large-area high-speed manufacturing into three distinct families: blade coating, slot die coating, and screen printing, as these common printing practices offer precise control, scalability, cost-effectiveness, high resolution, and efficient material usage. Additionally, this paper presents an in-depth investigation and comparison of superior PSCs and PSMs fabricated by printing on power conversion efficiency (PCE), stability, and scalability.

14 SOLAR ENERGY↗

DOE OSTI2021

Advances in Nb 3 Sn superconducting radiofrequency cavities towards first practical accelerator applications

Abstract Nb 3 Sn is a promising next-generation material for superconducting radiofrequency cavities, with significant potential for both large scale and compact accelerator applications. However, so far, Nb 3 Sn cavities have been limited to continuous wave accelerating fields <18 MV m −1 . In this paper, new results are presented with significantly higher fields, as high as 24 MV m −1 in single cell cavities. Results are also presented from the first ever Nb 3 Sn-coated 1.3 GHz 9-cell cavity, a full-scale demonstration on the cavity type used in production for the European XFEL and LCLS-II. Results are presented together with heat dissipation curves to emphasize the potential for industrial accelerator applications using cryocooler-based cooling systems. The cavities studied have an atypical shiny visual appearance, and microscopy studies of witness samples reveal significantly reduced surface roughness and smaller film thickness compared to typical Nb 3 Sn films for superconducting cavities. Possible mechanisms for increased maximum field are discussed as well as implications for physics of RF superconductivity in the low coherence length regime. Outlook for continued development is presented.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Advances in laser-based bremsstrahlung x-ray sources. II. Laser pulse propagation and guiding in nonuniform plasma media in the presence of self-focusing

An analytic Wentzel–Kramers–Brillouin model is presented of Gaussian laser pulse propagation through plasma with a quadratic transverse density profile and an arbitrarily varying, longitudinal density gradient under conditions of nonlinear self-focusing. From these solutions, it is shown that in the absence of nonlinear self-focusing and transverse nonuniformity, for exponential pre-plasma density profiles, the use of a low density coating of the laser target with electron density n0∼11 ncr (e.g., a CH foam of density 35 mg/cm3 for 1-micron laser light) maximizes laser intensity at best focus. Also, under laser and plasma conditions relevant to recent experiments on high-power laser systems, conditions are obtained for a Gaussian laser pulse to propagate stably through the pre-plasma medium. Such conditions would be expected to enhance the production of relativistic electrons from laser-target coupling, providing a possible explanation for the observed increase in MeV photon dose and enabling applications such as laser-based MeV X-ray radiography.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

Improving knife milling performance for biomass preprocessing by using advanced blade materials

Mechanical preprocessing of biomass, including size reduction, is a crucial step in converting biomass into biofuel. However, feedstock inevitably contains abrasive intrinsic and extrinsic inorganics that may cause excessive tool wear in preprocessing. Here, this work demonstrates that performance of a knife mill can be significantly improved by applying a more wear-resistant blade material. A series of full-scale knife mill tests were performed for size reduction of forest residue using blades of tungsten carbide (WC–Co), iron-borided tool steel, and diamond-like carbon (DLC) coated tool steel. Blade material loss was quantified in correlation to the amount of feedstock processed and wear mechanisms were investigated via worn surface characterization. While the thin DLC coating was removed quickly, the WC-Co and iron-borided blades improved the tool life by 8X and 3X compared with the M2 tool steel blades (baseline), respectively. The in-situ throughput and power consumption measurements provided additional insights. The WC-Co and iron-borided blades had ~3X higher throughput than the baseline blades by the end of the test with lower normalized power consumption. The experimental results were then used as input for a techno-economic analysis, which suggested that the more wear resistant blades could cut the knife milling cost by $2–3 per ton of biomass processed with downtime reduced by 65–85%.

36 MATERIALS SCIENCE↗