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DOE OSTI2021

Mechanical characterization of 304L-VAR stainless steel in tension with a full coverage of low, intermediate, and high strain rates

A 304L-VAR stainless steel is mechanically characterized in tension over a full range of strain rates from low, intermediate, to high using a variety of apparatuses. While low- and high-strain-rate tests are conducted with a conventional Instron and a Kolsky tension bar, the tensile tests at intermediate strain rates are conducted with a fast MTS and a Drop-Hopkinson bar. The fast MTS used in this study is able to obtain reliable tensile response at the strain rates up to 150 s -1 , whereas the lower limit for the Drop-Hopkinson bar is 100 s -1 . Combining the fast MTS and the Drop-Hopkinson bar closes the gap within the intermediate strain rate regime. Using these four apparatuses, the tensile stress-strain curves of the 304L-VAR stainless steel are obtained at strain rates on each order of magnitude ranging from 0.0001 to 2580 s -1 . All tensile stress-strain curves exhibit linear elasticity followed by significant work hardening prior to necking. After necking occurrs, the specimen load decreases, and the deformation becomes highly localized until fracture. The tensile stress-strain response of the 304L-VAR stainless steel exhibits strain rate dependence. The flow stress increases with increasing strain rate and is described with a power law. The strain-rate sensitivity is also strain-dependent, possibly due to thermosoftening caused by adiabatic heating at high strain rates. The 304L-VAR stainless steel shows significant ductility. The true strains at the onset of necking and at failure are determined. The results show that the true strains at both onset of necking and failure decrease with increasing strain rate. The true failure strains are approximately 200% at low strain rates but are significantly lower (~100%) at high strain rates. The transition of true failure strain occurs within the intermediate strain rate range between 10 -2 and 10 2 s -1 . A Boltzmann description is used to present the effect of nominal strain rate on true failure strain.

304L-VAR stainless Steel↗

DOE OSTI2018

Enabling high rate charge and discharge capability, low internal resistance, and excellent cycleability for Li-ion batteries utilizing graphene additives

A liquid-phase mixing method is adopted to uniformly disperse the graphene nanosheets onto LiNi 1/3 Co 1/3 Mn 1/3 O 2 cathode for high-performance Li-ion batteries (LIBs). The electrochemical performance was characterized using a full pouch cells with state-of-the-art electrode areal loading (compared to half coin cells). The addition of graphene sheets (i.e., only 1 wt%) significantly improves the high rate capability for charging and discharging operation. For example, 6 times improvement in 5 C charging was achieved providing further insights in enabling extreme fast charging for LIBs. Other benefits include longer cycleability, lower internal resistance, and higher lithium ion diffusion coefficient, demonstrated by charge-discharge cycling tests and electrochemical impedance spectroscopy. Higher capacity retention of 88.2% and decreased internal resistance of ~0.9 Ω are observed after 400 cycles. The diffusion coefficient of Li ions is 6.49 × 10 -8 cm 2 s -1 when charged to 4.2 V, which is approximately 1.37 times higher compared to the configuration with no graphene sheet (4.74 × 10 -8 cm 2 s -1 ). To conclude, the improved performance is ascribed to a robust network among the active materials formed by graphene sheets, which serves as an extended current conductor and facilitates charge transfer, ionic reversibility, and ionic transportation.

25 ENERGY STORAGE↗

DOE OSTI2024

Crack Propagation Modeling of a High-Speed Outer Rotor Motor

This study aims to investigate the propagation of initial cracks in electric motors and their rate of spread through the rotor structure under various operating conditions. Traction motors are subjected to high centrifugal load owing to their speed and rapid acceleration and deceleration. In the manufacturing process, some initial imperfections or cracks in the rotor components are likely to occur. Under the influence of loading, these cracks will grow, and factors such as loading frequency, material strength, and location of material voids will affect this threshold speed. In the current study, a fracture mechanics–based approach has been used to investigate the crack growth rate for a 100 kW outer rotor motor with a rated speed of 6,000 rpm and a peak speed of 20,000 rpm for an integrated drive application.

Barua, Himel↗

DOE OSTI2024

A chemical kinetic analysis of knock propensity of methanol-to-gasoline fuel

Production of low carbon gasoline-like fuels such as methanol-to-gasoline (MTG) is a promising approach to achieve rapid greenhouse gas emission reduction of the transportation sector. Despite the fact that gasoline that meets the ASTM D4814 standard for automotive spark-ignition engine fuel can be readily produced from these processes, it is unclear how the composition of MTG may affect engine performance and emissions. Here, in this paper, a surrogate for an MTG is used to numerically study the effects of gasoline composition on knock propensity and on the sensitivity of knock to thermal and fuel stratification, to oxygen dilution and to nitric oxide from exhaust gas recirculation of residual gases. Simulations were performed in ANSYS CHEMKIN-PRO using a comprehensive chemical kinetic mechanism for gasoline surrogates, and results of the MTG surrogate were compared against those of a petroleum-based regular E10 gasoline, termed PACE-20. A premium-grade MTG fuel was also formulated by adding ethanol to the MTG surrogate, and results were compared against those of four premium-grade, gasoline-like fuels representative of future alternative gasoline formulations. Surrogates and mechanism were evaluated by comparison against experimental engine data, and the model showed high accuracy at stoichiometric conditions (mean absolute error of ignition timing equal to 1.46 crank angle degrees) but larger deviations at lean conditions (mean absolute error of ignition timing equal to 5.52 crank angle degrees). Despite the fact that the MTG surrogate has a RON 1.1 units higher than that of PACE-20, it may show higher knock propensity at medium temperature conditions due to a less intense NTC behavior. MTG autoignition was more temperature- and equivalence ratio-sensitive than that of PACE20, suggesting that MTG can benefit more from naturally-occurring thermal stratification or from induced fuel stratification of the end gas to mitigate knock intensity. The sensitivity of autoignition reactivity to oxygen dilution and to NO concentration was higher for MTG than for regular gasoline at medium loads, but the opposite trend was observed at high loads due to the effect of pressure on the low-temperature chemistry of regular gasoline. Approximately 14 % vol ethanol content was required to upgrade the octane rating of MTG from regular grade to premium grade. Adding 13.6 % vol ethanol made the fuel autoignition less sensitive to both oxygen dilution and NO content (ignition time varies approx. 17 % and 50 % less with oxygen dilution and NO addition, respectively, when adding ethanol at high engine loads).

02 PETROLEUM↗

NASA NTRS1994

Hydro-isostatic deflection and tectonic tilting in the central Andes: Initial results of a GPS survey of Lake Minchin shorelines

Sufficiently large lake loads provide a means of probing rheological stratification of the crust and upper mantle. Lake Minchin was the largest of the late Pleistocene pluvial lakes in the central Andes. Prominent shorelines, which formed during temporary still-stands in the climatically driven lake level history, preserve records of lateral variations in subsequent net vertical motions. At its maximum extent the lake was 140 m deep and spanned 400 km N-S and 200 km E-R. The load of surficial water contained in Lake Minchin was sufficient to depress the crust and underlying mantle by 20-40 m, depending on the subjacent rheology. Any other differential vertical motions will also be recorded as departures from horizontality of the shorelines. We recently conducted a survey of shoreline elevations of Lake Minchin with the express intent of monitoring the hydro-isostatic deflection and tectonic tilting. Using real-time differential Global Positioning System (GPS), we measured topographic profiles across suites of shorelines at 15 widely separated locations throughout the basin. Horizontal and vertical accuracies attained are roughly 30 and 70 cm, respectively. Geomorphic evidence suggests that the highest shoreline was occupied only briefly (probably less than 200 years) and radiocarbon dates on gastropod shells found in association with the shore deposits constrain the age to roughly 17 kyr. The basin-side pattern of elevations of the highest shoreline is composed of two distinct signals: (27 +/- 1) m of hydro-isostatic deflection due to the lake load, and a planar tilt with east and north components of (6.8 +/- 0.4) 10(exp -5) and 9-5.3 +/- 0.3) 10(exp -5). This rate of tilting is too high to be plausibly attributed to steady tectonism, and presumably reflects some unresolved combination of tectonism plus the effects of oceanic and lacustrine loads on a laterally heterogeneous substrate. The history of lake level fluctuations is still inadequately known to allow detailed inferences of crust and mantle rheology. However, it is already clear that the effective elastic plate thickness is closer to 40 km than the 60-70 km crustal thickness in the central Andes and the effective viscosity is less than 5 10(exp 20) Pa s.

Bills, Bruce G.↗

DOE OSTI2023

Effects of particle size, shape and loading rate on the normal compaction of an advanced granular ceramic

Compaction behavior of granular materials is influenced by strain rate, particle size, and shape. In this report, boron carbide powders with different particle sizes under uni-axial strain conditions are studied using quasi-static compression, dynamic Kolsky bar experiments and normal plate impact. A rounded powder is compacted to investigate the effect of particle shape. The normal plate impact technique is an excellent tool in characterization of powder compaction behavior up to strain rates of ~10 5 s -1 . From our experiments, granular boron carbide shows a highly compressible behavior with significant volume compaction. Constitutive responses are obtained for four powders. Particle fracture is identified as key deformation mechanism. Dynamic loading introduces more particle fragmentation than quasi-static loading. Morphological characterization of particle shapes shows that the deformation from powder compaction alters the particle shape distribution, which is also rate-dependent. Particle size, shape and strain rate effects on the normal stress are discussed accordingly.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Monodomain Liquid‐Crystal Elastomer Lattices for Broad Strain‐Rate Mechanical Damping

Designing structures that effectively dissipate energy across a broad range of mechanical loading rates, including those from compression, shock, and vibration, poses a significant engineering challenge. In this study, liquid‐crystal elastomers (LCEs), which possess anisotropic properties due to the alignment of their polymer backbone, are explored. As a result, LCEs exhibit a soft elastic response under mechanical loading, making them ideal for energy dissipation. Advances in additive manufacturing (AM) enable simple fabrication of foamlike dissipative structures with complex lattice geometries. Herein, direct ink write 3D printing, an extrusion AM method, is used to fabricate aligned, monodomain LCE lattice structures for broad strain‐rate mechanical damping. In this work, it is shown that these structures can dissipate strain energy in quasi‐static environments, comparable to traditional elastomeric lattices, and provide improved damping under high strain‐rate drop testing due to LCE soft elasticity. Additionally, under dynamic mechanical vibration, monodomain LCE lattices enhance damping at structural natural frequencies and provide high‐frequency attenuation. Finally, in these findings, a promising method is presented for fabricating mechanical damping devices that effectively dissipate energy across a broad range of loading rates.

3D printings↗

DOE OSTI2018

MoS 2 /TiO 2 heterostructures as nonmetal plasmonic photocatalysts for highly efficient hydrogen evolution

In this study, we report a nonmetal plasmonic MoS2@TiO2 heterostructure for highly efficient photocatalytic H2 generation. Large area laminated Z-scheme MoS2 in conjunction with TiO2 nanocavity arrays are achieved via carefully controlled anodization, physical vapor deposition, and chemical vapor deposition processes. Broad spectral response ranging from ultraviolet (UV)-visible (vis) to near-infrared (NIR) wavelengths and finite element frequency-domain simulation suggest that this MoS2@TiO2 heterostructured photocatalyst possesses an enhanced activity for H+ reduction. A high H2 yield rate of 580 mmol h-1 g-1 is achieved using a low catalyst loading mass of 10.2 μg. The spatially uniform heterostructure, correlated to plasmon-resonance through conformal coating MoS2 that effectively regulated charge transfer pathways, is proven to be vitally important for the unique solar energy harvesting and photocatalytic H2 production. As an innovative exploration, our study demonstrates that the photocatalytic activities of nonmetal, earth-abundant materials can be enhanced with plasmonic effects, which may serve as an excellent catalytic agent for solar energy conversion to chemical fuel. Periodically patterned MoS 2 /TiO 2 heterostructures were rationally designed as nonmetal plasmonic photocatalysts for highly efficient hydrogen evolution.

Environmental Molecular Sciences Laboratory↗

DOE OSTI2018

Fiber from DDGS and Corn Grain as Alternative Fillers in Polymer Composites with High Density Polyethylene from Bio-based and Petroleum Sources

The steady increase in production of corn based ethanol fuel has dramatically increased the supply of its major co-product known as distiller’s dried grain with solubles (DDGS). Large amount of DDGS and corn flour are used as an animal feed. The elusieve process can separate DDGS or corn flour into two fractions: DDGS fraction with enhanced protein and oil content or corn flour fraction with high starch content, and hull fiber. This study investigated the feasibility of using fiber from DDGS and corn grain as alternative fillers to wood fiber in high density polyethylene (HDPE) composites made with two different sources of polymers. Two fiber loading rates of 30 and 50% were evaluated for fiber from DDGS, corn, and oak wood (control) to assess changes in various physical and mechanical properties of the composite materials. Two HDPE polymers, a bio-based HDPE made from sugarcane (Braskem), and a petroleum based HDPE (Marlex) were also compared as substrates. The biobased polymer composites with DDGS and corn fibers showed significantly lower water absorption than the Marlex composite samples. The Braskem composite with 30% DDGS fiber loading showed the highest impact resistance (80 J/m) among all the samples. The flexural properties showed no significant difference between the two HDPE composites.

36 MATERIALS SCIENCE↗

DOE OSTI2018

A Comparative Study of Fracture Toughness at Cryogenic Temperature of Austenitic Stainless Steel Welds

The ITER magnet system is based on the “cable-in-conduit” conductor (CICC) concept, which consists of stainless steel jackets filled with superconducting strands. The jackets provide high strength, limited fatigue crack growth rate and fracture toughness properties to counteract the high stress imposed by, among others, electromagnetic loads at cryogenic temperature. Austenitic nitrogen-strengthened stainless steels have been chosen as base material for the jackets of the central solenoid and the toroidal field system, for which an extensive set of cryogenic mechanical property data are readily available. However, little is published for their welded joints, and their specific performance when considering different combinations of parent and filler metals. Moreover, the impact of post-weld heat treatments that are required for Nb{sub 3}Sn formation is not extensively treated. Welds are frequently responsible for cracks initiated and propagated by fatigue during service, causing structural failure. It becomes thus essential to select the most suitable combination of parent and filler material and to assess their performance in terms of strength and crack propagation at operation conditions. An extensive test campaign has been conducted at 7 K comparing tungsten inert gas (TIG) welds using two fillers adapted to cryogenic service, EN 1.4453 and JK2LB, applied to two different base metals, AISI 316L and 316LN. A large set of fracture toughness data are presented, and the detrimental effect on fracture toughness of post-weld heat treatments (unavoidable for some of the components) is demonstrated. In this study, austenitic stainless steel TIG welds with various filler metals have undergone a comprehensive fracture mechanics characterization at 7 K. These results are directly exploitable and contribute to the cryogenic fracture mechanics properties database of the ITER magnet system. Additionally, a correlation between the impact in fracture toughness and microstructure resulting from the above treatment is provided.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hydrodynamics of countercurrent flows in a structured packed column: effects of initial wetting and dynamic contact angle

The structured packed column has gained considerable attention as a prospective technology to mitigate carbon dioxide emissions from thermal power plants. The computational flow investigation of such systems is a multiscale problem, and local hydrodynamics plays a key role in overall column efficiency. Accordingly, multiphase flow studies in the representative elementary unit (REU) of a packed column can offer insights into the local flow behavior such as flow pattern, interfacial area, etc. The interfacial area plays a key role in the overall interphase mass transfer and thereby in separation efficiency. The predicted effective area matches well with corresponding ones in experiments for Mellapak 250.Y packings. The contact angle (i.e., solid substrate behavior) is one of the critical factors that dictates wettings, and thereby the interfacial area. The dynamic contact angle (DCA) was considered in order to explore the effects of contact angle hysteresis on the interfacial area. DCA has more pronounced impact on the interfacial area for a solvent possessing a higher value of surface tension and equilibrium contact angle. The interfacial area shows temporal undulation and does not achieve a pseudo steady state due to the capillary force. In contrary, the interfacial area gets a net value for a solvent having low surface tension value. Further, specification of the static contact angle at the solid substrate shows the least value of the interfacial area. We also extensively studied the effect of the initial sheet condition (dry vs wet) on the interfacial area. The initially wetted sheets show slightly higher value of the interfacial area as compared to the initially dry sheets at a fixed flow rate for a solvent having high surface tension value. Wetting hysteresis decreases with increasing liquid loads. On the other hand, wetting hysteresis does not occur for a solvent having value of low surface tension and equilibrium contact angle.

structured packings, dynamic contact angle, interf↗

DOE OSTI2013

Alendronate functionalized mesoporous hydroxyapatite nanoparticles for drug delivery

Highlights: ► The synthesized mesoporous hydroxyapatite has nanostructure and bioactivity. ► The materials have high surface area and amino group. ► The materials show higher drug loading and slower release rate than pure HAP. - Abstract: Mesoporous nanosized hydroxyapatite (HAP) functionalized by alendronate (ALN) was synthesized using cationic surfactant CTAB as template. The structural, morphological and textural properties were fully characterized by X-ray diffraction (XRD), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy (FT-IR) and N{sub 2} adsorption/desorption. Then the obtained materials were performed as drug delivery carriers using ibuprofen (IBU) as a model drug to investigate their drug storage/release properties in simulated body fluid (SBF). The materials showed relatively slower release rate compared with HAP due to the ionic interaction between -NH{sub 3}{sup +} on the matrix and -COO{sup −}belongs to IBU. The system provides a new concept for improving the drug loading or slowing down the release rate.

36 MATERIALS SCIENCE↗

DOE OSTI2012

THE SINS/zC-SINF SURVEY of z {approx} 2 GALAXY KINEMATICS: OUTFLOW PROPERTIES

Using SINFONI H{alpha}, [N II], and [S II] AO data of 27 z {approx} 2 star-forming galaxies (SFGs) from the SINS and zC-SINF surveys, we explore the dependence of outflow strength (via the broad flux fraction) on various galaxy parameters. For galaxies that have evidence for strong outflows, we find that the broad emission is spatially extended to at least the half-light radius ({approx}a few kpc). Decomposition of the [S II] doublet into broad and narrow components suggests that this outflowing gas probably has a density of {approx}10-100 cm{sup -3}, less than that of the star-forming gas (600 cm{sup -3}). There is a strong correlation of the H{alpha} broad flux fraction with the star formation surface density of the galaxy, with an apparent threshold for strong outflows occurring at 1 M{sub Sun} yr{sup -1} kpc{sup -2}. Above this threshold, we find that SFGs with log m{sub *} > 10 have similar or perhaps greater wind mass-loading factors ({eta} = M-dot{sub out}/SFR) and faster outflow velocities than lower mass SFGs, suggesting that the majority of outflowing gas at z {approx} 2 may derive from high-mass SFGs. The mass-loading factor is also correlated with the star formation rate (SFR), galaxy size, and inclination, such that smaller, more star-forming, and face-on galaxies launch more powerful outflows. We propose that the observed threshold for strong outflows and the observed mass loading of these winds can be explained by a simple model wherein break-out of winds is governed by pressure balance in the disk.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2017

Transforming from planar to three-dimensional lithium with flowable interphase for solid lithium metal batteries

Solid-state lithium (Li) metal batteries are prominent among next-generation energy storage technologies due to their significantly high energy density and reduced safety risks. Previously, solid electrolytes have been intensively studied and several materials with high ionic conductivity have been identified. However, there are still at least three obstacles before making the Li metal foil-based solid-state systems viable, namely, high interfacial resistance at the Li/electrolyte interface, low areal capacity, and poor power output. The problems are addressed by incorporating a flowable interfacial layer and three-dimensional Li into the system. The flowable interfacial layer can accommodate the interfacial fluctuation and guarantee excellent adhesion at all time, whereas the three-dimensional Li significantly reduces the interfacial fluctuation from the whole electrode level (tens of micrometers) to local scale (submicrometer) and also decreases the effective current density for high-capacity and high-power operations. As a consequence, both symmetric and full-cell configurations can achieve greatly improved electrochemical performances in comparison to the conventional Li foil, which are among the best reported values in the literature. Noticeably, solid-state full cells paired with high–mass loading LiFePO4 exhibited, at 80°C, a satisfactory specific capacity even at a rate of 5 C (110 mA·hour g -1 ) and a capacity retention of 93.6% after 300 cycles at a current density of 3 mA cm -2 using a composite solid electrolyte middle layer. In addition, when a ceramic electrolyte middle layer was adopted, stable cycling with greatly improved capacity could even be realized at room temperature.

25 ENERGY STORAGE↗

DOE OSTI2020

Plane-Strain Tension Testing of ATF FeCrAl Cladding (Progress Report)

Performance of advanced accident-tolerant fuel (ATF) claddings must be assessed under all relevant scenarios, including normal and off-normal operating conditions, as well as during a reactivity-initiated accident (RIA). During RIA, the fuel pellet may expand and cause significant loads on cladding, a condition known as pellet cladding mechanical interaction (PCMI), which may even lead to cladding failure. This report describes the fiscal year (FY) 2020 research activities and results from the development of separate-effects testing for ATF cladding candidate iron-chromium-aluminum (FeCrAl) tube specimens under loading conditions expected during RIA/PCMI events. To assess material performance under PCMI, a high strain rate burst test, often termed the modified burst test (MBT), is commonly employed. However, execution of such a test in a hot cell requires significant research. To overcome the complexities of performing MBTs in a hot-cell environment on irradiated samples, a plane-strain tension (PST) test was proposed by several authors as an alternative approach for PCMI testing. A new fixture was developed so that PST specimens could be tested using a more accommodating design for hot-cell manipulators. This report presents the PST fixture design, evaluates the possibility of modifying the specimen geometry, and discusses experimental results with unirradiated Al 6061 and FeCrAl tubes at various lengths. Furthermore, this report discusses the relevance and compatibility of the PST results to RIA scenarios and compares the PST and MBT results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

A Review of the Research and Development of Brayton Cycle Technology in Nuclear Power Applications with a Focus on Compressor Technology

This study reviews the integration of Brayton Cycle (BC) systems in nuclear power generation, emphasizing their potential to enhance thermal efficiency and operational flexibility over traditional Rankine Cycle (RC) systems. Key working fluids, such as helium (He), supercritical carbon dioxide (sCO 2 ), nitrogen (N 2 ), and air, are evaluated for their performance, efficiency, and compatibility with nuclear systems. He is recognized for its high thermal conductivity and inertness at elevated temperatures, while sCO 2 demonstrates advantages in compactness and efficiency in midrange temperatures. This article also highlights the importance of compressor designs in optimizing BC performance and reviews, available compressor technologies. Axial and centrifugal compressor designs enable efficient gas compression while managing the thermal and mechanical stresses associated with high-pressure operations in nuclear systems. Combined with variable geometry components and advanced materials, these technologies address the challenges posed by varying load conditions. Despite the promising features of BC systems, several challenges persist, including high leakage rates and material degradation under extreme conditions, which necessitate robust sealing technologies and thorough testing. The insights gained from operational experiences at facilities, such as the Oberhausen II plant and the High-Temperature He Test Facility (HHV), underscore the complexities involved in designing high-temperature gas turbines for nuclear applications. This review concludes that as the nuclear industry evolves, BC systems hold significant promise for contributing to a sustainable energy future, particularly in the context of small modular reactors (SMRs) and microreactors. Further exploration of combined cycle configurations that combine BCs with RCs may enhance overall efficiency and flexibility in power generation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1977

Low cost silicon solar array project silicon materials task: Establishment of the feasibility of a process capable of low-cost, high volume production of silane (step 1) and the pyrolysis of silane to semiconductor-grade silicon (step 2)

Extended operation of a small process-development unit routinely produced high quality silane in 97+% yield from dichlorosilane. The production rate was consistent with design loadings for the fractionating column and for the redistribution reactor. A glass fluid-bed reactor was constructed for room temperature operation. The behavior of a bed of silcon particles was observed as a function of various feedstocks, component configurations, and operating conditions. For operating modes other than spouting, the bed behaved in an erratic and unstable manner. A method was developed for casting molten silicon powder into crack-free solid pellets for process evaluation. The silicon powder was melted and cast into thin walled quartz tubes that sacrificially broke on cooling.

Breneman, W. C.↗

NASA NTRS1984

Positive Electrode Fabrication for Bi-polar Ni-h2 Cells

Bi-Polar nickel hydrogen design studies indicated a potential improvement in energy density and specific energy if positive electrodes could be manufactured in configurations of twice or more of the present normal thickness. Such electrodes would have to achieve similar active material loading, utilization, and cycle life to conventional 0.8mm I.P.U. nickel hydrogen electrodes. A capability for producing 1.0mm dry sinter and 1.5mm slurry sinter structures on production processes and equipment was demonstrated. The EPI/USAF electrochemical impregnation process proved capable of loading thick electrodes to 1.60 g/cubic centimeters void or higher. Sample electrodes incurred 2000 high rate stress cycles without significant structural or performance degradation. Formation regimes developed for thin plaque are not optimal for thick plaque and further investigation into electrode capacity build-up would seem warranted. Thick electrode technology development is continuing under other programs and shows promise of fulfilling the projected energy density and specific energy improvements.

Edgar, T. A.↗