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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 505 records · Page 28

Bandgap Engineering of Cu(In 1-x Gax)Se 2 Absorber Layers Fabricated using CuInSe 2 and CuGaSe 2 Targets for One-Step Sputtering Process

Here we have demonstrated that the bandgap of Cu(In 1-x Ga x )Se 2 (CIGS) absorber layers was readily controlled by using a one-step sputtering process. CIGS thin-film sample libraries with different Ga/(In + Ga) ratios were synthesized on soda-lime glass at 550 °C using a combinatorial magnetron sputtering system employing CuInSe 2 (CIS) and CuGaSe 2 (CGS) targets. Energy-dispersive X-ray fluorescence spectrometry (EDS-XRF) confirmed that the CIGS films had different Ga/(In + Ga) ratios, which were varied by the sample configuration on the substrate and ranged from 0.2 to 0.9. X-ray diffraction and Raman spectroscopy revealed that the CIGS films had a pure chalcopyrite phase without any secondary phase such as Cu-Se or ordered vacancy compound (OVC), respectively. Furthermore, we found that the optical bandgap energies of the CIGS films determined by transmittance measurements ranged from 1.07 eV to 1.53 eV as the Ga/(In + Ga) ratio increased from 0.2 to 0.9, demonstrating that the one-step sputtering process using CIS and CGS targets is another simple route to control the bandgap energy of the CIGS absorber layer.

14 SOLAR ENERGY↗

Solute stabilization of nanocrystalline tungsten against abnormal grain growth

Microstructure and phase evolution in magnetron sputtered nanocrystalline tungsten and tungsten alloy thin films are explored through in situ TEM annealing experiments at temperatures up to 1000 °C. Grain growth in unalloyed nanocrystalline tungsten transpires through a discontinuous process at temperatures up to 550 °C, which is coupled to an allotropic phase transformation of metastable β-tungsten with the A-15 cubic structure to stable body centered cubic (BCC) α-tungsten. Complete transformation to the BCC α-phase is accompanied by the convergence to a unimodal nanocrystalline structure at 650 °C, signaling a transition to continuous grain growth. Alloy films synthesized with compositions of W–20 at.% Ti and W–15 at.% Cr exhibit only the BCC α-phase in the as-deposited state, which indicate the addition of solute stabilizes the films against the formation of metastable β-tungsten. Thermal stability of the alloy films is significantly improved over their unalloyed counterpart up to 1000 °C, and grain coarsening occurs solely through a continuous growth process. The contrasting thermal stability between W–Ti and W–Cr is attributed to different grain boundary segregation states, thus demonstrating the critical role of grain boundary chemistry in the design of solute-stabilized nanocrystalline alloys.

36 MATERIALS SCIENCE↗

Achieving strong and stable nanocrystalline Al alloys through compositional design

Abstract Al alloys often suffer from low mechanical strength and lack high-temperature microstructural and mechanical robustness. A series of binary and ternary nanocrystalline (NC) Al transition metal alloys with supersaturated solid solution and columnar nanograins have been recently developed by using magnetron sputtering, manifesting a new realm of mechanical properties and thermal stability. Distinct solutes cause evident differences in the phase transformations and efficiencies for grain refinement and crystalline-to-amorphous transition. Certain sputtered Al-TM alloys have shown room-temperature mechanical strengths greater than 2 GPa and outstanding thermal stability up to 400 °C. In addition, the NC Al alloys show mechanical anisotropy and tension–compression asymmetry, revealed by micromechanical tests. Through the process encapsulating various compositionally distinct systems, we attempt to illuminate the solute effects on grain refinement and properties and more importantly, tentatively unravel the design criteria for high-strength and yet thermally stable NC Al alloys. Graphic Abstract

36 MATERIALS SCIENCE↗

Deposition and dielectric characterization of highly oriented V 2 O 5 thin films

The possibility of ferroelectricity in orthorhombic V 2 O 5 thin flms was investigated. Films were deposited via either a chemical solution deposition (CSD) route or by RF magnetron sputtering. Highly (001) oriented V 2 O 5 flms were achieved with both deposition routes at temperatures as low as 300°C. No evidence for ferroelectricity was observed, even in flms which had been doped to provide local nuclei for polarization reversal. Loss originated from mid-gap trap states stemming from oxygen vacancies that were observed with photoluminescence, supplemented by piezoresponse force microscopy measurements. Furthermore, these trap states may have helped mimic ferroelectricity in previous reports on V 2 O 5 .

36 MATERIALS SCIENCE↗

Surface Characterization of NbTiN Films for Accelerator Applications

The development of next-generation SRF cavities requires the deployment of innovative material solutions with RF performance beyond bulk Nb. Theoretical interest has stimulated efforts to grow and characterize thin multi-layer superconductor/insulator/superconductor (SIS) structures for their potential capability of supporting otherwise inaccessible surface magnetic fields in SRF cavities *. The ternary B1-compound NbTiN is among the candidate superconducting materials for SIS structures. Single crystal NbTiN films with thicknesses below 15 nm are also of interest for the development of high resolution, high sensitivity (SNSPD) detectors for particle physics application. Using DC reactive magnetron sputtering, NbTiN can be deposited with nominal superconducting parameters. This contribution presents the on-going material surface and superconducting properties characterization in order to optimize the NbTiN films for each application.

Beverstock, David R.↗

Progress Towards RF Conditioning of Low-Loss Couplers for a Conduction-Cooled Cryomodule

This work presents current progress on the conditioning of two new 25 kW couplers optimized for use in a compact, conduction-cooled SRF cryomodule. A connecting waveguide, previously used for conditioning the 805 MHz SNS couplers, was altered for use at 915 MHz. The necessary modifications were determined via RF modeling, while thermal analysis results identified additional cooling requirements during RF conditioning and provided insight about potential higher-power operation. Initial low-power conditioning will be performed with a 2.5 kW solid-state amplifier, with plans to use an industrial magnetron for RF conditioning at 25 kW in the near future.

Stilin, N. [Thomas Jefferson National Accelerator ↗

Efficient continuous-wave normal conducting accelerator for industrial applications

A normal conducting, high power, high efficiency copper linear accelerator prototype is being developed for industrial applications. The system will be powered by low-cost high-efficiency magnetron RF sources and will use a gridded thermionic cathode electron gun. Leveraging the significant accelerator expertise at JLab and industry partners, these technologies will be combined to deliver high-power (>100 kW) electron beams with energies of 1 MeV or higher that are cost-effective to produce and operate. The design is modular such that energy and power can be increased by adding additional sections as required. The status of the design, prototype fabrication and plans for a beam demonstration at JLab are described.

Accelerator Physics↗

Lithium Oxysilicate Compounds Final Report.

In this study, the structure and composition of lithium silicate thin films deposited by RF magnetron co-sputtering is investigated. Five compositions ranging from Li2Si2O5 to Li8SiO6 were confirmed by inductively coupled plasma-optical emission spectroscopy (ICP-OES) and structure analysis on the evolution of non-bridging oxygens in the thin films was conducted with fourier transform infrared (FTIR) spectroscopy. It was found that non-bridging oxygens (NBOs) increased as the silicate network breaks apart with increasing lithium content which agrees with previous studies on lithium silicates. Thin film impurities were examined with x-ray photoelectron spectroscopy (XPS) and time of flight secondary ion mass spectroscopy (TOFSIMS) and traced back to target synthesis. This study utilizes a unique synthesis technique for lithium silicate thin films and can be referred to in future studies on the ionic conductivity of lithium silicates formed on the surface of silicon anodes in lithium ion batteries.

25 ENERGY STORAGE↗

Tunable Nitride Josephson Junctions.

We have developed an ambient temperature, SiO 2 /Si wafer - scale process for Josephson junctions based on Nb electrodes and Ta x N barriers with tunable electronic properties. The films are fabricated by magnetron sputtering. The electronic properties of the Ta x N barriers are controlled by adjusting the nitrogen flow during sputtering. This technology offers a scalable alternative to the more traditional junctions based on AlO x barriers for low - power, high - performance computing.

36 MATERIALS SCIENCE↗

Perovskite Solar Cells for High-Efficiency Tandems

The first monolithic perovskite/silicon tandem was made with a diffused silicon p-n junction, a tunnel junction made of n ++ hydrogenated amorphous silicon, a titania electron transport layer, a methylammonium lead iodide absorber, and a Spiro-OMeTAD hole transport layer (HTL). The power conversion efficiency (PCE) was only 13.7% due to excessive parasitic absorption of light in the HTL, limiting the matched current density to 11.5 mA/cm 2 . Werner et al. 15 raised the PCE to a record 21.2% by switching to a silicon heterojunction bottom cell and carefully tuning layer thicknesses to achieve lower optical loss and a higher current density of 15.9 mA/cm 2 . It is clear from these reports that minimizing parasitic absorption in the window layers is crucial to achieving higher current densities and efficiencies in monolithic tandems. To this end, the window layers through which light first passes before entering the perovskite and silicon absorber materials must be highly transparent. The front electrode must also be conductive to carry current laterally across the top of the device. Indium tin oxide (ITO) is widely utilized as a transparent electrode in optoelectronic devices such as flat-panel displays, smart windows, organic light-emitting diodes, and solar cells due to its high conductivity and broadband transparency. ITO is typically deposited through magnetron sputtering; however, the high kinetic energy of sputtered particles can damage underlying layers. In perovskite solar cells, a sputter buffer layer is required to protect the perovskite and organic carrier extraction layers from damage during sputter deposition. The ideal buffer layer should also be energetically well aligned so as to act as a carrier-selective contact, have a wide bandgap to enable high optical transmission, and have no reaction with the halides in the perovskite. Additionally, this buffer layer should act as a diffusion barrier layer to prevent both organic cation evolution and moisture penetration to overcome the often-reported thermal and environmental instability of metal halide perovskites. Previous perovskite-containing tandems utilized molybdenum oxide (MoO x ) as a sputter buffer layer, but this has raised concerns over long-term stability, as the iodide in the perovskite can chemically react with MoO x . Mixed-cation perovskite solar cells have consistently outperformed their single-cation counterparts. The first perovskite device to exceed 20% PCE was fabricated with a mixture of methylammonium (MA) and formamidinium (FA). Recent reports have shown promising results with the introduction of cesium mixtures, enabling high efficiencies with improved photo-, moisture, and thermal stability. The increased moisture and thermal stability are especially important as they broaden the parameter space for processing on top of the perovskite, enabling the deposition of metal oxide contacts through atomic layer deposition (ALD) or chemical vapor deposition (CVD) that may require elevated temperatures or water as a counter reagent. Both titanium dioxide (TiO 2 ) and tin oxide (SnO 2 ) have consistently proven to be effective electron-selective contacts for perovskite solar cells and both can be deposited via ALD at temperatures below 150 °C. We introduced a bilayer of SnO 2 and zinc tin oxide (ZTO) that can be deposited by either low-temperature ALD or pulsed-CVD as a window layer with minimal parasitic absorption, efficient electron extraction, and sufficient buffer properties to prevent the organic and perovskite layers from damage during the subsequent sputter deposition of a transparent ITO electrode. We explored pulsed-CVD as a modified ALD process with a continual, rather than purely step-wise, growth component in order to considerably reduce the process time of the SnO 2 deposition process and minimize potential perovskite degradation. These layers, when used in an excellent mixed-cation perovskite solar cell atop a silicon solar cell tuned to the infrared spectrum, enable highly efficient perovskite-silicon tandem solar cells with enhanced thermal and environmental stability.

42 ENGINEERING↗

Techniques for energetic ion assisted in-situ coating of long, small diameter, beam pipes with compacted thick crystalline copper film

High wall resistivity can cause heating and instabilities in accelerators. Electron clouds in accelerators limit machine performance through associated dynamical instabilities and/or vacuum pressure increases. Coating accelerator vacuum tubes with compacted thick crystalline copper will mitigate those problems and can enhance luminosity. Develop compact ion assisted deposition (IAD) devices by incorporating ion bombardment in a robotic cylindrical magnetron sputtering device configured for small radial dimension tubes for in-situ coating of long, small diameter tubes with defect free thick films copper. Selected an ion assisted plasma deposition technique for in-situ coating of long, small diameter tubes. Set up a cryogenic resonator for measuring conductivity of deposited copper at cryogenic temperature to optimize the deposition technique; preliminary design of phase II full-scale device. Coating of existing accelerator vacuum tubes with compacted thick crystalline copper is a very cost effective way to mitigate significant problems in accelerators trying to increase luminosity. IAD results in superior quality film deposition, which due to inefficiencies, is presently restricted to high value items. Advancing to industry forefront more cost effective IAD, will improve tools, ball bearings & other lower value industrial products, thus reducing waste as well as improving industrial accelerators and electron guns, impacting companies who utilize accelerators. Develop improved inexpensive plasma deposition for copper coating accelerator tubes with compacted thick crystalline copper. Although there are commercial applications, initial project focus is to facilitate cost-effective luminosity increase in RHIC at BNL as well as other machines.

43 PARTICLE ACCELERATORS↗

Linear and Nonlinear Optical Properties of Metal Nanocomposite Materials

The scientific theme of this award stated in its title is “Linear and Nonlinear Optical Properties of Metal Nanoparticle Composites.” The motivation for the proposal was based on prior work that highlighted unusual third-order nonlinear optical response of metal-nanoparticle composites created by Vanderbilt researchers at the Oak Ridge National Laboratory (ORNL) by implanting metal ions into fused-silica and sapphire substrates and annealing them under appropriate conditions to produce a solid solution comprising noble-metal nanoparticles embedded in an insulating matrix. For example, the well-known localized surface plasmon resonance (LSPR) of gold and silver nanoclusters and nanoparticles was known to yield enhanced effects on the nonlinear absorption and nonlinear refractive index of these materials. The project soon expanded to embrace a wider range of materials and nanostructures, including particularly vanadium dioxide with its insulator-to-metal transition, a wide variety of substrate hosts, and zinc oxide with its multi-faceted band-edge exciton that can be coupled to plasmonic degrees of freedom in silver and aluminum. We employed second- and third-order nonlinear optical spectroscopies and confocal microscopy to quantify the coupling between nanoparticles and adsorbates across interfaces. Because ORNL closed the ion-beam surface-modification facility in 2004, we then developed a nanofabrication technique combining focused ion-beam lithography and pulsed laser deposition to create ordered arrays of metal and oxide nanoparticles in various planar geometries and heterostructures. By 2008, aided by finite-difference time-domain and finite-element calculations, we began to design and fabricate plasmonic “workbenches” on which we could excite quasiparticles (e.g., excitons, phonons, plasmons) using optical signals and electrical impulses, and map the material response down to femtosecond time and nanometer length scales. We developed additional nanofabrication capabilities (e.g., dual-layer electron-beam lithography, quantum-well fabrication and multilayer magnetron sputtering and electron-beam deposition) to create a variety of novel heterostructures as model nanocomposite systems. This led to several new opportunities to study the optical properties of these composites informed by views of potential device configurations. Among the scientific themes that emerged in published papers based on new materials and nanostructures were the following: ultrafast electron dynamics in metamaterials, including ultrafast THz microscopy of the insulator-to-metal transition in VO 2 nanoparticles; plasmon-driven electron injection to promote phase transitions in VO 2 ; and second-harmonic generation in nanostructures without inversion symmetry, in particular, the Archimedean spiral with overall sub-wavelength dimensions. We also explored dimensional and structural effects in plasmonic coupling, including exciton-plasmon coupling in ZnO nanowires; exciton-plasmon coupling in structures incorporating two-dimensional dichalcogenides; and tunable plasmon-induced transparency in plasmonic heterostructures incorporating phase-changing VO 2 . Finally, it should be noted that the work on Archimedean nanospirals and plasmon-exciton coupling led directly into a current quantum-optics research project on photon correlations in diamond nanoparticles, exemplified by the first publication from that effort [Ref. [47] in the bibliography]. A more detailed account setting in the appropriate scientific context all forty-eight papers supported by this award follows.

36 MATERIALS SCIENCE↗

Heavy-Metal Ceramic Hohlraums for Magnetically Assisted Ignition Targets

Targets for magnetically-assisted ignition require specialized hohlraums that are made from an electrically non-conductive material. Such special-material hohlraums allow external magnetic fields to uniformly soak through the hohlraum and into the capsule prior to the laser drive. These requirements necessitate the development of an entirely new class of ceramic or intermetallic hohlraums since, in all previous hohlraum designs, solid-state electronic transport properties were not of interest and, hence, were not investigated. In this project, we have demonstrated the feasibility of the deposition of thick (>30 microns) and electrically-resistive (>100 micro-Ohm cm) gold-tantalum-based coatings by magnetron sputtering.

36 MATERIALS SCIENCE↗

Advancing the Physics of Magnetized Dusty Plasmas (Collaborative Research Final Report)

Dusty (or complex) plasmas are four-component systems consisting of the usual plasma constituents of electrons, ions, and neutral atoms with the addition of a third charged component - nanometer to micrometer sized solid particulates; i.e., "dust". The study of magnetized dusty plasmas is grounded in important questions that are relevant to space, astrophysical, and also technological plasmas and therefore have the potential to make a societal impact. The formation and control of nanometer-sized particles in industrial plasma processes is currently being exploited as a technique to induce the formation of nanocrystals on material surfaces. For example, when combined with magnetron sources, these are important processes that could lead to improved techniques for customizing material synthesis. The interaction between the edge plasma and walls of magnetic confinement fusion devices is a source of particulate material that can be transported throughout the plasma with potentially detrimental effects on plasma performance. Understanding the formation, transport, and destruction of these "dust" particles is of critical importance.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

System Integration of Rationally Designed Dilute Alloy Catalysts for Energy-Efficient Electrochemical CO 2 -To-Fuel Conversion

Energy effiecient electrochemical conversion of CO 2 to high-demand chemicals and transportation fuels using renewable solar and wind energy is a key technology needed for a high-productivity, low-carbon future. However, the development of scalable, low-cost, active, selective, and stable electrocatalysts remains a key challenge that needs to be overcome to enable high-volume conversion of CO 2 to feedstock chemicals for the chemical industry. In previous work, Lawrence Livermore National Laboratory (LLNL) has developed a rational design platform for dilute alloy transition metal electrocatalysts that promise to make electrochemical CO 2 conversion more energy efficient and selective. In this project, we worked with our industrial partners, Twelve and TotalEnergies, to improve scale up, integration, and stability of LLNL’s dilute alloy catalyst technology into an industry-relevant zero gap electrolyzer platform. Through virtual experiments and data analysis, we designed efficient and cost-effective copper-based catalysts. The catalyst was specifically designed to streamline the slowest and most energy-intensive step of the electrochemical chemical transformation of CO 2 to multi-carbon products – that is making the carbon-carbon bond by dimerization of the reaction intermediate carbon monoxide - resulting in up to 10% improvement in energy efficiency for C 2 products while simultaneously increasing the selectivity towards C 2 products. We tested two different scalable catalyst coating technologies and down-selected magnetron sputtering as the technique that provided the best control over catalyst loading, composition, and morphology. Using this technology, we successfully demonstrated integration of our dilute alloy catalysts into a 100 cm 2 electrolyzer platform with Faradaic efficiencies for ethylene production reaching 40% at a current density of 200 mA/cm 2 . We also developed the technology to integrate a well-defined nanoscale porosity by depositing alloy compositions that were compatible with dealloying, that is, selective leaching of an alloy component to generate nanoscale porosity. We observed that integration of the dealloying-derived nanoporosity improved catalyst performance and stability by leading to a more hydrophobic catalyst/anion exchange membrane interface. Unsolved problems that still need to be addressed are corrosion of the Cu catalyst -specifically if the used catalyst is exposed to air - as well as long term stability do to salt formation/deposition and flooding of the catalyst/electrolyzer flow channels, especially at higher current densities. As we only worked on optimization of catalyst composition, coating thickness, and morphology, further performance optimization will require a system level approach that includes optimization of electrolyzer design and membrane technology.

36 MATERIALS SCIENCE↗

Surface Characterization of NbTiN multilayer films for accelerator applications

Further enhancement of superconducting accelerating cavity performance calls upon the development of materials beyond bulk niobium (Nb). Superconducting RF (SRF) is a surface phenomenon; for most superconducting materials the RF penetration depth is in the range of hundreds of nanometers. Due to the field penetration enhancement occurring in films with a thickness smaller than their nominal penetration depth, multilayer superconductor/insulator/superconductor (SIS) structures are theorized to have potential to support surface magnetic fields beyond the reach of the current SRF cavities. A candidate superconductor for SIS structures is the ternary compound NbTiN. SIS structures based on NbTiN and AlN are currently under development at JLab. NbTiN can be deposited with nominal superconducting parameters using DC reactive magnetron sputtering. This contribution presents the characterization of surface, material and superconducting properties of NbTiN films and SIS structures. Notably, the first flux penetration (Hfp) measured by SQUID magnetometry of 200 to 5 nm thick films and Hfp enhancement by multilayer structures is evaluated.

Beringer, Douglas↗

Full Technical Report: High-Rate Carbide Growth by Evaporation

Boron carbide (B 4 C) is an attractive inertial confined fusion (ICF) ablator and a unique ultra-hard material with numerous current and potential applications. What makes B 4 C attractive as an ablator is its relatively high density and the ability to form a stable glassy phase combined with excellent chemical and mechanical stability. Despite these advantages, the fabrication of B 4 C ablators has remained a challenge. Magnetron sputtering, our current frontrunner approach for B 4 C deposition, exhibits low deposition rates (< 2 μm/h) and undesirable nodular defects within the film structure that are believed to generate from the dusty plasma around the sputtering source. The goals of this project were to (1) establish alternative plasma-free, electron beam evaporation (EBE) capabilities for the deposition of thin films that are needed in mission-critical programs and; (2) demonstrate the feasibility to deposit B 4 C films at high rates by EBE in a bottom-up geometry and characterize their stoichiometry. In this feasibility study, we initially developed the capability to convert a general-use vacuum chamber into an electron beam evaporator as needed, or on demand. Then, we successfully used this setup to deposit films made of boron carbide and various other materials. By adjusting the deposition parameters and the evaporation source material, we were able to demonstrate the feasibility of reaching deposition rates as high as 8 μm/h, which is about 4 times the maximum rates obtained through sputtering methods. We predict that these values can still be further improved by implementing enhanced thermal control measures for the target source and optimizing electron beam parameters (ie. current, sweeping and frequency) since ceramic materials with similar densities to B 4 C can exhibit deposition rates of about twice this value. We anticipate that the skills and capabilities developed throughout this project will prove relevant not only to the HED and ICF campaigns but also to numerous existing and prospective applications focused on the development of ultra-hard carbide coatings. The fresh set of tools here developed will also facilitate the preparation and research on future new target materials of interest beyond B 4 C.

36 MATERIALS SCIENCE↗

Oak Ridge National Laboratory Official TM Cover: Development and Qualification of Tungsten Reference Materials for LA-ICP-MS

Reference materials have been developed to provide areal density measurements of tungsten that is deposited on graphite when using laser ablation inductively coupled plasma mass spectrometry (LA-ICP-MS). Several reference materials of varying areal densities have been produced using a magnetron sputtering, thin film deposition technique. With multiple reference materials that have varying areal densities, a calibration curve has been developed for translating the detector response of an ICP-MS into a quantitative measurement. These results provide the opportunity to make calibrated comparisons across graphite samples that were exposed to tungsten transport experiments for nuclear fusion research. In addition, these methods may be applied to provide individual areal density measurements for the five unique isotopes of tungsten. It is found that areal density measurements via LA-ICP-MS agree with characterization for the same samples when using the more traditional Rutherford backscattering ion beam technique. Qualification of these reference materials was completed using ion beam laboratories at the University of Tennessee, Knoxville and Massachusetts Institute of Technology, and Sandia National Laboratory.

36 MATERIALS SCIENCE↗