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DOE OSTI2021

Scalable fabrication of high activity nanoporous copper powders for electrochemical CO 2 reduction via ball milling and dealloying

Electrochemical CO 2 reduction (ECR) is a promising technology to close the anthropic CO 2 circle using renewable energy to achieve carbon neutrality. Future commercialization of ECR will require the development of new catalyst synthesis routes that will allow significant upscaling of catalyst production from current research-level milligram quantities to the kilogram scale and beyond while maintaining the activity and selectivity demonstrated at the research level. Here, we report on generating and testing submicron-sized nanoporous copper (npCu) particles by using a scalable approach consisting of ball milling brittle Cu-based intermetallics followed by dealloying to add nanoporosity for high surface area. The resulting npCu particles have been tested in an industry-relevant large area (25 cm 2 ) electrolyzer platform and showed Faraday efficiencies (FE) for ethylene up to 34 % at current densities of 75–100 mA/cm 2 while keeping FE for hydrogen less than 30 %. Our results demonstrate that a combination of ball milling and dealloying is a promising approach to generate large quantities of high activity and high surface area npCu particles for ECR at an industry-relevant scale.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Scalable Gas Diffusion Electrode Fabrication for Electrochemical CO 2 Reduction Using Physical Vapor Deposition Methods

Electrochemical CO 2 reduction (ECR) promises the replacement of fossil fuels as the source of feedstock chemicals and seasonal storage of renewable energy. While much progress has been made in catalyst development and electrochemical reactor design, few studies have addressed the effect of catalyst integration on device performance. Using a microfluidic gas diffusion electrolyzer, we systematically studied the effect of thickness and the morphology of electron beam (EB) and magnetron-sputtered (MS) Cu catalyst coatings on ECR performance. We observed that EB-Cu outperforms MS-Cu in current density, selectivity, and energy efficiency, with 400 nm thick catalyst coatings performing the best. Additionally, the superior performance of EB-Cu catalysts is assigned to their faceted surface morphology and sharper Cu/gas diffusion layer interface, which increases their hydrophobicity. Tests in a large-scale zero-gap electrolyzer yielded similar product selectivity distributions with an ethylene Faradaic efficiency of 39% at 200 mA/cm 2 , demonstrating the scalability for industrial ECR applications.

36 MATERIALS SCIENCE↗

DOE OSTI2022

JET EROSION OF PARTICLE BEDS: PROJECTING CRITICAL SUSPENSION VELOCITIES FROM EFFECTIVE CLEARING / CLEANING RADII

Here we explore the relationship between effective cleaning/clearing radii, ECR, and critical suspension velocities, Ucs. Although one set of physics controls both the radial extent of erosion (i.e., the ECR) and the velocity needed to erode from the center of jet impingement to any given location (i.e., Ucs, typically defined from nozzle center to the vessel center), the relationship between these two remains unexplored quantitatively. Here we advance the model of Kuhn, et al., (PNNL-22816, 2013) as described by Pease, et al. (FEDSM2017-69444, 2017) to evaluate the relationship between the effective clearing/cleaning radius and the nozzle velocity on flat surfaces including flat bottomed vessels. Two governing dimensionless groups are identified. We present both a closed form analytical but transcendental solution and a non-iterative approximation modeled after the Serghides approximation of Colebrook’s nonlinear equation for both ECR versus nozzle velocity and Ucs. Comparison of the model to data from flume testing on a flat surface finds reasonable agreement.

jet, erosion, critical suspension velocity, effect↗

DOE OSTI2024

Enabling Capabilities and Resources: 2024 Principal Investigator Meeting Proceedings

As a major supporter of basic genome-enabled research, BER’s Biological Systems Science Division (BSSD) fosters scientific discovery by funding - fundamental biological research across disciplines in conjunction with enabling investigational tools and computational capabilities that include world-class user facilities. The overarching goal of BSSD is to provide the necessary fundamental science to understand, predict, manipulate, and design biological systems that underpin innovations for bioenergy and bioproduct production and enhance understanding of natural, DOE-relevant environmental processes (Biological Systems Science Division Strategic Plan, 2021). To accelerate the U.S. bioeconomy, BSSD pursues innovative science underpinning advances in sustainable biofuels and bioproducts and the development of next-generation technologies and computational resources for systems biology research. The 2024 BSSD Enabling Capabilities and Resources (ECR) Principal Investigator (PI) meeting brought together PIs across the BSSD ECR portfolio to confer on shared interests and opportunities. The meeting was held concurrently with the Genomic Science program (GSP) PI meeting to optimize collaboration on research to advance bioenergy and the bioeconomy. Rick Stevens of Argonne National Laboratory gave a keynote on How Generative Artificial Intelligence Can Impact Biological Research (see Keynote: How Generative Artificial Intelligence Can Impact Biological Research, this page). Plenary presentations included several joint sessions that illuminated the integration and understanding of the larger BSSD mission. GSP’s objective is to provide systems-level understanding of plants, microbes, and their communities through its Bioenergy Research, Biosystems Design, and Environmental Microbiome Research portfolios. The objective of the ECR portfolio is to support development of computational and instrumental platforms to advance fundamental GSP research—and BER more broadly— toward the overall goal of understanding the functional principles of living systems and their response to environmental challenges.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

A Perspective on Solar-Driven Electrochemical Routes for Sustainable Methanol Production

The transition towards sustainable and renewable energy sources is imperative in mitigating the environmental impacts of escalating global energy consumption. Methanol, with its versatile applications and potential as a clean energy carrier, a precursor chemical, and a valuable commodity, emerges as a promising solution within the realm of renewable energy technologies. This work explores the integration of electrochemistry with solar power to drive efficient methanol production processes, focusing on electrochemical reduction (ECR) of CO 2 and methane oxidation reaction (MOR) as pathways for methanol synthesis. Through detailed analysis and calculations, we evaluate the thermodynamic limits and realistic solar-to-fuel (STF) efficiencies of ECR and MOR. Our investigation encompasses the characterization of multijunction light absorbers, determination of thermoneutral potentials, and assessment of STF efficiencies under varying conditions. We identify the challenges and opportunities inherent in both ECR and MOR pathways, shedding light on catalyst stability, reaction kinetics, and system optimization, thereby providing insights into the prospects and challenges of solar-driven methanol synthesis, offering a pathway towards a cleaner and more sustainable energy future.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1988

Optical emission diagnostics of electron cyclotron resonance and glow discharge plasmas for a-Si:H and a-SiC:H film depositions

It is demonstrated that the steady-state and kinetic characteristics of ECR (electron cyclotron resonance) and RF glow discharge plasmas can be readily monitored by OES (optical emission spectroscopy) in real time during a-Si:H and a-SiC:H film depositions using an OMA detection system. The ECR and RF glow discharge plasmas used for a-Si:H and a-SiC:H film depositions were studied by monitoring the emission of SiH(asterisk), H(asterisk), H(asterisk)2, and CH(asterisk) excited states. The OES of the ECR plasma shows a strong emission at 434 nm from H(asterisk), which is not detectable in the glow discharge plasma. Steady-state OES studies have established preliminary correlations between SiH(asterisk) and CH(asterisk) emission intensities and the film deposition rate. Transient OES spectra of SiH4 and CH4 plasmas have shown different kinetics in SiH(asterisk) and CH(asterisk) emission intensities. Transient studies of the SiH(asterisk) emission intensity have indicated that additional mechanisms for producing the SiH(asterisk) species become evident in hydrogen-diluted silane plasmas.

Yang, C. L.↗

NASA NTRS1991

Electron cyclotron resonance microwave plasma deposition of a-Si:H and a-SiC:H films

The paper reports electron cyclotron resonance (ECR) deposition of a-Si:H and a-SiC:H thin films using SiH4, CH4, and hydrogen mixed gas plasmas. The ECR deposition conditions were investigated in the pressure region of 0.1 to 100 mtorr, and the film properties were characterized by light and dark conductivity measurements, XRD, Raman spectroscopy, optical transmission, and IR spectroscopy. In addition, the hydrogen dilution effect on ECR-deposited a-SiC:H was investigated.

Shing, Y. H.↗

NASA NTRS2007

Design and Data Management System

The Design and Data Management System (DDMS) was developed to automate the NASA Engineering Order (EO) and Engineering Change Request (ECR) processes at the Propulsion Test Facilities at Stennis Space Center for efficient and effective Configuration Management (CM). Prior to the development of DDMS, the CM system was a manual, paper-based system that required an EO or ECR submitter to walk the changes through the acceptance process to obtain necessary approval signatures. This approval process could take up to two weeks, and was subject to a variety of human errors. The process also requires that the CM office make copies and distribute them to the Configuration Control Board members for review prior to meetings. At any point, there was a potential for an error or loss of the change records, meaning the configuration of record was not accurate. The new Web-based DDMS eliminates unnecessary copies, reduces the time needed to distribute the paperwork, reduces time to gain the necessary signatures, and prevents the variety of errors inherent in the previous manual system. After implementation of the DDMS, all EOs and ECRs can be automatically checked prior to submittal to ensure that the documentation is complete and accurate. Much of the configuration information can be documented in the DDMS through pull-down forms to ensure consistent entries by the engineers and technicians in the field. The software also can electronically route the documents through the signature process to obtain the necessary approvals needed for work authorization. The workflow of the system allows for backups and timestamps that determine the correct routing and completion of all required authorizations in a more timely manner, as well as assuring the quality and accuracy of the configuration documents.

Messer, Elizabeth↗

DOE OSTI2024

Fabrication and Performance Evaluation of Double-Sided Copper Nanowire Arrays as Thermal and Electrical Interfacial Layers

Reducing contact interface thermal and electrical resistances is in great demand across various industries, particularly in the semiconductor industry. This study introduces an approach using double-sided copper nanowire (Cu NW) arrays on copper sheets as both thermal and electrical interfacial layers, designed to effectively accommodate the topographical inconsistencies between contact surfaces. Further, experimental outcomes reveal a significant reduction in thermal contact resistance (TCR), with a value of 2.5 mm 2 K W –1 , thereby exceeding the efficiency of reported nanostructural thermal interface materials (TIMs). Additionally, when utilized as an electrical interfacial layer, these double-sided Cu NWs arrays dramatically reduced electrical contact resistance (ECR), outperforming traditional conductive grease in applications necessitating separable bonding, though showing comparable performance to costly silver-based conductive epoxies required for permanent, inseparable bonds. The promising results of the double-sided Cu NWs arrays in reducing both TCR and ECR, confirmed by finite element simulation, highlight their substantial potential in advancing TIMs and electrical interconnection applications across various sectors.

42 ENGINEERING↗

DOE OSTI2026

Progress towards 28 GHz operations at the Facility for Rare Isotope Beams (FRIB)

This paper provides an overview on the design, operational parameters as well as recent development and recent performance, of the superconducting electron cyclotron resonance (ECR) ion source at the Facility for Rare Isotope Beams (FRIB). The ion source has been used in support of beam operations since the end of 2022 and was designed to operate at 28 GHz and be capable of delivering high intensity uranium beams to help support beam delivery of up to a final beam power of 400 kW. Currently operating at up to 20 kW many primary beams have been developed and routinely used with the superconducting ECR including uranium. Initially operated at 18 GHz, the ion source has now been coupled to a 28 GHz gyrotron and high intensity beams have been demonstrated ahead of the facility planned power ramp up. text with the article abstract. Replace this text with the article abstract.

Machicoane, G. A. [Michigan State University, East↗

DOE OSTI2024

Examining a hadronic γ-ray scenario for the radiative shell and molecular clouds of the old GeV supernova remnant G298.6−0.0

Abstract Based on the 13.7 yr Fermi-LAT data, Yeung, Bamba, and Sano (2023, PASJ, 75, 384) claimed detection of two γ-ray sources (namely Src-NE and Src-NW) associated with the supernova remnant (SNR) G298.6−0.0, and interpreted it as an old GeV SNR interacting with molecular clouds (MCs). In this follow-up study, we refine the flux measurements below 2 GeV with Fermi-LAT event types of better angular reconstruction. Then, we report our γ-ray spectral fittings and cosmic-ray phenomenology in a hadronic scenario, considering both the shell and MC regions of SNR G298.6−0.0. We confirm that the γ-ray spectra of both Src-NE and Src-NW exhibit spectral breaks, at $1.50_{-0.50}^{+0.60}$ and $0.68_{-0.11}^{+0.32}\:$GeV, respectively. Src-NW has a harder broad-band photon index than Src-NE, suggesting an appreciable difference between the physical separations of their respective emission sites from SNR G298.6−0.0. The cosmic-ray spectrum responsible for Src-NE starts with a minimum energy $E_\mathrm{CR,min}=1.38_{-0.16}^{+0.47}\:$GeV, and has a proton index $\Gamma _\mathrm{CR}=2.57_{-0.21}^{+0.18}$ below the exponential cutoff energy $E_\mathrm{CR,max}=240_{-150}^{+240}\:$GeV. Accordingly, we argue that Src-NE is dominated by the SNR shell, while only a minor portion of lower-energy emission is contributed by the MCs interacting with the SNR. The cosmic-ray population for Src-NW starts at a higher energy such that the ECR, min ratio of Src-NW to Src-NE is ≳2. The high ECR, min, as well as the high cosmic-ray energy density required (∼26 eV cm−3), supports the interpretation that Src-NW is predominantly the γ-ray emission from the farther MCs being bombarded by protons that had earlier escaped from SNR G298.6−0.0. By comparing the high-energy features of G298.6−0.0 with those of analogical SNRs, especially SNR W 28 and SNR W 44, we further constrain the age of SNR G298.6−0.0 to be 10–30 kyr, under the assumption of a purely hadronic scenario.

Astronomy & Astrophysics↗

DOE OSTI2026

Ambient and Initial Temperature Effects on Energy Consumption Rate Modeled in FASTSim

Ambient and initial temperatures significantly impact the energy consumption rate (ECR) of battery electric vehicles (BEVs) due to auxiliary loads and the temperature dependence of battery efficiency. This study introduces a streamlined, physics-based thermal modeling approach within the FASTSim tool that bridges the gap between oversimplified constant-load models and computationally expensive high-fidelity simulations. By employing a lumped thermal mass framework, the model captures fundamental energy balances and critical non-linear energy penalties while maintaining the computational efficiency required for expansive sensitivity studies. The simulations evaluated a compact BEV hatchback with a resistive heater over city (UDDS) and highway (HWFET) test cycles. Compared to a 22 degrees Celsius initial and ambient temperature baseline, a -7 degrees Celsius initial/ambient temperature resulted in a 221% increase in the ECR for the city cycle and a 100% increase for the highway cycle. Conversely, a 45 degrees Celsius initial / 40 degrees Celsius ambient temperature resulted in a 40% increase for UDDS and an 18% increase for HWFET. These results demonstrate that while cold conditions impose the most severe energy penalties due to resistive heating, the impact is consistently more pronounced in city driving where auxiliary loads represent a larger proportion of total energy. This lightweight yet robust framework enables researchers to rapidly quantify BEV thermal sensitivity across diverse climates without the need for high-overhead simulation environments.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS1989

A brief review of JPL's electric propulsion technology activities

Near-term objectives and recent technological progress of JPL's electric propulsion program are discussed. Particular attention is given to accomplishments for ion, magnetoplasmadynamic (MPD), electron-cyclotron resonance (ECR), and arcjet thrusters. Xenon ion thruster erosion tests indicate a 15-fold reduction in tantalum baffle erosion when nitrogen is added to the xenon propellant and steady-state cylindrical MPD thruster tests at powers up to 72 kW show distinct self-constricted and diffuse discharge modes. An ECR thruster was operated at up to 7 kW with plasma acceleration at energies up to 7 kW; there was plasma acceleration at energies approaching 100 electron volts.

Barnett, John W.↗

NASA NTRS1990

Deposition of diamondlike films by electron cyclotron resonance microwave plasmas

Hard a-C:H films have been deposited through electron cyclotron resonance (ECR) microwave plasma decomposition of CH4 diluted with H2 gas. It has been found that hard diamondlike films could only be produced under a RF-induced negative self-bias of the substrate stage. Raman spectra indicate the deposition of two distinct film types: one film type exhibiting well-defined bands at 1360 and 1580/cm and another displaying a broad Raman peak centered at approximately 1500/cm. Variation of the mirror magnetic-field profile of the ECR system was examined, demonstrating the manipulation of film morphology through the extraction of different ion energies.

Pool, F. S.↗

NASA NTRS1990

Electron cyclotron resonance deposition of diamond-like films

Electron cyclotron resonance (ECR) microwave plasma CVD has been developed at low pressures (0.0001 - 0.01 torr) and at ambient and high substrate temperatures (up to 750 C), to achieve large-area (greater than 4 in. diameter) depositions of diamondlike amorphous carbon (a - C:H) films. The application of a RF bias to the substrate stage, which induces a negative self-bias voltage, is found to play a critical role in determining carbon bonding configurations and in modifying the film morphology. There are two distinct types of ECR-deposited diamondlike films. One type of diamondlike film exhibits a Raman spectrum consisting of broad and overlapping, graphitic D (1360/cm, line width = 280/cm) and G (1590/cm, line width 140/cm) lines, and the other type has a broad Raman peak centered at appoximately 1500/cm. Examination of plasma species by optical emission spectroscopy shows no correlation between the CH-asterisk emission intensity and the deposition rate of diamondklike films.

Shing, Y. H.↗

NASA NTRS1991

Electric thruster models for multimegawatt nuclear electric propulsion mission design

Three types of electric thrusters currently under development at JPL have potential to support future missions which utilize multimegawatt nuclear electric propulsion. These electric thrusters are the electron bombardment ion thruster, the magnetoplasmadynamic (MPD) thruster, and the electron-cyclotron-resonance (ECR) thruster. The electron bombardment ion thruster is a relatively mature technology which has been developed for operation at kilowatt power levels but will require new development for application in the multimegawatt regime. The MPD engine represents a technology which may be very well suited to steady-state multimegawatt applications but which has been limited to sub-scale (100's of kW) and pulsed (MW) testing thus far. The ECR plasma engine represents a class of very promising new concepts which are still in the basic research phase of development, but which may possess important fundamental advantages over other electric thruster technologies. Models of these thrusters are described and used to make projections of thrusters specific mass, efficiency, and power handling capacity for operation in the multimegawatt regime.

Leifer, Stephanie D.↗

NASA NTRS1992

Deposition temperature dependence of the deep defect density for a-Si:H films grown by electron cyclotron resonance microwave plasma

The dependence on deposition temperature of the mobility gap density of states has been determined for hydrogenated amorphous silicon (a-Si:H) films grown by electron cyclotron resonance (ECR) microwave plasma CVD. A minimum in the integrated deep defect density of 1 x 10 exp 16/cu cm was found to occur at a temperature of approximately 250 C, while an Urbach slope minimum of 52 meV was observed at 175 C under our deposition conditions. Based on these measurements the ECR-grown films were found to be of excellent device quality and comparable to a-Si:H films grown by RF plasma-enhanced CVD.

Essick, J. M.↗

NASA NTRS2003

Laboratory Studies in UV and EUV Solar Physics

The Ion Beam Experiment at the Center for Astrophysics is dedicated to the study of ion-electron collision processes of importance in solar physics. A paper describing our most recent measurement 'Absolute cross section for Si(2+)(3s3p(sup 3)Rho (sup 0) yields 3s3p(sup 1)Rho(sup 0)) electron-impact excitation' was published during the past year. Dr. Paul Janzen received his PhD. from the Harvard Physics Department on the basis of this and other work, such as the new electron cyclotron resonance (ECR) ion source. The ion source is producing stable beams with large currents for our present work on C(2+), and it also produces stable beams with large currents of more highly charged systems, for future work on systems such as O(4+). The past year has been focussed on our current program to measure absolute cross sections for Electron Impact Excitation (EIE) in C(2+), one of the primary ions used for probing the solar transition region. C(2+) beams produced by the ion source have been transported to the interaction region of the experiment, where the collisions are studied, and Visiting Scientist Dr. Adrian Daw is currently collecting data to measure the C(2+)(2s2p(sup 3)Rho(sup 0) yields 2p(sup 2)(sup 3)Rho) EIE cross section as a function of collision energy, under the guidance of Drs. John Kohl, Larry Gardner and Bill Parkinson. Also this year, modifications were made to the ECR ion source in order to produce greater currents of highly charged ions. Testing of the ion source was completed. Modifications were designed to extend the photon detection capabilities of the apparatus to shorter UV wavelengths, or EUV. Following the work on C(2+)(2s2p(sup 3)Pho(sup 0) yields 2p(sup 2)(sup 3)Rho), the extended UV detection capabilities will be used to measure the C(2+)(2s(sup 2)(sup 1)S yields 2s2p(sup 1)Rho(sup 0)) EIE cross section. The EUV modifications complement those of the new ion source, by enabling detection of EUV light generated by high charge state ions and putting us in a position to measure the excitation cross sections for more highly charged ions as well.

Parkinson, William↗