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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

InAs Terahertz Metalens Emitter for Focused Terahertz Beam Generation

Metasurfaces have opened doors to combining multiple photonic functionalities in a single compact device. In particular, the ability to generate short terahertz (THz) pulses with precise wavefront engineering in a single THz metasurface redefined the role metasurfaces can play in THz systems. Here, an InAs metalens emitter which generates and focuses a THz pulse beam is demonstrated using a 130 nm thick InAs metasurface designed as a binary‐phase Fresnel zone plate. The THz beam is focused to a spot of ≈430 μm at 1 THz with a short focal length of 5 mm and large numerical aperture of 0.5. Nanoscale InAs Mie resonators comprising the metasurface enable THz generation with an amplitude as high as 20 times compared to plasmonic THz emitters and several times compared to a 1 mm thick ZnTe crystal. This InAs metasurface emitter provides a new paradigm for designing THz imaging, spectroscopy, and communication systems, where THz beam generation and shaping are performed with a single device without compromising the generation efficiency, while eliminating losses and avoiding limitations of phase matching of conventional nonlinear optics approaches.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Capability to Process and Characterize Uranium-Zirconium (U-Zr) and Uranium-Zirconium-Plutonium (U-Zr-Pu) Alloys

This work investigated co-reduction of anhydrous compounds of uranium, zirconium, and plutonium to produce uranium rich ternary nuclear fuel alloys. Metallothermic co-reduction is a novel method to produce all-metal nuclear fuels. Metal fuels offer thermal, fissility, compatibility, and security benefits over oxide fuels. Alloys of uranium–10% zirconium with plutonium contents of 0%, 2.5%, 5%, and 10% were produced, with yields of 60–85% of theoretical values in a traditional calciothermic bomb reduction apparatus. Microstructural analysis indicated transformation of uranium phase from gamma to beta and then alpha, in alternating lamellar plates typical of alpha phase uranium and delta phase uranium-zirconium, with zirconium and carbides at prior grain boundaries. Some of the analyses were inconclusive in their results and therefore require additional testing. Successful ternary co-reduction would simplify production of homogeneous feedstock and thereby streamline manufacture of homogeneous ternary metallic fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

(Invited) Continuum Mathematical Modeling of Water Electrolysis: A Tutorial

Widespread use of hydrogen energy is contingent on the development of reliable and economical sources of hydrogen. Electrolysis from renewably-derived low-carbon electricity is a potentially viable method of hydrogen generation. Prime among the electrolysis technologies are those utilizing ion-conducting polymers (ionomers) including proton-exchange-membrane water electrolyzer (PEMWE). However, these technologies need to exhibit increased efficiency, performance, and durability to become commercially viable. Like most electrochemical devices, PEMWEs involve multiple components (e.g., catalyst, ionomer, transport layers, membrane, plates) and multiple phases, with phenomena occurring across different time and length scales. Furthermore, it is difficult to experimentally probe many of the species and phenomena during operation. Thus, mathematical modeling at the continuum level has been an invaluable aid in exploring, understanding, and optimizing PEMWE cell and components. Furthermore, this is especially true in the highly coupled and complex physics and chemistries that occur with the membrane-electrode assembly (MEA). The physics in a typical volume-averaged non-isothermal model include multiphase transport in porous media, concentrated-solution theory, Ohm's Law, and Butler-Volmer kinetics, and ion, gas, and water transport in the ionomer.

Dizon, Arthur↗
DOE OSTI2023

Heat pipe with axial wick

A heat pipe has an evaporator portion, a condenser portion, and at least one flexible portion that is sealingly coupled between the evaporator portion and the condenser portion. The flexible portion has a flexible tube and a flexible separator plate held in place within the flexible tube so as to divide the flexible tube into a gas-phase passage and a liquid-phase artery. The separator plate and flexible tube are configured such that the flexible portion is flexible in a plane that is perpendicular to the separator plate.

Ambrose, Jay H.↗
DOE OSTI2023

Coating developments towards enabling aluminum as a bipolar plate material for PEM fuel cells

Bipolar plates represent a significant portion of the cost and weight of a proton exchange membrane fuel cell stack. As a result, there has been significant interest in using low weight and cost materials, such as aluminum. Aluminum has good mechanical and physical properties; however, it performs poorly in the corrosive environment within the fuel cell stack. To overcome the corrosion performance issue, there have been efforts towards developing coating processes to enable aluminum to attain corrosion targets. In an effort to enable aluminum as a viable bipolar plate material, a solid phase processing (diffusion bonding) approach for bonding a titanium foil to aluminum is investigated in this study. The microstructure, corrosion performance, mechanical properties and electrical resistance are investigated. To avoid the known reduction in contact resistance performance of titanium after exposure to bipolar plate media, the effect of addition of highly conductive gold particles after diffusion bonding, on contact resistance and corrosion behavior, is also studied and compared with diffusion bonded Ti to Al. In conclusion, the results indicate that diffusion bonded Ti to Al provides a viable alternative material combination for bipolar plate that avoids the micro pores and crevasses that are associated with vapor deposition or electroplating.

25 ENERGY STORAGE↗
DOE OSTI2024

Preliminary Design of Ironless Linear Induction Motors for ITER MSE Shutter Actuators

In this article, the shutters need to be closed or opened during the operation and calibration period time for the fusion diagnostic systems, such as the International Thermonuclear Experimental Reactor (ITER) motional stark effect (MSE). Standard electric motors and actuators will not work in a strong magnetic field environment due to the presence of the magnetic field of fusion reactors. The innovative linear induction motor (LIM) with an ironless feature overcomes this kind of challenge and can be used for any application that requires controlled motion with a large stroke in the magnetic field environment. It consists of a high-electrical conductivity plate like copper and three-phase motor windings with nonferrous or stainless-steel stators. The conductor plate attached with the shutter is simply driven by the underneath three-phase linear windings to achieve linear motion. The motor drive can be controlled remotely by a controller using the electrical connection, so no sensitive electronic components are located in the harsh environment where the motor itself is located. The design requirements and test facility have been described. Several 3-D transient Maxwell electromagnetic (EM) models with different locations of three-phase linear motor windings and shutter stators have been analyzed and evolved to meet any applications allowed in the harsh environment inside the vacuum vessel of fusion reactors. The preliminary design results are presented in this article.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

STAT7 v1.2 User Guide: The STAT7 Code for Statistical Propagation of Uncertainties in Steady-State Thermal Hydraulics Analysis of Plate-Fueled Reactors

The STAT7 software was developed to perform steady-state, single-phase thermal hydraulics analysis of plate-fueled reactors based on statistical propagation of uncertainties. Application of the software is for non-power research and test reactors, including conversion to low-enriched uranium fuel of U.S. High-Performance Research Reactors such as Massachusetts Institute of Technology Research Reactor. Since it can be necessary to repeat analysis during fuel reloading, STAT7 accommodates flexibility in analyzing many realistic aspects of reactor fuel management. STAT7 uses a Monte Carlo approach to model uncertainty in common fuel fabrication parameters and other key reactor operating parameters required for thermal hydraulics analyses of research and test reactors. These safety calculations are ultimately intended to protect against high fuel plate temperatures due to critical heat flux, or onset of flow instability. STAT7 supports water properties based on the IAPWS-IF97 functions (The International Association for the Properties of Water and Steam Industrial Formulation 1997 for the Thermodynamic Properties of Water and Steam) in addition to the fit functions. STAT7 predicts axial profiles of fuel, cladding, and coolant temperature along a lateral stripe that runs the full length of the fuel plate from the bottom to the top. STAT7 can simultaneously analyze all of the axial nodes of all of the fuel plates and all of the coolant channels for one latera stripe of a fuel element. Power splits are calculated for each axial node of each plate to determine how much of the power goes out each face of the plate. By running STAT7 multiple times, full core analysis can be performed by analyzing the margin to onset of nucleate boiling and onset of flow instability for each axial node of each stripe of each plate of each fuel element in the core.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Toward Lithium Recovery Using Modular (and Membraneless) Phase Separation and Extraction (MPSE) Technology with Ionic Liquid (IL) Solvents: Effect of Coatings

In this work, a single-channel slope-plate Modular and Membrane-less Phase Separation and Extraction (MPSE) device was fabricated using 3D printing. The slope-plate was designed with an insertable glass slide to enable surface modification with coatings. Self-assembled monolayers (SAMs) and perfluoropolyether (Zdol) coatings were applied to tailor surface wettability and enhance phase separation. Using a model biphasic system of water and hexadecane, both coatings significantly improved the separation efficiency compared to the uncoated device by promoting selective wetting. Building on these results, lithium extraction from a simulated saline solution was investigated using 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTf₂]) as the ionic liquid (IL) extractant. The IL effectively extracted Li⁺ from the aqueous phase in bulk extraction, demonstrating its potential for lithium recovery. However, the low interfacial tension between the IL and aqueous phases posed challenges for phase separation. The application of SAM and Zdol coatings effectively mitigated this issue. Overall, integrating tailored surface chemistry with the slope-plate MPSE design shows great promise as an efficient and scalable platform for studying liquid–liquid separation and optimizing ionic liquid–based extraction processes for lithium recovery from saline sources.

3D printing↗
DOE OSTI2025

Multiframe X-ray diffraction on the OMEGA EP laser

A method of measuring multiple temporally resolved powder x-ray diffraction measurements during a single dynamic compression laser experiment has been demonstrated on the OMEGA EP laser. Up to four time-gated snapshots of the x-ray diffraction pattern are collected on an ultrafast x-ray framing camera with a 2θ scattering angle coverage of 48°–65° and 400-ps temporal resolution with the potential for 10°–160° and 200-ps resolution. X-ray diffraction snapshots capture the transformation to a high-pressure β phase in ramp-compressed Zr, constraining the atomic structure and pressure–density equation-of-state in a single shot. Here, this platform will be used to constrain transition pressures, understand the role of kinetics, and verify the existence of hysteresis and metastability on phase transformations at the lattice level under single-shot dynamic compression.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Plate motion in sheared granular fault system

Plate motion near the fault gouge layer, and the elastic interplay between the gouge layer and the plate under stick-slip conditions, is key to understanding the dynamics of sheared granular fault systems. Here, a two-dimensional implementation of the combined finite-discrete element method (FDEM), which merges the finite element method (FEM) and the discrete element method (DEM), is used to explicitly simulate a sheared granular gouge fault system. In this work we focus on investigating the influence of normal load, driving shear velocity and plate stiffness on the velocities and displacements in the direction parallel to the shear direction (x-direction) measured at locations on the upper and lower plates just adjacent to the gouge. The simulations show that during slip phases the magnitudes of the measured velocities on the upper and lower plates are proportional to the normal load and may be inversely proportional to the square root of the plate's shear modulus. Whereas, the driving shear velocity does not show distinct influence on the measured velocities. Additionally, large slip velocities are generally associated with large macroscopic friction coefficient drops. For the models subjected to smaller normal loads, larger shear velocities and with stiffer shear plates, the same magnitude of slip velocity could cause a larger drop of macroscopic friction coefficient. During stick phases, the velocities of the upper and lower plates are respectively slightly greater and slightly smaller than half of the driving shear velocity and are both in the same direction of shear. The shear strain rate of the gouge is calculated from this velocity difference between the upper and lower plate during stick phases and thus the gouge effective shear modulus can be calculated. The results show that the gouge effective shear modulus increases proportionally with normal load, while the influence of shear velocity and plate stiffness on gouge effective shear modulus is minor. The simulations address the dynamics of a laboratory-scale fault gouge system and may aid in revealing the complexities of earthquake frictional dynamics.

58 GEOSCIENCES↗
DOE OSTI2023

Measurement of 2D density profiles using a second-harmonic, dispersion interferometer

A second-harmonic, dispersion interferometer is used to image large-area (≃5 cm 2 ) plasma-jet and gas-jet density profiles. Achromatic telescopes magnify the diameters of the primary-laser beam (1064 nm) and its second-harmonic (532 nm) before probing the sample and de-magnify the beam diameters after the sample, where the primary beam transfers its phase change to a second, second-harmonic beam, allowing the sample’s dispersive-phase change to be measured between two, orthogonally polarized second harmonic beams. The telescopes produce an azimuthally symmetric, dispersive-phase shift in the sample + background phase-change image and in the background phase-change image, which is removed by digital subtraction. The interferometer’s performance was verified using standard-optical components as dispersive elements (BK7 lenses and wedge plates), resolving a minimum, phase-change sensitivity of ΔΦ min ≳ 15 mrad and spatial resolution of Δx res ≃ 100 μm. The phase change produced by unknown-density objects (a pulsed-plasma-jet and a pulsed-gas-jet) was measured, and their data were used to recover the original, 2D density profiles using an inverse Abel transform: peak-number density, N gas ≃ 6 × 10 20 cm –3 and N e ≃ 5 × 10 16 cm –3 ; line-integrated density, ∫N gas dl ~ 2 × 10 19 cm –2 and ∫N e dl ~ 1 × 10 16 cm –2 . The techniques and methods developed here are scalable to even larger probe-beam diameters and frame-capture rates, leading to a diagnostic capability that is well-suited for applications involving the real-time measurement of density.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Quantification of heterogeneous, irreversible lithium plating in extreme fast charging of lithium-ion batteries

Realization of extreme fast charging (XFC, ≤15 minutes) of lithium-ion batteries is imperative for the widespread adoption of electric vehicles. However, dramatic capacity fading is associated with XFC, limiting its implementation. To quantitatively elucidate the effects of irreversible lithium plating and other degradation mechanisms on the cell capacity, it is important to understand the links between lithium plating and cell degradation at both the local and global (over the full cell) scales. Here, we study the nature of local lithium plating after hundreds of XFC cycles (charging C-rates ranging from 4C to 9C) in industrially-relevant pouch cells using spatially resolved X-ray diffraction. Our results reveal a spatial correlation at the mm scale between irreversible lithium plating on the anode, inactive lithiated graphite phases, and local state-of-charge of the cathode. In regions of plated lithium, additional lithium is locally and irreversibly trapped as lithiated graphite, contributing to the loss of lithium inventory (LLI) and to a local loss of active anode material. The total LLI in the cell from irreversibly plated lithium is linearly correlated to the capacity loss in the batteries after XFC cycling, with a non-zero offset originating from other parasitic side reactions. Finally, at the global (cell) scale, LLI drives the capacity fade, rather than electrode degradation. We anticipate that the understanding of lithium plating and other degradation mechanisms during XFC gained in this work will help lead to new approaches towards designing high-rate batteries in which irreversible lithium plating is minimized.

25 ENERGY STORAGE↗
DOE OSTI2021

An experimentally validated evaporative phase change heat transfer model for low mass flux applications using R134a in plate heat exchangers

Plate frame heat exchangers are common in liquid-coupled vapor compression systems due to their compactness and ease of maintenance. In some of these systems, the refrigerant within the evaporator can enter the heat exchanger as a subcooled liquid. As a result, the refrigerant passes through three different phases: single-phase liquid, two-phase fluid, and a superheated vapor. Unfortunately, there have been limited prior studies that have identified the best method to predict performance under these circumstances. Furthermore, previous investigations have not evaluated refrigerant evaporation in large industrial sized plate frame heat exchangers under conditions experienced in the present study experimental test facility, especially at mass fluxes below 7 kg m –2 s –1 . In the present investigation, a model was developed to predict the performance of plate and frame heat exchangers when the fluid enters as a subcooled liquid and exits as a superheated vapor. The model used full-sized plate heat exchanger geometry that was discretized into 20 sections to accurately capture local heat transfer and pressure drop effects. The model was validated using an R134a counter flow heat exchanger used in a turbo-compression cooling system test facility that had subcooled liquid entering the evaporator at low mass fluxes. A variety of empirical correlations were evaluated to determine what combination yielded the best predictive capability over the following range of conditions: 5.8 < G < 6.8 kg m –2 s –1 , 2 < q” < 2.8 kW m –2 , and 10 °C < T sat < 15 °C. When the correlations used a fixed control volume length in the heat flux calculation, the most accurate combination resulted in a mean absolute error of 5.5%. Finally, future studies can use the approach described here to optimize heat exchanger size and performance.

42 ENGINEERING↗
DOE OSTI2020

The use of U3Si2/Al dispersion fuel for high power research reactors

In order to investigate the irradiation performance of U3Si2/Al dispersion fuel at relatively aggressive reactor conditions, compared to how this fuel is typically used in a research or test reactor, post irradiation examination was performed on two fuel plates that were irradiated at ~270 W/cm2 average surface heat flux and to a maximum local burnup greater than 8 × 1021 fissions/cm3 in the Advanced Test Reactor as part of the RERTR-8 experiment. As part of the non-destructive examinations that were performed on both fuel plates, detailed thickness measurements using a high-fidelity measurement bench were performed on one fuel plate and a segment of the second fuel plate. This paper provides the first reported results of such high-resolution thickness measurements for U3Si2/Al dispersion fuel plates, containing primarily the U3Si2 fuel phase, irradiated at such power levels to high burnup. For destructive examination using optical metallography, samples were generated from both irradiated plates. Localized regions of high swelling (characteristic of internal blistering) were observed on the surface of both fuel plates, suggesting that the performance limits had been reached for each plate. Destructive examinations showed that the fuel particles that are primarily U3Si2, which become amorphous during irradiation, in both plates contained relatively large fission gas bubbles with evidence of fission gas bubble interconnection.

Wachs, Daniel M.↗
DOE OSTI2025

Reactive Suspension Electrolytes for Lithium Metal Batteries

Lithium metal batteries (LMBs) suffer from dendrite growth and capacity loss, which compromise safety and cycle life. Here, we present a simple reactive suspension electrolyte (RSE) strategy. When metal oxide (MO x ) nanoparticles are dispersed in the liquid electrolyte, in situ formation of Li 2 O and Li–M phases occurs at the lithium metal anode. By studying two different types of RSEs, Type 1 RSEs (i.e., CuO RSE) without metal-Li alloying and Type 2 RSEs (i.e., ZnO RSE and In 2 O 3 RSE) with metal-Li alloying capability, we elucidate the roles of each reaction compound. Here, we find that Li 2 O can improve reversibility of Li metal anode by stabilizing the interphase while Li–M alloy phases guide uniform Li metal plating. Compared to the carbonate-type reference electrolyte, RSEs demonstrate reduced nucleation overpotential, lower interfacial impedance, and higher Coulombic efficiency, leading to an extended cycle life in Li|Li 1 Ni 0.8 Co 0.1 Mn 0.1 O 2 full cells.

Lee, Junyoung [Stanford Univ., CA (United States)]↗