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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Multiscale Cryo Electron Microscopy Reveals Interfacial Degradation and Stabilization in Battery Electrodes

Electrochemical interfaces are dynamic systems, evolving based on their local environment and reactant surface structures. The electrode-electrolyte interface in Li-ion batteries can be protective, limiting parasitic reactions with the electrolyte to passivate the surface [1]. Additionally, this interphase has an impact on the Li-ion transport through that layer based on its composition, bonding environment, and thickness. These parameters are challenging to collect and may vary depending on the electrode surface site investigated relative to its spatial position in a coin cell. This study will detail a multiscale cryogenic electron microscopy approach where millimeter-scale cross-sections through the coin cell batteries were made using a cryogenic stage within a fs-laser plasma focused ion beam (laser PFIB) with complementary energy dispersive X-ray spectroscopy able to detect variations in the composition at electrode interfaces [2]. Microscale cross-sectioning and lamella sample preparation of battery electrodes was conducted at the Center for Integrated Nanotechnologies using a Ga-ion focused ion beam (FIB) with air-free and cryo-transfer [3], followed by nanoscale mapping of composition and bonding within the CEI through cryo-scanning transmission electron microscopy (cryo-STEM) electron energy loss spectroscopy [4]. This multiscale approach enabled identification of millimeter-scale features of a battery stack with visualization of degradation in electrodes such as cracks in cathode particles, gas evolution, and SEI evolution; microscale interfacial characteristics, such as heterogeneity in the SEI or barrier layer and identification of electrolyte networks to the electrode surfaces; and nanoscale measurement of the CEI thickness, mapping of transition metal bonding within the cathode particles to identify loss of active materials, and identification of beneficial electrolyte additives incorporated into the CEI structure. This multiscale approach allows for a statistical understanding of the primary mechanisms and parasitic degradation pathways that impact performance by limiting the ion transport pathways within Li+ batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Autonomous light management system for a window and method of controlling light transmission

An autonomous light management system for a window includes an electrochromic film stack comprising an electrochromic layer on a first transparent electrode, an ion storage layer on a second transparent electrode, and an electrolyte sandwiched between the ion storage and electrochromic layers. The electrochromic film stack exhibits a transmissive state or an absorptive state depending on charging or discharging of the electrochromic layer. The light management system further comprises an array of power units disposed on a front surface of the electrochromic film stack, where each power unit comprises at least one solar microcell. Collectively, the solar microcells cover an area no greater than about 6% of a total area of the front surface. The array of power units is configured to control the charging and discharging of the electrochromic layer, thereby manipulating light transmission through the electrochromic film stack.

Yoder, Mikayla A.↗
DOE OSTI2023

Intermediate Temperature Single Component Electrolysis Cell

This project aims at demonstrating a fundamentally new approach towards electrochemical hydrogen production using a single component cell design. Conventional electrolyzer cells consist of a stack of layers (oxygen and fuel electrodes, electrolyte layer) that require multiple processing steps and add to the fabrication cost and complexity. Here we explore the viability of a single-layer electrolyzer device based on the single-layer SOFC concepts described in literature (Asghar et al, 2020). The single layer material is a composite of ionic conductor and catalytic material consisting of ceria doped with Gd and Sm co-processed with CuFe 2 O 4 .

08 HYDROGEN↗
DOE OSTI2025

Stress evolution and creep deformation in solid-oxide electrolysis cell systems – Dynamic modeling and multi-objective optimization to maximize stack life and efficiency

Here, this study develops a thermal stress model of solid-oxide electrolysis cells (SOECs) including a model for creep strain and failure probability that is integrated with a dynamic plant-wide model of a hydrogen production process. Uncertainties in key material properties of the cell are quantified to assess their impact on stress profile variability. The oxygen electrode is found to have about 10 times higher failure probability compared to the fuel electrode. The study shows that if the stack operation is not optimized, cycling operation would lead to stress build-up eventually leading to catastrophic failure. A dynamic optimization problem is set up for obtaining the optimal operational profile considering a variable hydrogen production rate. Due to the tradeoff between the efficiency and stress build-up, the dynamic optimization problem is multi-objective. It is observed that the optimizer can considerably reduce the stress build-up (i.e., can increase the stack life) albeit at the cost of a lower efficiency thus exhibiting strong tradeoffs between capital and operating costs. For example, if the stack would be replaced in 0.5 yr, specific energy requirement would be 48.5 kWh/kg H 2 while for a stack replacement time of about 6 yr, the specific energy requirement rises by about 4.2 %.

SOEC↗
DOE OSTI2020

Role of electron pathway in dimensionally increasing water splitting reaction sites in liquid electrolytes

Hydrogen from water splitting is one of the most promising alternatives for fossil fuels in solving the global energy crisis, while its electrochemical reaction mechanism, especially in liquid electrolytes, remains unclear. Herein, how the electrode conductivity affects the reaction sites of oxygen evolution reactions (OERs) in acidic and alkaline solutions was investigated by employing visualization system and electrochemical testing. Inserting Au nanolayers greatly increased electrode conductivities, improved OER kinetics and reduced cell ohmic resistance, leading to excellent water splitting performances in both acidic and alkaline electrolytes. Furthermore, the in-situ visualization results showed more reaction sites and higher catalyst utilizations were achieved by augmenting the electrode conductivity, and reaction sites increased from 1-dimension to 2-dimension. Additionally, it was discovered that electrical conductivities of acidic and alkaline solutions are insufficient to overcome the sharp drop of potential in the electrical double layer for activating OER uniformly on low-conductivity catalysts, indicating the importance of electrical conductivity of the electrode in acidic and alkaline water electrolyzers. This study provided a guidance on how to develop efficient and compact electrodes for acidic and alkaline water electrolyzer stacks and other electrochemical devices, such as fuel cell, N2 reduction, CO 2 conversion, etc.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Two-terminal electronic charge resistance switching device

A two-terminal memory device and methods for its use are provided. In the device, a bottom electrode is electrically continuous with a first operating terminal, and a control gate electrode is electrically continuous with a second operating terminal. A stack of insulator layers comprising a hopping conduction layer and a tunnel layer is contactingly interposed between the bottom electrode and the control gate electrode. The tunnel layer is thinner than the hopping conduction layer, and it has a wider bandgap than the hopping conduction layer. The hopping conduction layer consists of a material that supports electron hopping transport.

Marinella, Matthew↗
DOE OSTI2020

High-performance and cost-effective membrane electrode assemblies for advanced proton exchange membrane water electrolyzers: Long-term durability assessment

In this work, improved activity and durability performance of a two-cell (86 cm 2 ) proton exchange membrane water electrolyzer (PEMWE) stack is reported for the first time. Both membrane electrode assemblies (MEAs) contain one order of magnitude lower platinum group metal (PGM) loadings compared to the state-of-the-art PEMWEs and incorporate novel Pt recombination layers. The high-performance and cost-effective MEAs are fabricated by the unique reactive spray deposition technology (RSDT). This advanced methodology allows for one-step fabrication of MEAs and ensures precise control and distribution of the catalyst composition and loading. The RSDT-fabricated MEAs contain only 0.2 and 0.3 mg PGM cm –2 loading in the cathode and anode electrodes, respectively, and demonstrate excellent activity and durability for over 3000 h of operation at industrially-relevant operating conditions without showing significant loss in performance. This novel work shows that a significant cost reduction for PEMWEs is achieved while maintaining excellent durability, high catalysts activities, and low hydrogen cross-over.

Proton exchange membrane water electrolyzer↗
DOE OSTI2023

Carbon Electrode with Sputtered Au Coating for Efficient and Stable Perovskite Solar Cells

Halide perovskite solar cells (PSCs) represent a low-cost and high-efficiency solar technology. However, most of the highly efficient PSCs need a noble electrode, such as Au, through thermal evaporation. Here it is reported that a sputtered Au electrode on a PSC could damage the organic hole transport layer (HTL) and the perovskite layer. Here, we report a simple, yet effective sputtered gold nanoparticle decorated carbon electrode to fabricate efficient and stable planar PSCs. The sputtered Au layer on the doctor-bladed coated carbon electrode can be directly applied to the perovskite semicells by mechanical stacking. By optimizing the gold thickness, a power conversion efficiency (PCE) of 16.87% was obtained for the composite electrode-based PSC, while the reference device recorded a PCE of 12.38%. The composite electrode-based device demonstrated 96% performance retention after being stored under humid conditions (50-60%) without encapsulation for ~100 h. This demonstrates a promising pathway toward the commercialization of large-scale manufacturable sputtered electrodes for the PSC solar module.

14 SOLAR ENERGY↗
DOE OSTI2023

Using nickel-molybdenum cathode catalysts for efficient hydrogen gas production in microbial electrolysis cells

A low-cost cathode catalyst based on a NiMo alloy was examined here to replace noble metals for the hydrogen production in microbial electrolysis cells (MECs). Two NiMo catalysts were synthesized through either an electrochemical assisted (NiMo Elec) or a hydrothermal (NiMo Ht) approach. The NiMo Ht method enriched the electrocatalyst with Mo atoms compared to the NiMo Elec approach, producing a similar current density with a minimal overpotential of 50mV compared to Pt. Further, in MEC tests using the NiMo Ht catalyst, H 2 was generated at a highest rate of 81±3 L H2 /L-d (current density of 44.4 ± 0.9 A/m 2 ) at a cell voltage of -0.86 V, and a Coulombic efficiency of >97%. Modifying the closely stacked MEC design to include a reference electrode, and analysis of the electrode potentials using the electrode potential slope method, revealed a large contribution of the cathode resistance (5.3±0.5mΩm 2 ) compared to the anode (1.4±0.2mΩm 2 ) and ohmic resistance (0.83mΩm 2 ) for a total internal resistance of 7.6±0.5mΩm 2 . The high performance of the NiMo Ht catalyst coupled with its low cost provides an economically viable approach to advance the generation of biohydrogen in MECs.

25 ENERGY STORAGE↗
DOE OSTI2021

High Throughput In-Line Coating Metrology Development for Solid Oxide Fuel Cell Manufacturing

Coatings play key roles in solid oxide fuel cell (SOFC) stack durability. For example, diffusion barrier coatings on Cr-containing interconnect and balance of plant (BOP) components protect electrodes from Cr poisoning over the long operational lifetimes (>10,000 hours) of the fuel cell stack. Common defects in coatings, such as cracks, pinholes, and porosity, result in a failure to protect the electrodes, resulting in shorter operational lifetime and thus higher cost. It is very unlikely, even in the best coating process, that all these defects can be mitigated, hence identifying critical defects in parts, and removing defective parts from production before they can damage the stack, becomes paramount. Furthermore, these quality control techniques must be operational in the production/assembly line (in-line), i.e., high throughput and non-destructive, and cost effective. Redox Power Systems, LLC (Redox) together with the National Renewable Energy Laboratory (NREL) developed much needed high throughput, in-line metrology techniques for protective coatings. The overall goal of the project is to lower cost while increasing robustness, reliability, and endurance of SOFC stacks. To accomplish this, we had several objectives, including: to identify key coating and substrate defects that lead to coating failure through the use of detailed characterization methods (e.g., microscopy, XRD, EDS, electrochemistry); to assess capabilities of in-line metrology techniques, e.g., optical profilometry (Redox) and thermography (NREL), to probe these defects, or evidence thereof; demonstrate long-term performance of “defect-free” protective coatings, as identified by in-line metrology, in solid oxide fuel cell (SOFC) stack operation. In the first part of this project, the ability to identify key defects expected to lead to coating and SOFC degradation using in-line metrology tools were evaluated. Coated interconnect samples with controlled defect types and populations were tested under conditions similar to SOFC operation, followed by detailed post-test analysis to reveal the defects responsible for observed degradation. In the second part of the project, the optimal in-line metrology techniques and methodologies were used to map the defect distribution in full-size interconnects with critical defects intentionally allowed to exist in some cases. These interconnects underwent SOFC testing for extended periods (up to ~3,000 hours) followed by post-test analysis to evaluate the effectiveness of in-line metrology techniques in mitigating MCO coating related degradation. Key accomplishments in this project included the following: Demonstrated ASR of < 0.05 ohm-cm 2 at 650 °C for 1,000 hours with low defect (determined by in-line metrology) interconnect samples (average ASR=37 milliohms-cm 2 after over 1,000 hours). Demonstrated that low defect coatings on interconnects (as screened using in-line metrology) have low volatilization of chromium at ~650 °C for 1,000 hours as detected using Cr-getter material (< 5 at% increase above baseline); 1022 hour duration tests under humidified, elevated temperature (750 °C rather than 650 °C) compared a base case against different coating thicknesses. Demonstrated capability to identify initial key defects of interest with in-line metrology techniques using up to 8 cm by 10 cm having coatings with and without intentional defects of interest using thermal imaging and optical profilometry. Correlated key defects identified using metrology techniques with observed coating performance (e.g., ASR and Cr volatility). Conducted several 4 cm by 4 cm cell tests using MCO-interconnects that were pre-screened using some of the metrology techniques developed in the project (e.g., optical profilometry). An analysis of ASR measurements were able to show that defect-free coatings resulted in the anticipated performance in the cell tests.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

An Overview of the Design and Optimized Operation of Vanadium Redox Flow Batteries for Durations in the Range of 4–24 Hours

An extensive review of modeling approaches used to simulate vanadium redox flow battery (VRFB) performance is conducted in this study. Material development is reviewed, and opportunities for additional development identified. Various crossover mechanisms for the vanadium species are reviewed, and their effects on its state of charge and its state of health assessed. A stack design focusing on flow fields and an electrode design tailored to various flow fields are reviewed. An operational strategy that takes these parameters into account is reviewed for various operating envelopes, chosen based on end user preference in terms of minimizing capital cost or operation and maintenance cost. This work provides a framework for the design and operation of a VRFB for various grid services.

25 ENERGY STORAGE↗
DOE OSTI2021

The DUNE Vertical Drift Photon Detection System

The Deep Underground Neutrino Experiment (DUNE) is a long-baseline neutrino experiment designed to mainly investigate oscillation parameters, supernova physics and proton decay. Its far detector will be composed of four liquid argon time projection chamber (LArTPC) underground modules, in South Dakota-USA, which will detect a neutrino beam produced at Fermilab, 1300 km away, where a near detector will be in place. The second DUNE far detector module, Vertical Drift, will be a single phase LArTPC with electron drift along the vertical axis with two volumes of 13.5 m x 6.5 m x 60 m dimensions separated by a cathode plane. The charge collection will be performed by two anode planes placed at the top and bottom of the module, each composed by stacked layers of a perforated PCB technology with electrode strips. The photon detection system (PDS) will make use of large size X-Arapuca tiles distributed over three detection planes. One plane will consist of a horizontal arrangement of double sided tiles installed on the high voltage cathode plane and two vertical planes, each placed on the longest cryostat membrane walls. A light active coverage of 14.8% over the cathode and 7.4% over the laterals should allow improvements in the low energy physics range that can be probed in DUNE, especially regarding supernova neutrinos (~10 MeV). We present the initial characterization of the Vertical Drift PDS using a Monte Carlo simulation and preliminary studies on its reconstruction capabilities at the MeV scale. The information obtained with the PDS alone should allow determination of a neutrino interaction region with a precision of at least 65 cm for events with deposited energy above 5 MeV and the deposited energy can be reconstructed with precision better than 10%, both at the center of the volume.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Cost analysis of hydrogen production by high-temperature solid oxide electrolysis

In this study, we estimate construction and operation costs of gigawatt-scale solid oxide electrolysis (SOE) facilities for producing high purity hydrogen gas from water. Manufacturing and assembly costs for two types of SOE cell stacks are estimated using a detailed design for manufacture and assembly (DFMA®) analysis. Modular balance of plant (BOP) process equipment is designed and sized with Aspen®, and cost estimated using equipment vendor quotes. Factory and on-site assembly and installation costs for SOEC stack and BOP equipment integration into modular SOE process units are calculated using a simplified DFMA® method. Total stack costs on a stack input power (SIP) basis reduce to <$100/kW e DC SIP for >500 MW e DC SIP /year production rates with electrode cermet, interconnects, and high-temperature heat treatments dominating the total cost. Integration of stacks with larger BOP equipment operating at higher pressures offers ~36% cost reduction in total facility capital cost due to an economies of physical scale effect since BOP equipment comprises >50% of facility costs. Optimized H 2 prices decrease from ~$\$$4/kgH 2 to ~$\$$2/kgH 2 for 1 GWe DCSIP facilities using $\$$0.025/kWh electricity price. All costs are reported in 2021 US dollars.

08 HYDROGEN↗
DOE OSTI2023

Pathways to High-Power-Density Redox Flow Batteries

Redox flow batteries (RFBs) promise to fill a crucial missing link in the energy transition: inexpensive and widely deployable grid and industrial-scale energy storage for intermittent renewable electricity. While numerous lab-scale and demonstration-scale RFBs have been delivered, widespread commercial deployment is still limited by high electrolyte, stack, and balance of plant capital costs. Increasing the power density of RFBs is correlated with lower stack costs, primarily because the area needed for expensive electrode and membrane components to reach a target power density is reduced. Here, in the present contribution, we summarize the areal power densities reported for lab-scale RFBs, critically evaluate major pathways employed for power optimization, and identify opportunities for developing yet-higher power density systems.

25 ENERGY STORAGE↗
DOE OSTI2023

Reduced-temperature sintering of spinel-type coatings and layers with metallic alloy powder precursors

A method of forming a spinel coating on a substrate is disclosed including the steps of coating at least a portion of the substrate with a precursor including an alloy powder, and sintering the precursor at a temperature of less than 1000 degrees Celsius to form the spinel coating. The alloy powder used for the precursor can include particles having a particle size of less than 10 micrometers. The method can be utilized to form spinel coatings as contact surfaces between electrodes and interconnects of solid oxide fuel cell (SOFC) stacks.

Zhu, Jiahong↗
DOE OSTI2021

Long-Term Structural and Chemical Stability of Carbon Electrodes in Vanadium Redox Flow Battery

Predicting the performance decay in carbon electrodes is critical to maximizing the longevity of redox flow battery (RFB) systems. This study investigates the effect of long-term cycling (over 8000 cycles) on the structural and chemical evolution of carbon electrodes. We find that the microstructural aspects such as graphitic stacking order and interlayer spacing along with overall morphological construct remains largely unchanged even after the prolonged cycling process. Conversely, significant changes in surface chemistry such as evolution of functional groups and point defects are evident from our combined multimodal spectroscopic and computational analysis. The XPS and FTIR analysis reveals chemical absorption of chloride counter anions at point defects within graphitic surface. Additionally, our results suggest that vanadium cation plays an important role in counter anion-carbon surface interaction and subsequently the surface chemistry evolutions. Our findings provide insights about surface chemical evolution that is critical for predicting electrode performance and longevity of RFB.

Modachur Sivakumar, Bhuvaneswari↗