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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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Mechanical Properties of Aged A709

A709 plate is in the process of being developed and qualified through a collaboration by Argonne National Laboratory (ANL), Idaho National Laboratory (INL), and Oak Ridge National Laboratory (ORNL). The goal is to qualify A709 plate in Section III, Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC). This would permit the construction of A709 plate for fast-reactor structural applications. A tradeoff between creep and creep-fatigue properties was established in prior work. A processing route was identified as providing the optimal balance between creep-rupture and elevated-temperature cyclic properties for the solution annealed condition. This condition, however, resulted in a shorter than desired creep-rupture life. Aging is probed to evaluate its potential at further improving mechanical properties. Aging statically precipitates the solutes in solution prior to service. The processing routes identified as providing the best creep-rupture properties and best balance in mechanical properties are investigated. This report discloses the results from tensile, creep, and elevated-temperature cyclic testing performed at INL on the aged material. The aged properties are compared to solution annealed properties. A709 offers improvement in performance compared to 316H particularly at high temperatures; 316H is a material qualified in Section III, Division 5 of the ASME BPVC. For certain high-temperature fast-reactor design conditions, 316H cannot be used while A709 can.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Defect‐Free Sound Insulator Using Single Metal‐Based Friction Stir Process Array

Metals are excellent conductors for phonon transportation such as vibration, sound, and heat. Generally, metal sound insulators require multimaterial structure or defects and unimetal sound insulators are challenging. Therefore, a design of a defect-free sound insulator made by single alloys with multiple friction stir processes (FSPs) is proposed. Periodic friction stir processing can induce superlattice-like local mechanical properties’ modifications. By experimental acoustic characterization, it is observed that FSP can introduce clear acoustic–elastic property contrast on an aluminum plate by the presence of stir zone and heat-affected zones. In numerical simulations, the signature FSP-induced property profile is periodically and parallelly arranged on a long aluminum plate. The transmission gap frequencies are present on the frequency spectrum with the sound propagation direction perpendicular to the FSP paths. Disorder offsets on FSP periodicity are further introduced. Anderson localization is found on a resonance frequency, which provides −11 dB sound reduction by an exponential decay. Due to the finite design length, the slight disorder can also enhance sound insulation in the periodic transmission gap frequency. In conclusion, with analysis and comparison with different configurations, the best performance in the models can achieve −30 dB sound insulation in the 350 mm-long aluminum alloy plate with 14 parallel FSPs.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Dendrite–Free Potassium Metal Anodes in a Carbonate Electrolyte

Potassium (K) metal anodes suffer from a challenging problem of dendrite growth. In this study, it is demonstrated that a tailored current collector will stabilize the metal plating–stripping behavior even with a conventional KPF 6 –carbonate electrolyte. A 3D copper current collector is functionalized with partially reduced graphene oxide to create a potassiophilic surface, the electrode being denoted as rGO@3D–Cu. Potassiophilic versus potassiophobic experiments demonstrate that molten K fully wets rGO@3D–Cu after 6 s, but does not wet unfunctionalized 3D–Cu. Electrochemically, a unique synergy is achieved that is driven by interfacial tension and geometry: the adherent rGO underlayer promotes 2D layer–by–layer (Frank–van der Merwe) metal film growth at early stages of plating, while the tortuous 3D–Cu electrode reduces the current density and geometrically frustrates dendrites. The rGO@3D–Cu symmetric cells and half–cells achieve state–of–the–art plating and stripping performance. Here, the symmetric rGO@3D–Cu cells exhibit stable cycling at 0.1–2 mA cm –2 , while baseline Cu prematurely fails when the current reaches 0.5 mA cm –2 . The half–cells cells of rGO@3D–Cu (no K reservoir) are stable at 0.5 mA cm –2 for 10 000 min (100 cycles), and at 1 mA cm –2 for 5000 min. The baseline 3D–Cu, planar rGO@Cu, and planar Cu foil fails after 5110, 3012, and 1410 min, respectively.

25 ENERGY STORAGE↗
DOE OSTI2022

An Investigation of Chemo-Mechanical Phenomena and Li Metal Penetration in All-Solid-State Lithium Metal Batteries Using In Situ Optical Curvature Measurements

Solid-electrolytes (SEs) can provide a pathway to increase energy-density in lithium metal batteries. However, lithium metal penetration through garnet based LLZO solid electrolytes has been identified as a critical failure process. This phenomenon is related to chemo-mechanical processes which are difficult to probe. In particular, characterizing the dynamic mechanical deformations that occur in electrode-SE structures is very challenging. Here study reports in situ curvature measurements that are thus designed to probe chemo-mechanical phenomena that occur during lithium plating. The novel experimental cell configuration created for this work shows that pressure builds up in the Li metal during plating, up until the point where short circuits occur. The resulting data are analyzed with a detailed finite element model (FEM) to quantitatively evaluate stress evolution. The results show that Li metal plating within a surface flaw can produce stress build-up prior to short-circuiting. The combined results from both the experiments and the FEM suggest that it is critical to minimize surface defects and flaws during the manufacturing processes.

25 ENERGY STORAGE↗
DOE OSTI2022

Current‐Dependent Lithium Metal Growth Modes in “Anode‐Free” Solid‐State Batteries at the Cu|LLZO Interface

Abstract Controlling the lithium growth morphology in lithium reservoir‐free cells (RFCs), so‐called “anode‐free” solid‐state batteries, is of key interest to ensure stable battery operation. Despite several benefits of RFCs like improved energy density and easier fabrication, issues during the charging of the cell hinder the transition from lithium metal batteries with a lithium reservoir layer to RFCs. In RFCs, the lithium metal anode is plated during the first charging step at the interface between a metal current collector and the solid electrolyte, which is prone to highly heterogeneous growth instead of the desired homogeneous film‐like growth. Herein, the lithium morphology during the first charging step in RFCs is explored as a function of current density and current collector thickness. Using operando scanning electron microscopy, an increase in the lithium particle density is observed with increasing current density at the Cu|Li 6.25 Al 0.25 La 3 Zr 2 O 12 interface. This observation is then applied to improve the area coverage of lithium by pulsed plating. It is also shown that thin current collectors ( d = 100 nm) are unsuited for RFCs, as lithium whiskers penetrate them, resulting in highly heterogeneous interfaces. This suggests the use of thicker metal layers (several µm) to mitigate whisker penetration and facilitate homogeneous lithium plating.

25 ENERGY STORAGE↗
DOE OSTI2023

Interface Design for High‐Performance All‐Solid‐State Lithium Batteries

All‐solid‐state batteries suffer from high interface resistance and lithium dendrite growth leading to low Li plating/stripping Coulombic efficiency (CE) of <90% and low critical current density at high capacity. Here, in this work, both challenges are simultaneously addressed and the Li plating/stripping CE is significantly increased to 99.6% at 0.2 mA cm −2 /0.2 mAh cm −2 , and critical current density (CCD) of > 3.0 mA cm −2 /3.0 mAh cm −2 by inserting a mixed ionic‐electronic conductive (MIEC) and lithiophobic LiF‐C‐Li 3 N‐Bi nanocomposite interlayer between Li 6 PS 5 Cl electrolyte and Li anode. The highly lithiophobic LiF‐C‐Li 3 N‐Bi interlayer with high ionic conductivity (10 −5 S cm −1 ) and low electronic conductivity (3.4×10 −7 S cm −1 ) enables Li to plate on the current collector (CC) surface rather than on Li 6 PS 5 Cl surface avoiding Li 6 PS 5 Cl electrolyte reduction. During initial Li plating on CC, Li penetrates into porous LiF‐C‐Li 3 N‐Bi interlayer and lithiates Bi nanoparticles into Li 3 Bi. The lithiophilic Li 3 Bi and Li 3 N nanoparticles in LiF‐C‐Li 3 N‐Li 3 Bi sub‐interlayer will move to CC along with plated Li, forming LiF‐C/Li 3 N‐Li 3 Bi lithiophobic/lithiophilic sublayer during the following Li stripping. This interlayer enables Co 0.1 Fe 0.9 S 2 /Li 6 PS 5 Cl/Li cell with an areal capacity of 1.4 mAh cm −2 to achieve a cycle life of >850 cycles at 150 mA g −1 . The lithiophobic/lithiophilic interlayer enables solid‐state metal batteries to simultaneously achieve high energy and long cycle life.

25 ENERGY STORAGE↗
DOE OSTI2022

Additively manufactured cryogenic microchannel distillation device for air separation

Abstract The efficiency of air separation is tested using three different small‐scale cryogenic distillation columns. The performance of a random packed column is compared to the performance of two microchannel distillation (MCD) columns that use thin wicking structures and gas flow channels to achieve process intensification. The MCD columns tested include a plate‐type layered column and an additively manufactured porous honeycomb (AMPH) column. For columns with 25.4 cm of active height and run under similar conditions, the packed, plate‐type layering, and AMPH columns achieved approximate height equivalent of a theoretical plate (HETP) values of 5.5, 3.7, and 3.2 cm for nitrogen, and 5.9, 4.9, and 3.3 cm for argon. The AMPH column can produce up to 0.4 SLM of more than 90% purity oxygen with 12 W of cooling lift. These results demonstrate the feasibility of using additive manufacturing to construct MCD devices and pave a way for constructing novel MCD designs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the perturbation effect and LET dependence of beam quality correction factors in carbon ion beams

Background: In a recent study, we reported beam quality correction factors, f Q , in carbon ion beams using Monte Carlo (MC) methods for a cylindrical and a parallel-plate ionization chamber (IC). A non-negligible perturbation effect was observed; however, the magnitude of the perturbation correction due to the specific IC subcomponents was not included. Furthermore, the stopping power data presented in the International Commission on Radiation Units and Measurements (ICRU) report 73 were used, whereas the latest stopping power data have been reported in the ICRU report 90. Purpose: The aim of this study was to extend our previous work by computing f Q correction factors using the ICRU 90 stopping power data and by reporting IC-specific perturbation correction factors. Possible energy or linear energy transfer (LET) dependence of the f Q correction factor was investigated by simulating both pristine beams and spread-out Bragg peaks (SOBPs). Methods: The TOol for PArticle Simulation (TOPAS)/GEANT4 MC code was used in this study. A 30 × 30 × 50 cm 3 water phantom was simulated with a uniform 10 × 10 cm 2 parallel beam incident on the surface. A Farmer-type cylindrical IC (Exradin A12) and two parallel-plate ICs (Exradin P11 and A11) were simulated in TOPAS using the manufacturer-provided geometrical drawings. The f Q correction factor was calculated in pristine carbon ion beams in the 150–450 MeV/u energy range at 2 cm depth and in the middle of the flat region of four SOBPs. The k Q correction factor was calculated by simulating the f Qo correction factor in a 60 Co beam at 5 cm depth. The perturbation correction factors due to the presence of the individual IC subcomponents, such as the displacement effect in the air cavity, collecting electrode, chamber wall, and chamber stem, were calculated at 2 cm depth for monoenergetic beams only. Additionally, the mean dose-averaged and track-averaged LET was calculated at the depths at which the f Q was calculated. Results: The ICRU 90 f Q correction factors were reported. The p dis correction factor was found to be significant for the cylindrical IC with magnitudes up to 1.70%. The individual perturbation corrections for the parallel-plate ICs were <1.0% except for the A11 p cel correction at the lowest energy. The f Q correction for the P11 IC exhibited an energy dependence of >1.00% and displayed differences up to 0.87% between pristine beams and SOBPs. Conversely, the f Q for A11 and A12 displayed a minimal energy dependence of <0.50%. The energy dependence was found to manifest in the LET dependence for the P11 IC. A statistically significant LET dependence was found only for the P11 IC in pristine beams only with a magnitude of <1.10%. Conclusions: The perturbation and k Q correction factor should be calculated for the specific IC to be used in carbon ion beam reference dosimetry as a function of beam quality.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2023

High-throughput mass spectrometry analysis using immediate drop-on-demand technology coupled with an open port sampling interface

Rationale: The sampling throughput of immediate drop-on-demand technology (I.DOT) coupled with an open port sampling interface (OPSI) is limited by software communication. To enable much-needed high-throughput mass spectrometry (MS) analysis capabilities, a novel software was developed that allows for flexible sample selection from a 96-well plate and for maximized analysis throughput using I.DOT/OPSI-MS coupling. Methods: Wells of a 96-well I.DOT plate were filled with propranolol solution and were used to test maximum sampling throughput strategies to minimize analysis time. Demonstration of chemical reaction monitoring was done using acid-catalyzed ring closure of 2,3-diaminonaphthalene (DAN) with nitrite to form 2,3-naphthotriazole (NAT). Analytes were detected in positive electrospray ionization mode using selected reaction monitoring. Results: A maximum throughput of 1.54 s/sample (7.41 min/96-well plate with three technical replicates) was achieved, and it was limited by the peak width of the MS signal resulting in an occasional slight overlap between the peaks. Further, relative standard deviation was 10 ± 1% with all tested sampling strategies. Chemical reaction monitoring of DAN to NAT using nitrite was successfully accomplished with 2 s/sample throughout showing almost complete transformation in 10 min with no signal overlap. Conclusions: This work illustrates the development of a noncontact, automated I.DOT/OPSI-MS system with improved throughput achieved through an optimized software interface. Its achievable analysis time and precision make it a viable approach for drug discovery and in situ reaction monitoring studies.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

High speed butt joining of 1” thick 2139-T8

Thick plate (=1”) butt joining of Al alloys is challenging due to high tool forces, uneven material flow, and heat distribution in the through-thickness direction. Tool design and welding parameters used for executing thick plate butt joining have remained mostly static over the past decade. Reported welding speeds that produce viable joint strength (mostly on 6xxx alloys) typically range below 100 mm/min (4inches /min). Researchers at Pacific Northwest National Laboratory (PNNL) in association with Ground Vehicle Systems Center (US Army GVSC) have been working to demonstrate greater joining efficiency at higher welding speeds in a 1” thick AA2139-T8 plate. Using innovative tool features and effective force and temperature control a joint efficiency of 80% was demonstrated at a welding speed of 7 inches /min (178mm/min).

Das, Hrishikesh↗
DOE OSTI2022

Improvements to the High-Field-Side Transient CHI System on QUEST

Transient coaxial helicity injection (CHI) is a promising candidate for solenoid-free plasma current start-up in a low-aspect-ratio tokamak in support of developing fully non-inductive scenarios. The aim of the transient CHI research on QUEST is to develop a reactor-relevant CHI design. On QUEST, a CHI discharge is initiated by driving current along magnetic field lines that connect an electrically insulated electrode plate (which is referred to as a bias electrode) to a vessel component at the bottom region of the spherical tokamak. In the first application of CHI on QUEST, the electrically insulated electrode plate was biased with respect to the outer vessel in a configuration referred to as low-field-side (LFS) injection. To maintain a narrow injector flux footprint width throughout the discharge, QUEST is now developing a high-field-side (HFS) injection configuration, in which the electrically insulated electrode plate is biased with respect to the inner vessel components. Through the implementation of a CHI-dedicated gas injection system, studies in the HFS injection configuration have now demonstrated good magnetic flux evolution into the vacuum vessel. Toroidal currents up to 43 kA have been achieved, and the generated current has increased in proportion to the magnetic flux connecting the electrodes. Finally, these results which show agreement with the CHI-scaling suggest that much higher levels of toroidal current can be generated on QUEST in an optimized CHI system in which the magnetic flux connecting the CHI electrodes is further increased.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

An Internal Digital Image Correlation Technique for High-Strain Rate Dynamic Experiments

Full-field, quantitative visualization techniques, such as digital image correlation (DIC), have unlocked vast opportunities for experimental mechanics. However, DIC has traditionally been a surface measurement technique, and has not been extended to perform measurements on the interior of specimens for dynamic, full-scale laboratory experiments. This limitation restricts the scope of physics which can be investigated through DIC measurements, especially in the context of heterogeneous materials. The focus of this study is to develop a method for performing internal DIC measurements in dynamic experiments. The aim is to demonstrate its feasibility and accuracy across a range of stresses (up to 650 MPa), strain rates (10 3 - 10 6 s -1 ), and high-strain rate loading conditions (e.g., ramped and shock wave loading). Internal DIC is developed based on the concept of applying a speckle pattern at an inner-plane of a transparent specimen. The high-speed imaging configuration is coupled to the traditional dynamic experimental setups, and is focused on the internal speckle pattern. During the experiment, while the sample deforms dynamically, in-plane, two-dimensional deformations are measured via correlation of the internal speckle pattern. In this study, the viability and accuracy of the internal DIC technique is demonstrated for split-Hopkinson (Kolsky) pressure bar (SHPB) and plate impact experiments. The internal DIC experimental technique is successfully demonstrated in both the SHPB and plate impact experiments. In the SHPB setting, the accuracy of the technique is excellent throughout the deformation regime, with measurement noise of approximately 0.2% strain. In the case of plate impact experiments, the technique performs well, with error and measurement noise of 1% strain. The internal DIC technique has been developed and demonstrated to work well for full-scale dynamic high-strain rate and shock laboratory experiments, and the accuracy is quantified. Here, the technique can aid in investigating the physics and mechanics of the dynamic behavior of materials, including local deformation fields around dynamically loaded material heterogeneities.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Toward extreme high-temperature supercritical CO 2 power cycles: Leakage characterization of ceramic 3D-printed heat exchangers

We report future supercritical carbon dioxide (sCO 2 ) Brayton power cycles demand high-performance gas-to-gas heat exchangers (HXs) operating under extreme temperature and pressure conditions at which most existing superalloy materials fail to function safely. Ceramic HXs are deemed excellent candidates for advanced sCO 2 power plants as they can withstand high-temperature working environments. Particularly, ceramic 3D printing enables compact HX topologies employing complex and efficient heat transfer features. However, ceramic 3D-printed walls separating hot and cold flow streams are susceptible to a through-plane leakage inherent to a powder-based manufacturing process, including ceramic 3D printing. A potential leakage through ceramic separating walls poses a significant challenge in developing reliable ceramic 3D-printed HXs and could deteriorate thermal performance. In this study, various parameters, including feedstock slurry, 3D-printing direction, and post-processing conditions, are considered, for the first time, to characterize the argon gas leakage rate associated with alumina 3D-printed parts. Three 3D-printed ceramic structures of flat plates, curved tubes, and small-scale plate-and-frame HXs with various thicknesses are systematically studied to determine powder and ceramic 3D-printing conditions to eliminate the through-plane leakage. The results showed that an alumina 3D-printed plate with a thickness of 0.75 mm demonstrates a permeability of 6 x 10 -4 milli-darcy. An alumina 3D-printed tube with a wall thickness of 0.9 mm revealed a permeability of 9.6 x 10 -7 milli-darcy. Furthermore, leakage test results of functional 3D-printed modules showed a dependency on the 3D-printing direction. Particularly, alumina cell-scale HXs employing 1.5-mm-thick horizontal and vertical 3D-printed separating walls demonstrated impermeability and gas permeability of 7.2 x 10 -5 millidarcy, respectively. Insights gained from the present study facilitate the development of complex ceramic 3D-printed HXs and other balance of plant components for next-generation high-temperature high-pressure sCO 2 power cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design of a 2 MW ZrC/W-based molten-salt-to-sCO 2 PCHE for concentrated solar power

To increase the power cycle efficiency and lower the levelized cost of electricity (LCOE) of concentrated solar power (CSP) plants, printed circuit heat exchangers (PCHEs) capable of operating above 700 °C with molten chloride salt and a sCO 2 -based fluid are needed. In this paper, the design of a high-pressure, high-temperature, 2 MW PCHE comprised of a thermomechanically-robust, zirconium carbide/tungsten (ZrC/W) composite is conducted for CSP plants. The ZrC/W composite is a material with high thermal conductivity, high stiffness, and high failure strength at high temperatures, along with excellent resistance to thermal cycling and thermal shock. In this work, a thermomechanical design analysis was conducted to select appropriate material thicknesses of the ZrC/W plates, and to determine the geometrical dimensions and the thermal performance of the PCHE. The influences of the plate number and heat exchanger length on power density and pressure drop have also been systematically investigated. Economic analyses were conducted to compare the cost of ZrC/W-based PCHEs to those comprised of IN740H (a state-of-the-art, nickel-based superalloy) and 316 stainless steel (316SS). Finally, at a sufficiently high plate production rate, the manufacturing cost of ZrC/W-based PCHEs can be significantly lower, while achieving a much higher power density, compared with state-of-the-art, nickel alloy-based and stainless steel-based PCHEs.

14 SOLAR ENERGY↗
DOE OSTI2024

Theoretical modeling of a bottom-raised oscillating surge wave energy converter structural loadings and power performances

Here, this study presents theoretical formulations to evaluate the fundamental parameters and performance characteristics of a bottom-raised oscillating surge wave energy converter (OSWEC) device. Employing a flat plate assumption and potential flow formulation in elliptical coordinates, closed-form equations for the added mass, radiation damping, and excitation forces/torques in the relevant pitch-pitch and surge-pitch directions of motion are developed and used to calculate the system's response amplitude operator and the forces and moments acting on the foundation. The model is benchmarked against numerical simulations using WAMIT and WEC-Sim, showcasing excellent agreement. The sensitivity of plate thickness on the analytical hydrodynamic solutions is investigated over several thickness-to-width ratios ranging from 1:80 to 1:10. The results show that as the thickness of the benchmark OSWEC increases, the deviation of the analytical hydrodynamic coefficients from the numerical solutions grows from 3% to 25%. Differences in the excitation forces and torques, however, are contained within 12%. While the flat plate assumption is a limitation of the proposed analytical model, the error is within a reasonable margin for use in the design space exploration phase before a higher-fidelity (and thus more computationally expensive) model is employed. A parametric study demonstrates the ability of the analytical model to quickly sweep over a domain of OSWEC dimensions, illustrating the analytical model's utility in the early phases of design.

13 HYDRO ENERGY↗
DOE OSTI2022

Imposition of local boundary conditions in peridynamics without a fictitious layer and unphysical stress concentrations

Here, this study introduces a general approach for the imposition of local boundary conditions in non- ordinary state-based peridynamics (NOSB PD) to eliminate the displacement kinks near the boundary without a fictitious layer under quasi-static loading conditions. It identifies the underlying reason for the unphysical displacement kinks. Under an imposed linear displacement field, the NOSB PD equilibrium equation is not satisfied near the boundary due to the unsymmetric horizon of material points. However, the equilibrium equation derived by using the PD differential operator is satisfied at such material points. Therefore, the material body is divided into three regions to satisfy the equilibrium equations and to impose displacement and tractions boundary conditions. This approach does not deviate from the original NOSB PD; however, it provides a simple solution to eliminate the displacement kink near the boundary, which leads to unphysical stress concentrations. Its efficacy is demonstrated by considering elastic rectangular and square plates subjected to various types of boundary conditions leading to homogeneous as well as nonhomogeneous deformations. The creep response of a rectangular plate further proves the robustness of the present approach. Also, a quasi-static crack propagation from a pre-existing crack in a square plate under mode-I, mode-II and mixed-mode loading conditions demonstrates its capability for failure prediction based on the critical stretch criteria. Finally, its applicability for 3D analysis is demonstrated by considering a rectangular prism under applied stretch and normal stress.

42 ENGINEERING↗
DOE OSTI2025

Enabling fast-charging of lithium-ion batteries through printed electrodes

It has been well recognized that introducing secondary porous networks (SPNs) into the electrodes can effectively improve the electrochemical performance of lithium-ion batteries (LIBs), especially under fast-charging operations. However, the process complexity and high cost limit the commercial success of advanced electrodes with SPNs. To address this issue, we developed a facile screen-printing process to produce structured graphite electrodes with SPNs. The experimental results demonstrated that, by tuning the diameter and center-to-center (C2C) distance of emulsion dots on the stencil screen, the pore diameters and C2C pore distances of SPNs in screenprinted electrodes can be precisely controlled in the range of 100 mu m to 1 mm and 100 mu m to 3 mm respectively. In addition, the SPNs with hexagonal and square-shape pore alignments have also been imprinted onto the electrode coatings through adjusting the patterns of screen stencils. Used as anodes, the printed graphite electrodes demonstrated significantly reduced overpotential and voltage fluctuation under fast-charging operations from 2C to 6C. Coupled with LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) cathodes, the full cells with printed graphite anodes exhibited an unprecedently stable performance with almost no capacity decay up to 170 cycles when charged to 80 % SOC at 2C. Observations from electron microscopy showed plated lithium undetectable at the surface of printed graphite electrodes after numerous cycles. The electrochemical analysis on the voltage evolution during the cell rest period indicated the significantly delayed onset of lithium plating in the presence of printed graphite electrodes. In conclusion, all these results suggest that the significantly improved cell performance is associated with the shortened Li-ion diffusion distance, reduced polarization and suppressed Li plating in the printed electrodes with patterned SPNs.

25 ENERGY STORAGE↗
DOE OSTI2022

Design optimization of an additively manufactured prototype recuperator for supercritical CO 2 power cycles

Supercritical CO 2 (sCO 2 ) power cycles are being developed due to their potential for high efficiency and reduced capital cost. It is necessary that these recuperators operate at high pressures and temperatures, up to 30 MPa and 900 K, with effectiveness values > 95% and pressure drops <1% to achieve high cycle efficiencies. Moreover, it is also necessary to have reasonable cost recuperators to control the capital costs of the sCO 2 power cycles. In this study, a Plate Pin-Fin (PPF) heat exchanger has been proposed as an sCO 2 recuperator. This preliminary recuperator design leverages capabilities enabled by additive manufacturing. Although the PPF design has characteristics similar to those of a plate heat exchanger, small diameter and relatively long fins are used to increase surface area, enhance heat transfer, and provide structural support for the partition plates that separate the fluid streams. Existing correlations for heat transfer and pressure drop were adapted for the PPF heat exchanger. These correlations were implemented in a 1D analytical model and used for the optimization of a 5-kW th high temperature recuperator for an indirect sCO 2 cycle by varying the design parameters to minimize the quantity of material required. A 3D conjugate heat transfer numerical simulations were conducted to validate the heat transfer and pressure loss correlations. A steepest descent method was used to minimize heat exchanger mass for a 5-kW prototype recuperator subject to a maximum specified pressure drop. Additionally, the design analysis indicated that an optimum PPF recuperator would be attained for the minimum allowable pin transverse spacing, minimum pin width, minimum pin height and near maximum cell aspect ratio. Moreover, at a low material requirement of 0.216 kg/kW and a pressure drop, which is almost five times lower than the allowable pressure drop design target, the optimized PPF heat exchanger has the high potential to be an alternative to a printed circuit heat exchanger, which is a conservative design basis for the current state-of-the-art sCO 2 recuperators.

42 ENGINEERING↗