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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Flame-retardant cellulose-aerogel composite from agriculture waste for building insulation

Bio-based thermal insulation materials are in high demand due to their availability, reproducibility, and carbon-sequestration nature. However, high flammability, moisture condensation, and high thermal conductivity of biogenic material are major concerns for sustainable building applications. In this study, we report the fire-retardant cellulose aerogel insulation nanocomposites derived from wheat straw and silica aerogel, in which sodium bicarbonate improves its fire retardancy. We combined blended straw fibers and hammermilled straw fibers to create a structural hierarchy composite. The blended straw, with its longer and thicker size, served as reinforcement, while the hammermilled straw fibers acted as filler. This hierarchical structure was further integrated with aerogel for applications in green buildings. The as-prepared materials show a low thermal conductivity of 24.1 mW/m.K, high flexural modulus of 736 MPa, hydrophobicity with a water contact angle of 110.42°, and excellent fire retardancy. Altogether, this work provides an effective method for the synthesis of fire-retardant biogenic thermal insulation materials and shows a promising way for next-generation bio-based insulation materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multifunctional Superelastic Graphene Aerogels Derived from Ambient-Dried Graphene Oxide/Camphene Emulsions

Graphene oxide (GO) emulsions have been widely adopted to fabricate lightweight graphene aerogels (GAs). However, preparing high-performance GAs from conventional GO emulsions under ambient conditions seems rather challenging because of the structural collapse caused by strong capillary forces during drying. Here, we report a new, low-cost route to prepare high-performance, multifunctional GAs by the ambient drying of GO/camphene emulsions. Benefiting from the liquid-solid and solid-gas phase transitions of camphene, highly porous GO aerogels were obtained under ambient conditions. Moreover, the thermally annealed GO aerogels exhibited excellent mechanical properties, fire resistance, thermal insulation performance, and oil adsorption capability.

ambient drying↗
DOE OSTI2022

Mixed-Metal Nickel–Iron Oxide Aerogels for Oxygen Evolution Reaction

Alkaline electrolyte membrane electrolyzers are a promising technology to efficiently produce clean hydrogen without the use of critical raw materials. At the heart of these electrolyzers are the electrocatalysts, which facilitate the cathodic and anodic reactions, with the latter oxygen evolution reaction (OER) being the most sluggish. In recent years, aerogels have become a very well-studied class of materials due to their unique properties, including very high surface area. Until now, aerogels have not been used to catalyze the OER by themselves but were mainly considered catalyst supports. Here, mixed-metal nickel–iron oxide aerogels were synthesized with a modified epoxide route synthesis and tested as OER catalysts. Depending on the Ni/Fe ratio, they show very high catalytic activity and low overpotential to reach 10 mA cm –2 (at η = 380 mV). This activity is beyond that of the existing state-of-the-art platinum group metal-free OER catalysts.

PGM free catalysts↗
DOE OSTI2023

Biomimetic Fe–Cu Porphyrrole Aerogel Electrocatalyst for Oxygen Reduction Reaction

The development of bioinspired catalysts for oxygen reduction reaction is one of the most prominent pathways in the search for active materials to replace Pt-based catalysts in fuel cells. Herein, we report innovative bioinspired catalysts using a directed synthetic pathway to create adjacent Cu and Fe sites. This catalyst is composed of a covalent 3D framework in an aerogel form. Aerogels are high surface area and porous hierarchical structures that can allow the formation of ultrahigh active site density and optimized mass transport of reactants and products to and from the catalytic sites. The aerogel-based catalyst exhibits high performance in a half-cell in 0.1 M KOH, with an onset potential of 0.94 V vs RHE and half-wave potential of E 1/2 = 0.80 V vs RHE, high selectivity toward the four-electron reduction of oxygen to hydroxide anions, and high durability. These results are well-translated to the anion exchange membrane fuel cell (AEMFC), reaching an open circuit potential of 0.97 V and iR-corrected peak power density of 0.51 W cm –2 . Based on density functional theory calculations, the improved activity relative to the Fe-porphyrin and Cu-corrole is ascribed to the effect of the extended carbon network and the proximity of the metal sites.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Shock propagation in aerogel and TPP foams for inertial fusion energy target design

Achieving practical inertial fusion energy (IFE) requires the development of target designs with well-characterized microstructure and compression response. We measured shock dynamics in low-density (17.5–500 mg/cm 3 ) aerogel and two-photon polymerization (TPP) foams using x-ray phase contrast imaging (XPCI) methods and the Velocity Interferometer System for Any Reflector. By analyzing shock front evolution, we examined how target type and density influence shock propagation and energy dissipation. Talbot-XPCI shows that aerogels support a smooth, bowed shock front due to their homogeneous nanometer-scale pore network. In contrast, TPP foams exhibit irregular, stepwise propagation driven by interactions with their periodic micrometer-scale lattice. Shock velocity follows a power-law relation: aerogels deviate from classical ρ −1/2 scaling due to pore-collapse dissipation, while TPP foams follow the trend with larger uncertainties from density variations. Comparisons with xRAGE simulations reveal systematic underestimation of shock speeds. These results provide the first experimental constraints on shock propagation in TPP foams over a wide density range and highlight the influence of internal structure on anisotropic shock behavior. Our findings support improved benchmarking of EOS and hydrodynamic models and inform the design of foam architectures that promote implosion symmetry in IFE capsules.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Carbon-Sequestration Straw Cellulose-Aerogel Gradient Thermal Insulation Material

Green superinsulation materials are essential for net-zero sustainable building envelopes. Realizing such potential is indispensable for simultaneously achieving carbon-sequestration and superinsulation performance. Here, we report the synthesis of a water glass-based silica aerogel exhibiting a thermal conductivity of 17.2 mW/m·K and a high porosity of 92%. Here, we used carbon-sequestration wheat straw fiber to create a gradient cellulose-aerogel composite to improve mechanical stability. The as-prepared gradient composite exhibits a thermal conductivity of 27.1 mW/m·K and a flexural modulus of 824 MPa, while exhibiting superhydrophobicity (water contact angle of 135.4°) for the development of green building insulation materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Excellent antioxidizing, thermally insulating and flame resistance silica‐polybenzoxazine aerogels for aircraft ablative materials

Abstract High‐performance thermal protective composites with lightweight, micro‐ ablation and high‐efficient thermal insulation are urgently required for thermal protection systems in advanced hypersonic speed vehicles. However, the practical applications of thermal protective composites have long been hampered by the main issues such as low mass residual rate and poor long‐term antioxidation of the matrix in high‐temperature aerobic environments. Here, we report a novel silica‐polybenz oxazine (SiO 2 ‐PBO) aerogels with interpenetrated networks, possessing the ability to antioxidation, thermal insulation, and flame‐retardant properties. The resulting SiO 2 ‐PBO aerogels exhibit low density (0.25 g/cm 3 ), low thermal conductivity (0.035 W/(m·K)), and superior peak heat release rate value (15.3 W/g). Moreover, the mass residual rate is up to 70.46 wt% in the N 2 atmosphere and remains 57.83 wt% despite existing in the air atmosphere and experiencing the highest temperature of 800°C. Briefly, SiO 2 ‐PBO aerogels as‐prepared could be a potential matrix for a new gene ration of high‐performance thermal protective composites in the future.

Xiao, Yunyun↗
DOE OSTI2023

Highly transparent silanized cellulose aerogels for boosting energy efficiency of glazing in buildings

Abstract To maintain comfortable indoor conditions, buildings consume ~40% of the energy generated globally. In terms of passively isolating building interiors from cold or hot outdoors, windows and skylights are the least-efficient parts of the building envelope because achieving simultaneously high transparency and thermal insulation of glazing remains a challenge. Here we describe highly transparent aerogels fabricated from cellulose, an Earth-abundant biopolymer, by utilizing approaches such as colloidal self assembly and procedures compatible with roll-to-roll processing. The aerogels have visible-range light transmission of 97–99% (better than glass), haze of ~1% and thermal conductivity lower than that of still air. These lightweight materials can be used as panes inside multi-pane insulating glass units and to retrofit existing windows. We demonstrate how aerogels boost energy efficiency and may enable advanced technical solutions for insulating glass units, skylights, daylighting and facade glazing, potentially increasing the role of glazing in building envelopes.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

A macromolecular assembly directed ceramic aerogel monolith material

Ceramic aerogels exhibit remarkable thermal insulation for energy efficient building applications, while it is indispensable to understand their nanoporous structure evolution to control their thermal regulation performance. In this study, we design and synthesize a lightweight porous silica aerogel monolithic material, and demonstrate its thermal insulation performance regulated by the morphology of porous nanostructures controlled by surfactant induced self-assembly. The micelle networks and in situ gas bubble formation guide the formation of uniform pores in the as-synthesized monolith, which shows superior thermal and acoustic insulation and robust mechanical stability with a thermal conductivity of 0.032 W m –1 K –1 , a soundproof performance improvement by 17% at a frequency of 800 Hz, and a 1.3 MPa compressive strength with a Young's modulus of 15 MPa. Lastly, these findings provide a new route to manufacture low-cost aerogel monolithic insulation materials for energy efficient building applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

EXPERIMENTAL STUDY ON COST-EFFECTIVE ADDITIVE MANUFACTURING OF SILICA AEROGEL

The conventional aerogel insulation material manufacturing from supercritical drying suffers from issues of massive energy consumption and prolonged processing time. With the consideration of large market demand of the aerogel insulation material in the next decade, a low-cost and scalable fabrication technique is highly desired. In this paper, a direct ink writing (DIW) method is used to three-dimensionally fabricate the silica aerogel insulation material, followed by ambient pressure drying. Compared to the supercritical drying and freeze drying, the reported method significantly reduces the fabrication time and costs. The cost-effective DIW technique offers the capability to print complex hollow internal structure, coupled with the porous structure, is found to be beneficial to the thermal insulation property. The addition of fiber to the ink assures the durability of the fabricated product. The foam ink preparation methods and the printability are demonstrated in this paper, along with the printed samples for characterizing thermal insulation properties and mechanical properties.

42 ENGINEERING↗
DOE OSTI2026

Ultra-clear Aerogels for Insulated Glass in Refrigeration Doors (CRADA Final Report)

Display refrigerators commonly employ glass doors to provide product visibility; however, these doors exhibit significantly poorer thermal insulation than solid doors, resulting in increased heat transfer and higher energy consumption. To address this limitation, this project investigated the use of silica aerogel as a transparent insulating medium for refrigerator glass doors, with the objective of enhancing thermal performance without compromising visual clarity. In Phase I of the project, we assessed the feasibility of silica aerogel insulation through laboratory and full-scale studies, including material characterization, durability testing, and heat transfer measurements, along with the development and performance evaluation of prototype glass doors under realistic operating conditions. In Phase II, the project focused on scaling the technology toward practical deployment. This included scaling up the manufacturing process to achieve a surface area roughly 20 times larger for commercial applications, developing full-scale prototypes that integrated silica aerogel into standard display refrigerator doors, and conducting field evaluations to assess thermal performance, energy savings, and operational durability under real-world conditions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

System and method for forming activated carbon aerogels and performing 3D printing

Making a carbon aerogel involves 3-D printing an ink to make a printed part, removing the solvent from the printed part, and carbonizing the printed part (with the solvent removed) to make the aerogel. The ink is based on a solution of a resorcinol-formaldehyde resin (RF resin), water, and an organic thickener. Advantageously, the RF resin contains an acid catalyst, which tends to produce carbon aerogels with higher surface areas upon activation than those produced from methods involving an ink composition containing a base catalyzed resin.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Adsorption cooling system using carbon aerogel

A highly adsorptive structure includes: a substrate; and a carbon aerogel adhered to the substrate, wherein the carbon aerogel is characterized by having physical characteristics of in-situ formation on the substrate, and wherein the carbon aerogel is configured to selectively adsorb and desorb one or more refrigerants selected from the group consisting of: acid halides, alcohols, aldehydes, amines, chlorofluorocarbons, esters, ethers, fluorocarbons, perfluorocarbons, halocarbons, halogenated aldehydes, halogenated amines, halogenated hydrocarbons, halomethanes, hydrocarbons, hydrochlorofluorocarbons, hydrofluoroethers, hydrofluoroolefins, inorganic gases, ketones, nitrocarbon compounds, noble gases, organochlorine compounds, organofluorine compounds, organophosphorous compounds, organosilicon compounds, oxide gases, refrigerant blends and thiols.

Baumann, Theodore F.↗
DOE OSTI2023

Methods of making permeable aerogels

Methods of making permeable aerogels (100) can include providing a sol mixture (110) comprising an organic scaffold, an inorganic aerogel precursor, and a first solvent. The organic scaffold can be insoluble in the first solvent. The sol mixture can react to form a gel (120) such that an interconnected channel network is formed which is at least partially defined by the organic scaffold. The first solvent in the gel can be exchanged (130) with a second solvent. The second solvent can dissolve the organic scaffold to expose the interconnected channel network. The gel can be dried (140) to form the permeable aerogel.

Carlson, Krista↗
DOE OSTI2024

Additive manufacturing of hierarchical three- dimensional micro-architected aerogels

Disclosed here is a method for making a three-dimensional micro-architected aerogel, comprising: (a) curing a reaction mixture comprising a co-sol-gel material (e.g., graphene oxide (GO)) and at least one catalyst to obtain a crosslinked co-sol-gel (e.g., GO hydrogel); (b) providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of the crosslinked co-sol-gel (e.g., GO hydrogel); (c) curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three-dimensional structure; (d) drying the wet gel to produce a dry gel; and (e) pyrolyzing the dry gel to produce a three-dimensional micro-architected aerogel (e.g., graphene aerogel). Also disclosed is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a dispersion of a crosslinked co-sol-gel.

Worsley, Marcus A.↗
DOE OSTI2021

Porphyrin Aerogel Catalysts for Oxygen Reduction Reaction in Anion-Exchange Membrane Fuel Cells

Platinum group metal (PGM)-free catalysts for oxygen reduction reaction have shown high oxygen reduction reaction activity in alkaline media. In order to further increase the power density of anion-exchange membrane fuel cells (AEMFCs), PGM-free catalysts need to have a high site density to reach high current densities. In this work, synthesis, characterization, and utilization of heat-treated iron porphyrin aerogels are reported as cathode catalysts in AEMFCs. The heat treatment effect is thoroughly studied and characterized using several techniques, and the best performing aerogel is studied in AEMFC, showing excellent performance, reaching a peak power density of 580 mW cm –2 and a limiting current density of as high as 2.0 A cm –2 , which can be considered the state-of-the-art for PGM-free based AEMFCs.

25 ENERGY STORAGE↗
DOE OSTI2025

Breaking the Linear Scaling Relations for the Oxygen Reduction Reaction with a Dual‐Atom Catalyst Composed of a MnFe‐Porphyrrole Aerogel

Bimetallic catalysts offer enhanced catalytic performance through synergistic interactions between the two metals, allowing them to break the linear scaling relations and reach high electrocatalytic activity. This study presents bimetallic aerogel-based catalyst synthesized as a covalent, three-dimensional framework containing neighboring iron and manganese sites. The aerogel structure provides a high surface area and porosity, facilitating an ultra-high active site density and efficient mass transport. The MnFe porphyrrole's unique structure is obtained by alternately linking Mn-porphyrin and Fe-corrole complexes. It exhibited outstanding performance with an onset potential of 0.99 V RHE . Comparative studies with a free-base Fe porphyrrole catalyst (E onset 0.97 V RHE ) revealed that while Mn incorporation led to only a slight improvement in half-cell performance, it resulted in significantly enhanced performance in anion exchange membrane fuel cell. The MnFe catalyst achieved an OCV of 0.97 V and a peak power density of 0.27 W cm −2 , outperforming the free-base Fe counterpart. Using density functional theory calculations, we show that the higher ORR activity of MnFe-porphyrrole is due to charge transfer between Mn and Fe atoms, which is absent in the reference free-base Fe-porphyrrole. These findings underscore the advantages of bimetallic catalysts in improving ORR activity and fuel cell efficiency by leveraging synergistic effects.

Aerogel↗
DOE OSTI2020

High Speed In-situ X-ray Imaging of 3D Freeze Printing of Aerogels

3D freeze printing (3DFP) combines drop-on-demand (DOD) inkjet printing with freeze casting to fabricate lightweight and multifunctional aerogels with customized geometries. Freeze casting is an efficient and easily implemented method capable of fabricating porous, sponge-like structures for many different applications. This process enables tailoring the microstructure of the final product (i.e., pore morphology, alignment, average size distribution, etc.) by controlling the fabrication conditions and freezing kinetics. Furthermore, its combination with DOD printing provides the capability of engineering the macrostructure without relying on a mold as reported for 3D freeze-printed aerogels made from graphene, silver nanowires, and other nanocomposites. In this paper, we performed in-situ X-ray imaging to understand the inside process dynamics in 3DFP using a commercially available colloidal silica ink. We investigated the 3DFP process with the following hierarchy: first, single droplets; then, uniform lines obtained from coalescence of droplets; and finally, three consecutive lines deposited layer by layer. With the help of X-ray imaging, the importance of the balance between material deposition and freezing rates was shown in-situ by the observation inside of the freeze front following the tip of the printed line. The effects of the substrate temperature on the elimination of undesired interfacial boundaries were also shown by the observed ice crystals penetrating from lower to upper layer.

36 MATERIALS SCIENCE↗