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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 OSTI2021

Synthesis of monodisperse high entropy alloy nanocatalysts from core@shell nanoparticles

We report that high-entropy alloy (HEA) nanoparticles (NPs) hold great promise in electrocatalysis because of their nearly unlimited compositions, tailorable active sites, and high durability. However, the synthesis of these compositionally complex structures as monodisperse NPs remains a challenge by colloidal routes because the different rates of metal precursor reduction lead to phase separation. Here, we report the conversion of core@shell NPs into HEA NPs through annealing, with conservation of sample monodispersity. This potentially general route for high-quality HEA NPs was demonstrated by preparing PdCu@PtNiCo NPs via seed-mediated co-reduction, wherein Pt, Ni, and Co were co-deposited on PdCu seeds in solution. These multimetallic NPs were then converted to single-crystalline and single-phase PdCuPtNiCo NPs through annealing. On account of their small particle size, highly dispersed Pt/Pd content, and low elemental diffusivity, these HEA NPs were found to be a highly efficient and durable catalyst for the oxygen reduction reaction. They were also highly selective for the four-electron transfer pathway. We expect that this new synthetic strategy will facilitate the synthesis of new HEA NPs for catalysis and other applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Integration of a high oxygen permeability ionomer into polymer electrolyte membrane fuel cell cathodes for high efficiency and power density

In this work, we present a study on the integration of a high oxygen permeability ionomer (HOPI) with high durability carbon supported platinum (Pt/C) catalysts to prepare cathode catalyst layers (CCLs) for polymer electrolyte membrane fuel cells (PEMFCs). A key motivation is the production of PEMFCs with high efficiency and durability for heavy-duty fuel cell vehicles. Our results from integrating a pre-commercial HOPI with robust, state-of-the-art catalysts with medium and low surface area carbon supports show significant increases in specific activities (67% increase over the standard commercial ionomer) at low current densities and reduced oxygen (O 2 ) transport resistances (R O2 ’s) at high current densities, enabling both higher efficiency and peak power density. The reduction in the R O2 with the HOPI is most significant at low relative humidity (RH), due to its more rigid backbone structure resisting compaction at lower water contents. In our ink optimization analysis, we show that the HOPI in this study achieves its peak performance with an ionomer to carbon ratio (I/C) of 0.6 and a moderately alcohol-rich ink solvent when fabricating catalyst layers by the decal method with an automatic wet film coater.

08 HYDROGEN↗
DOE OSTI2022

Dual Passivation of Cathode and Anode through Electrode–Electrolyte Interface Engineering Enables Long-Lifespan Li Metal–SPAN Batteries

The reliability and durability of lithium metal (Li 0 )–sulfur batteries are largely limited by the undesired Li 0 plating-stripping irreversibility and the detrimental polysulfide dissolution, yet approaches that can simultaneously address the above anodic and cathodic problems are scarce. In this study, we report the stable operation of a Li 0 -SPAN (sulfurized polyacrylonitrile) battery via an anode–cathode dual-passivation approach. By combination of a fluorinated localized high concentration electrolyte (LHCE) and a Li 3 N-forming additive (TMS-N 3 ), robust and highly conductive electrode passivation layers are formed in situ on the surface of both the Li 0 anode and the SPAN cathode. The resulting highly reversible, dendrite-free, and high-density Li 0 plating morphology enables a high Coulombic efficiency of 99.4%. Advanced tender energy X-ray spectroscopy also reveals the eliminated Li 2 S formation and minimized polysulfide dissolution in SPAN cathodes, leading to a high capacity of 580 mAh/g SPAN and stable cycling with negligible capacity decay (0.7%) for 800 cycles. This electrode–electrolyte interphase engineering strategy has tackled the major limitations of Li–S batteries in both ether- and carbonate-based electrolyte systems and under a wide temperature range from –10 to +50 °C, thus providing insightful guidelines for the rational design of highly durable and high-energy-density Li 0 -S batteries.

25 ENERGY STORAGE↗
DOE OSTI2026

Electrospun Ti–Zr Oxide Heterostructures Enable Strongly Anchored Ultralow-Ir Anodes for Durable Acidic Oxygen Evolution

Proton-exchange-membrane water electrolysis (PEMWE) requires acidic oxygen-evolution-reaction (OER) anodes that combine high activity, high durability, and low Ir loading. Here, we report a Ti-Zr composite electrospun oxide (ESO) nanorod support that enables ultralow-Ir anodes for high-performance PEMWE. Zr-containing Ti oxide heterostructures stabilize anatase-rich TiO2, tune the local oxygen-coordination environment, and strengthen interfacial anchoring of IrOx under acidic anodic conditions. The electrospun nanorod network further creates an open, mechanically coherent catalyst layer that improves Ir utilization, ionomer penetration, and mass transport. At an anode loading of 0.2 mgIr cm-2, the optimized Ir/TiZr20-ESO anode delivers a PEMWE mass activity of 0.99 A mgIr-1 at 1.45 V, 28.3 and 43.0 times higher than commercial Ir black and commercial IrO2/TiO2, respectively. The same anode reaches 3.0 and 4.0 A cm-2 at 1.75 and 1.83 V, respectively, and sustains 2000 h operation at 2.0 A cm-2. Also, accelerated stress tests up to 525 hours over 31,500 cycles confirm promising long-term durability, with an insignificant performance decay of 0.4 μV per cycle. Density functional theory indicates that the Ti-Zr oxide heterostructure suppresses Ti demetallation and strengthens IrO2 interfacial binding, rationalizing the improved high-current-density stability.

25 ENERGY STORAGE↗
DOE OSTI2024

Corrosion-Resistant Non-Carbon Electrocatalyst Supports for PEFCS

Insufficient durability of commercial catalysts is a persistent issue for PEFC applications.1 Herein, Pt on Nb-doped-TiO 2 is reported as a highly durable electrocatalyst on which the direct 4-electron reduction of oxygen to water is more facile compared to Pt/C. All performance metrics are reported comparing Pt/Nb-TiO2 with a 15% Pt loading, against a commercial Pt/C catalyst (46.5% Pt loading, Tanaka, K. K.). Nb-doped-TiO 2 with high surface area and high electronic conductivity was synthesized using the supercritical fluid method. Initially, the durability of the catalyst was characterized using accelerated stability tests (ASTs) involving 10,000 high potential cycles (DOE/FCCJ protocol) and the Pt/Nb-TiO 2 was found to retain 78% of its initial electrochemically active surface area (ECSA) compared to the 57.6 % retained by Pt/C. These observations were in excellent agreement with previous reports that the Pt particle size of Pt/C grew from 2nm to 8nm during the AST protocol along with severe corrosion and amorphization of the carbon surface.2, 3 TEM and XPS studies of the Pt-Nb-doped-TiO 2 catalyst showed that the Pt particle size grew from 3nm to 6nm and the Nb(IV) and Ti(III) in the support were oxidized to Nb(V) and Ti(IV) after the durability test. Thus, the improvement in Pt/Nb-TiO 2 ECSA retention was attributed to the lower extent of particle growth and lack of oxidative support loss upon oxidation as compared to Pt/C. The oxygen reduction reaction (ORR) performance was characterized by linear polarization using a rotating disk electrode (RDE). The electrochemical surface areas of Pt/Nb-TiO 2 and Pt/C were found to be 48m2·g -1 and 83m2·g -1 respectively, and the mass activity for the ORR at 0.9V vs. RHE were found to be 150 mA·mg-1Pt and 124 mA·mg-1Pt respectively. The improved mass activity on Pt/Nb-TiO 2 was attributed to strong metal support interaction (SMSI) between the Nb-TiO 2 support and the Pt catalyst based on the 625 meV decrease in the binding energy of the Pt4f x-ray photo-electron spectroscopy (XPS) peaks of Pt/Nb-TiO 2 compared to Pt/C. To quantify the impact of the SMSI, a kinetic model was applied to calculate the elementary reaction rate constants for the various steps of the ORR on both catalysts. The reaction rate constant (k1) for the direct 4-electron transfer pathway to produce H 2 O was significantly larger in Pt/Nb-TiO 2 as compared to Pt/C. Thus, the reduction in the electron binding energy as observed in the XPS was found to aid the facile filling of the higher energy 2p orbitals of O 2 thereby leading to improved 4-electron transfer kinetics and improved overall activity.

08 HYDROGEN↗
DOE OSTI2023

Aluminophosphate Waste Forms for Immobilizing Cations from Electrochemical Salt Wastes

This report provides experimental details and results of evaluating aluminophosphate waste forms for treating and immobilizing the salt cations from salt wastes generated during electrochemical reprocessing of used nuclear fuel. In the waste form process for these materials, chloride salt streams are reacted with NH 4 H 2 PO 4 , the chlorine is removed from the salts and driven off as NH 4 Cl (a solid condensate that can be captured), and then the product can be vitrified in conjunction with glass-forming chemicals (e.g., Fe 2 O 3 , Al 2 O 3 ) to create a high-durability waste form. This study was initiated with some literature review on aluminophosphates containing high alkali oxide content and some of this information is summarized in this report. Following literature review, three new samples were synthesized where two contained Fe 2 O 3 +Al 2 O 3 (i.e., samples G3 and G5 ) and one was only Al 2 O 3 (Fe 2 O 3 -free) (i.e., sample G6 ). In addition to these samples, G1 was also made, which is the baseline reference waste form referred to as DPF5-336 (made without Al 2 O 3 ). Samples G1, G3, G5, and G6 had phases of Li 3 Fe 2 (PO 4 ) 3 (likely), monazite (below XRD detection limits), AlPO 4 , and AlPO 4 , respectively. Characterizations on these materials included optical images, scanning electron microscopy, energy dispersive X-ray spectroscopy, and X-ray diffraction. These samples were shipped to Argonne National Laboratory for chemical durability testing. Depending on how the samples perform in these tests, an additional phase of aluminophosphate formulations could be designed and tested. This report completes the milestone M4FT-23PN030104041 with details provided in Appendix B.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Development of novel techniques for non-invasive air leakage and moisture detection in building envelopes

Unwanted air leakage and moisture in building envelopes can cause high energy consumption, detrimental indoor air quality, poor occupant comfort, and reduction in building material durability. High moisture can cause rot and mold, leading to costly and time-consuming repairs that add to the carbon burden of the building envelope. Novel detection techniques for locating and measuring air leakage flow and areas of high moisture in building envelopes will be presented. The techniques are easy, fast, and non-destructive which can enable quick building envelope assessment, foster retrofits, and lead to energy savings and carbon emission reduction.

Boudreaux, Philip [ORNL] (ORCID:0000000229564665)↗
DOE OSTI2023

Design Considerations and Analysis of Multi-Level Erasure Coding in Large-Scale Data Centers

Multi-level erasure coding (MLEC) has seen large deployments in the field, but there is no in-depth study of design considerations for MLEC at scale. In this paper, we provide comprehensive design considerations and analysis of MLEC at scale. We introduce the design space of MLEC in multiple dimensions, including various code parameter selections, chunk placement schemes, and various repair methods. We quantify their performance and durability, and show which MLEC schemes and repair methods can provide the best tolerance against independent/correlated failures and reduce repair network traffic by orders of magnitude. To achieve this, we use various evaluation strategies including simulation, splitting, dynamic programming, and mathematical modeling. We also compare the performance and durability of MLEC with other EC schemes such as SLEC and LRC and show that MLEC can provide high durability with higher encoding throughput and less repair network traffic over both SLEC and LRC.

Wang, Meng↗
DOE OSTI2024

Development of Low-Cost, High-Performance, Easy-To-Apply, Non-Flammable, Inorganic Phase Change Material (PCM) Technology (Project Final Report)

This report describes a 45-months long research program focused on the development of novel, easy-to-apply, non-flammable, and high-performance inorganic phase change materials (PCMs) for building and industrial applications. The University of Massachusetts Lowell (UML) formed a world-class team consisting of researchers form InsolCorp (only N. American manufacturer of inorganic PCM systems for building applications), and a group of industrial advisors, to develop a universal/multipurpose, simple-to-manufacture and cost-effective PCM technology. The project team expects that the results of this work will spur in the future the adoption of thermal storage materials – a key building energy saving technology as identified by DOE BTO – for a variety of building envelope applications. The main goal of this project was to demonstrate a suite of low-cost, multipurpose, and durable inorganic PCM formulations with phase transition temperatures encompassing typical building applications (between +5 o C and +55 o C). The first objective was to design, fabricate, and experimentally validate a performance of inexpensive, durable, highly efficient, non-flammable, and easy to manufacture PCMs. To allow a variety of building applications, the project team focused on formulations that exhibit repeatable phase transitions between +5 o C and +55 o C. To follow the DOE BTO cost efficiency target without compromising thermal performance, our work was based on inorganic compounds (mostly salt hydrates) and their blends, which represent a fraction of the cost of most of organic PCMs with about twice as high density as well as significantly higher thermal conductivity and phase change enthalpy. The second objective was to develop easy-to-manufacture and -install packaging/encapsulation designs that are 1) a superior barrier to current state-of-the-art macro-packaging, which significantly reduces the risk of loss of hydration water and PCM leak, and 2) optimal in enhancing the heat exchange rates with the surroundings and within the PCM core to ensure complete charging/discharging of the entire PCM within the product. Finally, the project’s intend was to scale-up the fabrication process to demonstrate installation on system-scale applications, and to validate the performance under field conditions. This work aimed at developing low-cost, high-energy storage, and reliable latent heat storage technology for building applications. This development was realized by formulating and integrating the following two technology components: 1) inorganic salt hydrate based PCMs that have high latent enthalpies and are low-cost and durable, and 2) PCM encapsulation (packaging) technology that maximizes PCM concentration and enhances heat transport characteristics in the product and with the external environment/materials. High thermal storage capacity, low cost and fire resistance are key to the building market entry for PCM technology. Therefore, the project’s focus was on salt-hydrate-based formulations which satisfy all these criteria. Packaging and/or encapsulation of PCM is a key processing step. The project team recognized that a low-cost and simple-to-manufacture salt hydrate-based PCM technology holds the best chance to be successful in the building construction market, a market which is traditionally extremely sensitive to cost and where commodity thermal insulations are the benchmark for envelope-related energy saving measures. That is why, in this project, the main intention was to minimize the production cost and maximize the product energy storage density without sacrificing the PCM performance. It was achieved through: 1. Minimizing the non-PCM components (plastics, additives, packaging/encapsulation materials, etc.) because they are significantly more expensive than salt hydrates, 2. Using highly thermally conductive and lightweight PCM carrier (packaging material) to facilitate more complete phase cycling, and 3. Optimizing the thickness and minimizing air spaces in product design (such as in pouched PCM). For this purpose, our approach was to enable an easy system design, including selection of the PCM operating temperatures, optimizing the necessary heat storage capacity (by stacking together several layers of PCM products), and if needed, a synchronized usage of PCM products of different temperatures. A specially designed, robust, highly thermally conducting and highly impermeable packaging (to retain salt hydrate water during phase transition cycles) was designed and tested to increase the overall system thermal performance and durability. All PCM products developed during this project were tested in both lab scale and in full scale field conditions. It is expected that, after further developments and commercialization, the developed PCM technologies may be also applied in space conditioning, energy storage technologies, and heat transfer applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Development of Advanced Solid Sorbents for Direct Air Capture (Final Report)

RTI International is partnering with Creare, and Mohammed VI Polytechnic University (UM6P) successfully met all major technical objectives as outlined below: Identified one MOF adsorbent for DAC; Identified one amine-P-dendrimer adsorbent for DAC; Performed Computational fluid dynamics simulations of the MOF and amine-P-dendrimer adsorbents and validate them with experimental data; Selected one adsorbent for DAC; Demonstrated the scale-up of selected candidate and perform cost review; Performed a preliminary process design; Performed technology maturation plan and environmental health and safety risk assessment. After a thorough comparison between both adsorbents (MOFs and P-dendrimers) and based on their technical merits, the amine-based P-dendrimers sorbent was selected as the best performing adsorbent for DAC. In fact, the amine-based P-dendrimers have demonstrated superior performance over the MOF sorbents under relevant DAC conditions. The selected sorbent has been used in subsequent projects (DE-FE0032099 and DE-AR0001412) and has demonstrated similar superior performance with no loss of activity after long-term sorption-desorption testing (e.g., 100 cycles). This sorbent has demonstrated a very high and stable sorption performance, excellent kinetics, and fast regeneration at 80 °C, specifically at 75% relative humidity (RH). The incorporation of RTI’s high-performance, high-durability amine-based P-dendrimers sorbent and Creare’s hybrid additive manufacturing (H-AM) technology that will produce high performance, compact heat and mass exchange structures at low cost using methods, will lead to a contactor that is optimized for wind-driven operation. This contactor technology provides a technically viable pathway for reducing the cost of DAC to <$100/tonne of CO 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2021

Recent developments in Pt–Co catalysts for proton-exchange membrane fuel cells

Development of Pt-based oxygen reduction reaction catalysts with high efficiency and high durability is central to the application of proton-exchange membrane fuel cell systems. Pt–Co bimetallic catalysts have drawn extensive attention owing to their capability of delivering high performance and long lifetime for fuel cell applications including light-duty and heavy-duty vehicles. However, further improvements in durability and performance are needed to meet market requirements. To fully exploit the potential of Pt–Co catalysts, new insights into the relationship between catalyst properties and fuel cell performance and durability are needed, and more effective methods to tailor the features of Pt–Co catalysts need to be developed. This review provides a summary and perspective on recent efforts, including work on customizing the Pt shell and Pt:Co ratio, tailoring the crystal structure, and improving carbon support properties, with a particular emphasis on mechanisms leading to enhancement of mass activity, power density, and durability in membrane electrode assembly testing.

25 ENERGY STORAGE↗
DOE OSTI2020

Structural Changes and Reversibility Upon Deintercalation of Li from LiCoPO 4 Derivatives

In an effort to improve the cycle life and rate capability of olivine LiCoPO 4 , Cr, Fe, and Si were added to produce nominal Li 1.025 Co 0.84 Fe 0.10 Cr 0.05 Si 0.01 (PO 4 ) 1.025 . This cathode material has an energy density comparable to LiCoPO 4 , with markedly improved electrochemical performance. Here, we apply operando X-ray diffraction to gain an understanding of the crystallographic delithiation mechanism of this new substituted electrode material, compared to both LiCo 0.75 Fe 0.25 PO 4 and LiCo 0.75 Fe 0.25 PO 4 . Throughout charging, the extent of solid-solution domains was significantly increased in Li 1.025 Co 0.84 Fe 0.10 Cr 0.05 Si 0.01 (PO 4 ) 1.025 and LiCo 0.75 Fe 0.25 PO 4 compared to LiCoPO 4 . These domains reduce the mechanical strain during electrode function, providing a clear explanation for the high durability with Co substitution. Li 1.025 Co 0.84 Fe 0.10 Cr 0.05 Si 0.01 (PO 4 ) 1.025 operated at notably higher average potential than LiCo 0.75 Fe 0.25 PO 4 , which would increase the energy density of the cell. Ex situ measurements reveal the persistence of structural irreversibilities in the substituted phase after the first cycle, identifying avenues for further improvement in durability. Overall, this finding sheds light on the strategies for judicious cation substitution in LiCoPO 4 electrodes to maximize the cycle life while preserving high energy density, especially compared to LiFePO 4 .

25 ENERGY STORAGE↗
DOE OSTI2023

Coaxial Nanowire Electrodes Enable Exceptional Fuel Cell Durability

Polymer-electrolyte-membrane fuel cells (PEMFCs) hold great promise for applications in clean energy conversion, but cost and durability continue to limit commercialization. This work presents a new class of catalyst/electrode architecture that does not rely on Pt particles or carbon supports, eliminating the primary degradation mechanisms in conventional electrodes, and thereby enabling transformative durability improvements. The coaxial nanowire electrode (CANE) architecture consists of an array of vertically aligned nanowires, each comprising an ionomer core encapsulated by a nanoscale Pt film. This unique design eliminates the triple-phase boundary and replaces it with two double-phase boundaries, increasing Pt utilization. It also eliminates the need for carbon support and ionomer binder, enabling improved durability and faster mass transport. Fuel cell membrane electrode assemblies based on CANEs demonstrate extraordinary durability in accelerated stress tests (ASTs), with only 2% and 5% loss in performance after 5000 support AST cycles and 30000 catalysts AST cycles, respectively. The high-power density and extremely high durability provided by CANEs can enable a paradigm shift from random electrodes based on unstable platinum nanoparticles dispersed on carbon to ordered electrodes based on durable Pt nanofilms, facilitating rapid deployment of fuel cells in transportation and other clean energy applications.

25 ENERGY STORAGE↗
DOE OSTI2020

Single Cobalt Sites Dispersed in Hierarchically Porous Nanofiber Networks for Durable and High-Power PGM-Free Cathodes in Fuel Cells

Increasing catalytic activity and durability of atomically dispersed metal–nitrogen–carbon (M–N–C) catalysts for the oxygen reduction reaction (ORR) cathode in proton-exchange-membrane fuel cells remains a grand challenge. In this study, a high-power and durable Co–N–C nanofiber catalyst synthesized through electrospinning cobalt-doped zeolitic imidazolate frameworks into selected polyacrylonitrile and poly(vinylpyrrolidone) polymers is reported. The distinct porous fibrous morphology and hierarchical structures play a vital role in boosting electrode performance by exposing more accessible active sites, providing facile electron conductivity, and facilitating the mass transport of reactant. The enhanced intrinsic activity is attributed to the extra graphitic N dopants surrounding the CoN 4 moieties. The highly graphitized carbon matrix in the catalyst is beneficial for enhancing the carbon corrosion resistance, thereby promoting catalyst stability. The unique nanoscale X-ray computed tomography verifies the well-distributed ionomer coverage throughout the fibrous carbon network in the catalyst. The membrane electrode assembly achieves a power density of 0.40 W cm –2 in a practical H 2 /air cell (1.0 bar) and demonstrates significantly enhanced durability under accelerated stability tests. The combination of the intrinsic activity and stability of single Co sites, along with unique catalyst architecture, provide new insight into designing efficient PGM-free electrodes with improved performance and durability.

25 ENERGY STORAGE↗
DOE OSTI2024

Acid Etching‐Driven Self‐Assembly of Mn‐Shell Inducing Rock‐Salt Phase for Enhanced Single‐Crystal Ni‐Rich Cathodes

With the wide adoption of Li‐ion batteries, Ni‐rich cathode is considered as one of the most promising candidates of cathodes due to its high energy density and low cost. However, stability decreased with increasing Ni content in the Ni‐rich cathode. To solve this bottleneck, many strategies, such as coating, doping, surface modification, and special morphologies, have been developed. Herein, we introduce a groundbreaking approach for enhancing Ni‐rich cathode through an innovative acid etching process that promotes Mn shell self‐assembly, inducing a rock‐salt phase on the surface. This method not only simplifies the Ni‐rich cathode modification process, but also significantly improves the structural stability and electrochemical performance of Ni‐rich cathode. Our findings demonstrate that developed single‐crystal Ni‐rich cathode shows 3–34 % better stability compared to both commercial modified Ni‐rich cathode and unmodified counterparts. The unique Mn shell effectively mitigates reversible phase shifts during cycling, contributing to a remarkable enhancement in cycling stability. Additionally, this novel fabrication technique paves the way for cost‐effective production of high‐performance cathode materials, offering substantial benefits for lithium‐ion battery technology. And this study proves the potential of this method in advancing the design and development of durable, high‐capacity cathode materials for next‐generation batteries.

Ni-rich cathode↗
DOE OSTI2025

Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior

Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancing durability and activity toward oxygen evolution reaction using single-site Re-doped NiFeO x catalysts at ampere-level

NiFeO x materials are known as among the most active catalysts toward oxygen evolution reaction (OER) for hydrogen generation in alkaline media. Nevertheless, the long-term durability of NiFeO x catalysts for OER is still too far to the industrial application. Herein, we prepared a NiFeReO x catalyst with single-site Re dopants and observed that the single-site Re dopants could significantly enhance the durability without compromising the activity. A cell voltage of 1.82 V without iR correction is noted at the current density of 3000 mA cm –2 in anion-exchange membrane water electrolyzer (AEMWE) with NiFeReO x catalyst, and a very small degradation is observed under 2000 and 1000 mA cm –2 , which remarkably outperforms the pristine NiFeO x . Additionally, the overpotential of 305 mV at 10 mA cm –2 is achieved with the NiFeReO x catalyst, which is lower than 50 mV compared with the pristine NiFeO x catalyst, together with a smaller Tafel slope of 54.3 mV dec -1 . The boosted OER durability and activity of the NiFeReO x catalyst could be attributed to the strong electron-withdrawing property of Re 7+ single atoms leading to the electronic structure optimization and stabilization of Ni/Fe active sites. Our insights propose a new path for designing NiFeO x catalysts with high durability and activity toward OER.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗