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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 OSTI2023

Creep Properties of Shale and Predicted Impact on Proppant Embedment for the Caney Shale, Oklahoma

The Caney shale is an emerging hydrocarbon play located in southwest Oklahoma, USA. Within the Caney shale exist facies which were initially dubbed “reservoir” and “ductile” based on evaluation of well logging data. While past work has shown the distinction of “brittle” and “ductile” is not mechanically justifiable according to formal definitions, here the current work shows some important differences between nominally ductile and reservoir zones. First, the “ductile” zones are more clay rich and have textural differences which can be expected to lead to differences in mechanical properties. One important impact of these differences is observed in triaxial creep experiments showing the “ductile” zones are more prone to creep deformation. Numerical simulations predict the “reservoir” zones will experience very little proppant embedment due to creep deformation of hydraulic fractures around proppant particles. On the other hand, “ductile” zones can be expected to undergo creep-driven proppant embedment leading to loss of fracture aperture ranging up to 100% loss, depending upon the spatial density of the proppant distribution. Hence, this research shows the identification of nominally “ductile” zones from well logs, while a misnomer, can be useful in finding clay-rich, creep-prone zones which will be the most prone to proppant embedment and hence vulnerable to greater production decline over time.

58 GEOSCIENCES↗
DOE OSTI2025

On the bulk compaction of brittle granular materials, Part III: Brittle‐to‐ductile transition and yield strength

A new and simple method is presented that enables the estimation of the yield strength (σ y ) of brittle materials (e.g., ceramics, glasses). It results from the combination of sufficiently high-stress compaction of their granular form, postmortem analysis of the crushed particles to identify the critical particle size corresponding to their brittle-to-ductile transition, and the use of a developed and simple analytical expression. Here, this method was an outcome from Part I of this three-paper series. To execute it, a granular brittle material is compacted to a sufficiently high stress, whereby the acting comminution produces both a fraction of particles having a sufficiently small size formed by ductile or plastic-like deformation and a remaining fraction of larger particles formed from brittle fracture. Postmortem microscopy is then used to identify the smallest particle size whose morphology indicates it formed from brittle fracture (d B2D ). The brittle material's σ y can then be estimated using a combination of the d B2D , Kendall's and Griffith's theories, a priori knowledge of the material's fracture toughness (K Ic ), and a fracture mechanics shape factor constant (Y) using σ y = √((32 π K Ic 2 )/(3 Y 2 d B2D )). The method's development and its use to estimate σ y for several vitreous silicates, α-quartzes, and NaCl are provided.

Compaction↗
DOE OSTI2025

Deciphering volume changes in Li-S solid-state battery components during cycling: Implication for advanced battery design

Here, in this work, we developed custom fixtures to investigate the mechanical and electrochemical behavior of all-solid-state lithium batteries during cycling under constant pressure and constant volume conditions. We successfully monitored vertical displacements during constant pressure cycling and pressure variations during constant volume cycling, allowing us decouple volume changes in the sulfur, Li 2 S cathodes, LixIn anode, and solid-state electrolyte. Scanning electron microscopy and electrochemical impedance spectroscopy confirmed that two structural changes occur during ASSLB cycling: (1) irreversible fractures in the active material particles, and (2) void formation within the electrode matrix. While the fractures in primary particles are permanent, void formation can be mitigated through stack pressure, which promotes particle rearrangement in the electrode matrix. Our findings emphasize the importance of stack pressure in maintaining the microscale integrity of all-solid-state lithium batteries, preventing void formation and enhance battery performance and durability.

Cell Design↗
DOE OSTI2026

Unraveling design principles of protein landscapes in photosynthetic membranes in plant chloroplasts

The supramolecular organization of proteins within photosynthetic membranes is crucial for energy conversion in plants. Here, we introduce an analytical and computational pipeline that integrates high-resolution cryo–scanning electron microscopy, biochemical quantification, advanced Monte Carlo computer simulations, and statistical methods to elucidate the elusive protein landscapes of grana membranes in intact Arabidopsis leaves. Our integrated analysis challenges the prevailing view that particles on the exoplasmic fracture faces in freeze-fracture samples represent photosystem II exclusively. Instead, these particles also include cytochrome b 6 f complexes. Furthermore, our steric clash analysis demonstrates that stacked membranes contain a mixture of larger PSII supercomplexes (C 2 S 2 M 2 and C 2 S 2 ) in addition to a smaller complex (C 2 ). This suggests that in vivo PSII supercomplexes exist in an equilibrium distribution of differing sizes. Furthermore, we discovered that, although size exclusion effects govern the global protein arrangement, local packing exhibits orientational order indicative of lateral attractive protein-protein interactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Correlation among porosity, mechanical properties, morphology, electronic conductivity and electrochemical kinetics of dry-processed electrodes

Dry processing (DP) has received great interest recently, which poses many advantages over the conventional slurry-based processing. Here, this work investigates the effect of compression on electrode mechanical properties, morphology, electronic conductivity, and electrochemical kinetics. Similar to the slurry-based electrodes, LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC) cathodes with intermediate porosity (i.e., 32%) demonstrate lowest charge transfer resistance, highest electronic conductivity and best rate performance. Fracture of NMC secondary particles is observed in the dry processed NMC cathodes. Reducing electrode porosity results in more fracture in the NMC secondary particles.

25 ENERGY STORAGE↗
DOE OSTI2022

Underlying limitations behind impedance rise and capacity fade of single crystalline Ni-rich cathodes synthesized via a molten-salt route

Layered oxide LiNi x Mn y Co z O 2 (NMC) cathodes are often synthesized as polycrystalline secondary particles. Due to intergranular fracture stemming from volume changes of randomly oriented primary particles during charge/discharge, the synthesis of larger single-crystalline cathodes is of high interest. In this work, molten salt assisted growth of micron-sized Ni-rich crystals is achieved with excellent crystallinity, low cation mixing, and negligible impurities. However, electrochemical performance is compromised by high surface reactivity resulting in decomposition of electrolyte and subsequent formation of a thick CEI layer. While intergranular fracture is eliminated, planar gliding and severe intragranular fracture along the (003) plane occurs in the high voltage region within the first few cycles and is associated primarily with H2 to H3 structural transitions. In addition, H2 to H3 transitions are highly irreversible with cyclic voltammograms revealing polarization growth within <5 cycles. Subsequently, the single-crystalline material exhibited markedly reduced available capacity and enhanced capacity fade from sharp impedance growth compared to its polycrystalline counterpart. Here, this work furthers a fundamental understanding into the limitations of single-crystalline Ni-rich cathodes, and the obstacles limiting the advantages offered by the single-crystalline morphology.

25 ENERGY STORAGE↗
DOE OSTI2023

Autonomous Fracture Conductivity Using Expandable Proppants in Enhanced Geothermal Systems

Summary Early thermal breakthrough in enhanced geothermal systems (EGS) due to the presence of preferential flow channels is a major challenge that endangers efficient and economic heat extraction in such systems. Previous studies mainly focused on adjusting circulation rates of the working fluid, which still leaves significant amounts of untapped heat behind. Currently, there is a lack of technologies for altering flow distribution within the fracture network to achieve uniform heat sweeping in the reservoir. This work presents a novel concept for making proppants to autonomously control fracture conductivity based on the surrounding temperature. Here, proppants with negative thermal expansion coefficients have demonstrated the capability for appropriate fracture conductivity adjustment as a function of temperature to achieve uniform flow across the fracture network. Particle-particle interactions governing such functions are explicitly modeled, and then the Lattice Boltzmann methods (LBM) is used to determine the potential impact of closure stress and temperature changes on the permeability of the proposed proppant packs. Microscale analyses are further used to determine the required material properties to achieve a certain improvement in the permeability of the proppant pack. Our analyses show an enhancement in permeability and the associated fracture conductivity by half of their initial values. Field-scale analysis further confirms the effectiveness of the proposed concept as 31.4% more heat can be extracted from EGS over 50 years of production when the proposed proppants are used. Such novel proppants may effectively delay thermal breakthrough, sweep heat from larger rock volumes, and elongate the life span of the EGS project.

Engineering↗
DOE OSTI2025

Effect of multiple calcination cycles on CO 2 capture efficiency during carbonation of MgO in a mineral looping process

Magnesium oxide (MgO) is considered as a potential sorbent for direct air capture of carbon dioxide in a looping process. Previous research on mineral looping for carbon capture from flue gas using MgO has shown deactivation of the sorbent with repeated cycles but repeated cycling for carbonation at ambient conditions has not been yet investigated. Here, we tested three cycles of carbonation for MgO nano-scale powders with different starting surface area. We find that carbonation efficiency is higher at higher surface area. No decrease in carbonation efficiency was observed with cycling, instead we find that carbonation efficiency and surface area are stable or even increasing with cycling. Based on our experimental data, we hypothesize that the carbonation in presence of relative humidity leads to first hydration of MgO, leading to formation of brucite (Mg(OH) 2 ). This formation of Mg(OH) 2 is a volume-increasing reaction, which leads to fracturing of MgO particles and results in an increase in surface area. We observed formation of amorphous and crystalline hydrated carbonates. The crystalline phase observed was nesquehonite (MgCO 3 ⋅ 3H 2 O). Our results show that MgO does not show any deactivation with repeated cycling for carbon capture at ambient conditions and in the presence of humidity. These findings therefore indicate that MgO is a suitable candidate as sorbent material for direct air capture of carbon dioxide.

Ambient weathering↗
DOE OSTI2020

HOSS: Hybrid Optimization Software Suite

HOSS software, developed at LANL, is a powerful, flexible, and parallelized package that enables the user to predict deformation and failure of materials in a variety of situations. LANL’s HOSS software is an R&D 100 finalist that integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to handle millions of interacting and fracturing solids and/or particle systems. This nextgeneration simulation software integrates solid mechanics and computational fluid dynamics into a multi-physics platform able to provide state-of-the-art simulation solutions for a wide field of applications including oil and gas, construction, mining, defense, material sciences, and biomechanics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electrically conductive proppant

Electrically conductive sintered, substantially round and spherical particles and methods for producing such electrically conductive sintered, substantially round and spherical particles from an alumina-containing raw material. Methods for using such electrically conductive sintered, substantially round and spherical particles in hydraulic fracturing operations.

Cannan, Chad↗
DOE OSTI2022

Automated Defect Identification for Tri-structural Isotropic Fuels (AUDIT)

During the manufacture of tri-structural isotropic (TRISO)-coated nuclear fuel particles, the potential exists for the formation of internal fissure defects in the uranium oxycarbide (UCO) kernels. These fissures result in a defective fuel particle that can fracture during subsequent fuel processing. Therefore, it is necessary to detect the presence of fissured kernels in a batch to determine if the batch meets specification prior to blending with other batches and upgrading processes. Previous attempts at identifying fissures involved manual inspection of micrographs of UCO fuel kernel cross-sections. This process is tedious, time-consuming and may introduce counting errors making it a good candidate for automation. This work presents a method for the automated detection of fissures in UCO kernels. Image segmentation is used for the extraction of relevant features in the micrographs which then serve as the input to a convolutional neural network used to automatically distinguish between fissured and non-fissured kernels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

A Particle-Based Conditional Sampling Scheme for the Simulation of Transport in Fractured Rock With Diffusion Into Stagnant Water and Rock Matrix

In situ experiments and field-scale characterization studies have pointed out that, in fractured crystalline media, groundwater flow is highly channelized. This implies that, at the scale of a single fracture, only part of the fracture surface area is in contact with flowing water, while the rest of in-plane water is essentially stagnant and can be accessed by solutes via molecular diffusion. Despite their importance for contaminant retention, to date, there are no numerical or analytical approaches that could be used to assess the implication of stagnant water zones on solute transport in realistic large-scale Discrete Fracture Network-based models. In this study, we present an efficient and flexible algorithm for the simulation of transport in fractured rock with diffusion into stagnant water and rock matrix. The algorithm is a generalization of a previously developed numerical framework for time domain particle tracking in sparsely fractured rock. The key of the generalization is that total time in fracture (τ f ) is first evaluated using a Monte Carlo sampling and then a second sampling is performed conditioned on τ f . The algorithm has been successfully validated against existing independent solutions and the implication of diffusion into stagnant water and secondary diffusion into the matrix has been assessed for a realistic modeling scenario. The results show that, due to diffusion into stagnant water, contaminants are more strongly retarded. This increased retention is more significant for sorbing species, as a larger number of sorption sites is accessible. A high sensitivity to the flowing channel/stagnant water zone geometry has also been observed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Inelastic peridynamic model for molecular crystal particles

The peridynamic theory of solid mechanics is applied to modeling the deformation and fracture of micrometer-sized particles made of organic crystalline material. A new peridynamic material model is proposed to reproduce the elastic–plastic response, creep, and fracture that are observed in experiments. The model is implemented in a three-dimensional, meshless Lagrangian simulation code. In the small deformation, elastic regime, the model agrees well with classical Hertzian contact analysis for a sphere compressed between rigid plates. Under higher load, material and geometrical nonlinearity is predicted, leading to fracture. Finally, the material parameters for the energetic material CL-20 are evaluated from nanoindentation test data on the cyclic compression and failure of micrometer-sized grains.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

A stress-based fracture model for reacting metal ejecta

The evolution of reacting metal ejecta continues to be a topic of interest at the forefront of metals in reactive and extreme environments. Ejecta are small particles formed when the surface of a metal undergoes Richtmyer–Meshkov instability from a strong shock. Experiments have shown that in the case where ejecta are in ambient conditions that induce a reaction, the ejecta behave irregularly. The ejecta temperature rises and then plateaus, and the acceleration profile shows unexpected jumps. These variations are assumed to be related to the exothermic heat release and particle mass loss caused by the reaction. To explain this phenomenon, efforts to model this in simulations have increased. While current models can capture many of these physical processes, they currently assign a constant reaction shell thickness with little physical reasoning. This work remedies this problem by assigning a dynamic physically informed shell thickness to the reacting particles, using solid analysis. The shell thickness of the particles impacts the rate of change of reacted mass in the system, as well as the rate at which the particles react. The model is based on a simple stress–strain relationship and gives a dynamic assignment for when the reacting particle should begin to fracture. We compare our model to the previous computational and simulation data to analyze the effects of different model parameters.

42 ENGINEERING↗
DOE OSTI2019

Characterizing the Influence of Fracture Density on Network Scale Transport

The topology of natural fracture networks is inherently linked to the structure of the fluid velocity field and transport therein. Here we study the impact of network density on flow and transport behaviors. We stochastically generate fracture networks of varying density and simulate flow and transport with a discrete fracture network model, which fully resolves network topology at the fracture scale. We study conservative solute trajectories with Lagrangian particle tracking and find that as fracture density decreases, solute channelization to large local fractures increases, thereby reducing plume spreading. Furthermore, in sparse networks mean particle travel distance increases and local network features, such as velocity zones where flow is counter to the primary pressure gradient, become increasingly important for transport. As the network density increases, network statistics homogenize and such local features have a reduced impact. We quantify local topological influence on transport behavior with an effective tortuosity parameter, which measures the ratio of total advective distance to linear distance at the fracture scale; large tortuosity values are correlated to slow-velocity regions. Additionally, these large tortuosity, slow-velocity regions delay downstream transport and enhance tailing on particle breakthrough curves. Finally, we predict transport with an upscaled, Bernoulli spatial Markov random walk model and parameterize local topological influences with a novel tortuosity parameter. Furthermore, Bernoulli model predictions improve when sampling from a tortuosity distribution, as opposed to a fixed value as has previously been done, suggesting that local network topological features must be carefully considered in upscaled modeling efforts of fracture network systems.

58 GEOSCIENCES↗
DOE OSTI2019

Collapse of Reacted Fracture Surface Decreases Permeability and Frictional Strength

Abstract Geochemical and geomechanical perturbations of the subsurface caused by the injection of fluids present risks of leakage and seismicity. This study investigated how acidic fluid flow affects hydraulic and frictional properties of fractures using experiments with 3.8‐cm‐long specimens of Eagle Ford shale, a laminated shale with carbonate‐rich strata. In low‐pressure flow cells, one set of samples was exposed to acidic brine and another set was exposed to neutral brine. X‐ray computed tomography and energy‐dispersive X‐ray spectroscopy revealed that samples exposed to acidic brine were calcite‐depleted and had developed a porous altered layer, while the other set showed no evidence of alteration. After reaction, samples were compressed and sheared in a triaxial cell that supplied normal stress and differential pore pressure at prescribed sliding velocities, independently measuring friction and permeability. During the initial compression, the porous altered layer collapsed into fine particles that filled the fracture. This effectively impeded flow and sealed the fracture, resulting in fracture permeability to decrease 1 to 2 orders of magnitude relative to the unaltered fractures. This is a favorable outcome in subsurface applications where the goal is to reduce leakage risks. However, during shear the reacted fracture had lower frictional strength because the fine‐grained particles in the collapsed layer prevented the formation of interlocking microasperities. Therefore, coupled geochemical and geomechanical processes that could favorably seal fractures could also increase the likelihood of induced seismicity. These findings have important implications for geological carbon sequestration, pressurized fluid energy storage, geothermal energy, and other subsurface technologies.

58 GEOSCIENCES↗
DOE OSTI2025

Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries

The growing demand for high-energy, low-cost lithium-ion batteries (LIBs) to power electric vehicles (EVs) necessitates advances in both materials and manufacturing processes. Conventional cathode fabrication methods, such as slurry casting and drying, are energy-intensive and pose challenges for scalability and environmental compliance. In this study, we propose cold-spray (CS) deposition as a solvent-free approach for fabricating LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) composite cathodes. Powder blends of NMC622, poly(vinylidene fluoride) (PVDF), and carbon black (CB) are directly deposited onto stainless steel and Inconel substrates under varied gas temperatures, pressures (and thus velocities), and standoff distances. The effects of temperature on the deposit morphology, coating density, and volume are systematically investigated. Computational fluid dynamics simulations reveal that increasing the gas temperature enhances the particle velocity, narrows the spray angle, and reduces the mass concentration radially at the nozzle outlet. CS deposition results in a dense cathode microstructure, accompanied by fracture in polycrystalline NMC622 particles. X-ray diffraction analysis further verifies that there are no phase changes during the deposition process. The electrochemical performance of the cold-sprayed cathodes reveals an initial capacity of approximately 96 mAh g –1 for single-crystal NMC622 and 167 mAh g –1 for polycrystalline NMC622. While these values are modest compared to state-of-the-art slurry-cast cathodes, which typically exhibit 180–200 mAh g –1 under optimized conditions. The results demonstrate a competitive performance given the solvent-free nature of the CS process and compare favorably with tape-cast samples made from identical feedstock. In conclusion, he CS process enables the formation of dense, binder-integrated cathode coatings without the need for solvent processing, offering a promising pathway for scalable, energy-efficient dry electrode manufacturing of next-generation LIBs.

Batteries↗
DOE OSTI2024

Computational modeling of coupled mechanical damage and electrochemistry in ternary oxide composite electrodes

Performance degradation of ternary layered oxide cathodes largely originates from their loss of structural integrity in cyclic usage. Mechanical damage, such as intergranular fracture of the active particles, is not only a mechanical cleavage process but also interferes with electrochemical kinetics such as infiltration of liquid electrolyte, surface corrosion of the constituent primary particles, and may eventually isolate the primary grains from the electron conducting network. Here, in this work, we develop a computational framework that integrates electrochemistry of a LiNi x Mn y Co 1−x−y O 2 (NMC) composite cathode with mechanical damage of the active particles. To fully examine the intricate chemomechanical behavior of the electrode, we evaluate the effects of the anisotropic material properties, the influence of mechanical potential on Li transport, and the concurrent intergranular fracture and electrolyte penetration along the grain boundaries upon multiple cycles. Electrolyte infiltration benefits capacity retention but aggravates further mechanical damage by corrosion. Structural failure mostly occurs in the first charging due to the anisotropic mechanical strain between the primary grains, while the resulting damage remains stable in the later few cycles. The results are consistent with experimental observations and the integration of electrochemistry and mechanical failure enables a step further understanding of the complex mechanism of battery degradation.

Battery degradation↗