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DOE OSTI2025

The Sensitivity of Nickel Substitution in the Structural Design of Manganese-Based Layered and Lithiated Spinel Electrodes for Li-Ion Batteries

A concerted effort is being made at Argonne National Laboratory to explore and develop high-performance lithium-manganese-nickel-oxide cathode materials for the lithium battery industry. They are both energy- and cost-competitive relative to cobalt- and nickel-rich systems, such as LiCoO 2 , LiNi 0.8 Co 0.15 Al 0.05 O 2 , and LiNi 0.8 Mn 0.1 Co 0.1 O 2 . The recent discovery of the structural versatility of LiNi 0.5 Mn 0.5 O 2 , has revealed that it can exist in three configurations: lithiated spinel, partially disordered layered, and completely disordered rock salt within a common cubic-close-packed oxygen array. This versatility opens up the possibility of designing structurally integrated electrode components with interlinking 2-D (layered) and 3-D (spinel) channels for Li-ion transport. This paper highlights the sensitivity of Ni substitution and synthesis temperature on the structural and electrochemical properties of LiNi 0.50 Mn 0.50 O 2 , LiNi 0.53 Mn 0.47 O 2 , LiNi 0.47 Mn 0.53 O 2 , and LiNi 0.25 Mn 0.75 O 2 electrodes, as well as a cobalt-containing composition, LiNi 0.333 Mn 0.333 Co 0.333 O 2 , when synthesized at a relatively low temperature of 400 °C.

25 ENERGY STORAGE↗

DOE OSTI2026

Predicting Particle-Size Distributions in Fuel-Cell Inks

Prediction of the catalyst-activated carbon particle sizes of fuel-cell inks remains a critical challenge in enhancing the performance and durability of fuel cells. The performance and structural integrity of the catalyst layers in the cell depend not only on the properties of the ionomer, but also on the carbon supports that host the catalyst. To investigate how these carbon aggregate structures form, we present a model that calculates the cooperative size distributions of ionomer and carbon aggregates in various water/alcohol mixtures and compares those results to available experimental data. Aggregation of both the suspended ionomers and the carbon particles is interwoven as the carbon aggregation depends heavily on the ionic strength of its environment, namely protons dissociating from the ionomer’s sulfonic-acid-group side chains. We demonstrate that the surrounding mixed solvent as well as Nafion TM binder concentration strongly influence the degree of aggregation for carbon particles. The validated model provides a framework for exploring aggregation under a wide range of conditions for various electrochemical-technology inks.

Srivastav, Harsh [University of California, Berkel↗

DOE OSTI2024

Fabrication status of production SSR1 jacketed cavities for PIP-II at Fermilab

This paper provides an overview of the current fabrication status of superconducting SSR1 spoke cavities intended for integration into the PIP-II SRF linac at Fermilab. It explores the ongoing development and fabrication processes of the jacketed SSR1 cavity, highlighting key modifications made in the mechanical design to enhance structural integrity.

Aiazzi, T.↗

DOE OSTI2026

Detailed Method for the Purification of Rhamnogalacturonan-I (RG-I) in Arabidopsis thaliana

The plant cell wall is a dynamic and complex extracellular matrix that not only provides structural integrity and determines cell shape but also mediates intercellular communication. Among its major components, pectins play essential roles in cell adhesion, wall porosity, hydration, and flexibility. Rhamnogalacturonan-I (RG-I), a structurally diverse pectic polysaccharide, remains one of the least understood components of the plant cell wall. Its backbone is substituted with arabinan, galactan, and arabinogalactan side chains that vary in length, branching, and composition across tissues, species, and developmental stages. In addition, RG-I can undergo modifications such as backbone acetylation, further contributing to its structural complexity and functional diversity. To advance understanding of RG-I, we present a detailed method for isolating RG-I from the model plant Arabidopsis thaliana . Leveraging Arabidopsis as a model system provides major advantages owing to its well-characterized genome and powerful molecular toolkit, enabling deeper investigation into the roles of RG-I in plant development and responses to environmental stress. Our method consists of two major steps: an initial chemical extraction using oxalate, followed by endo-polygalacturonase (EPG) digestion to fragment the pectic domains. An advantage of this approach is that it produces a dry material that can be stored at room temperature without special handling and does not introduce chemicals that may interfere with downstream analyses. The purified RG-I can be used for detailed compositional and structural analyses, as well as for functional studies of enzymes involved in pectin biosynthesis, modification, and degradation. Although this protocol was developed for isolating RG-I from Arabidopsis rosette leaves, it is also applicable to other Arabidopsis organs and other plant species.

25 ENERGY STORAGE↗

DOE OSTI2026

Assess The Water Resistance And Thermal Performance Of Pre-flashing Methods When Adding Continuous Insulation During Re-siding (AIRS)

Retrofitting existing buildings by adding continuous insulation during re-siding projects has become a popular method for enhancing energy efficiency, especially given the aging building stock and stricter energy codes. When properly integrated with existing window systems, continuous insulation can significantly improve thermal performance, but it also presents challenges related to water resistance and building envelope integrity. Research indicates that the interface between windows and wall assemblies is critical as improper installation or sealing can lead to water intrusion, materials deterioration, and energy loss. Moreover, studies show that fully integrating the windows with the insulation layer can reduce window heat loss by up to 40%, emphasizing the importance of optimizing window placement and sealing during retrofitting to ensure both energy efficiency and structural performance. In this study, we conducted experimental tests to evaluate the water penetration and thermal performance of two window types: an aluminum window with a 2-inch installation fin and a wood window, representing typical mid-20th century designs. Using the Heat, Air, and Humidity (HAM) chamber at Oak Ridge National Laboratory (ORNL), we assessed bulk water penetration and performed COMSOL analysis for thermal flux and examined the effectiveness of different pre-flashing methods, i.e., standard self-adhered flashing tape and high-performance flashing tape with low-expansion foam, to enhance water resistance. The results indicate that applying proper flashing techniques and moisture management strategies can mitigate these risks, improving the overall performance and durability of retrofitted buildings. Additionally, proper sealing during retrofitting is essential, as improper installation can lead to moisture issues that compromise both energy efficiency and structural integrity.

Shen, Zhenglai [ORNL]↗

DOE OSTI2024

Fabrication status of production SSR1 jacketed cavities for PIP-II at Fermilab

Aiazzi, T.↗

DOE OSTI2024

Arctic Critical Infrastructure: Assessing and Predicting the Risk to Critical Permafrost Infrastructure from Climate Change: A New Thermomechanical Approach

This study presents the development of a computational framework designed to predict the interaction between permafrost and infrastructure, addressing potential failure modes and mitigation strategies in the context of climate change. The framework, rooted in advanced modeling and simulation (mod/sim) techniques, integrates thermomechanical coupling to account for the complex interplay between heat flow, ice content, and mechanical behavior in permafrost. Existing models fail to fully capture these dynamics, particularly as they relate to the effects of ice saturation on structural integrity. Our innovative Arctic Coastal Erosion (ACE) framework fills this gap by coupling thermal and mechanical models to accurately simulate subsidence and deformation in permafrost environments. We applied the ACE framework to a representative runway, demonstrating its capability to predict settlement due to rising temperatures and subsequent permafrost thaw. This proof-of-concept showcases the potential of the framework to evaluate risks to Arctic infrastructure, which supports over four million people and 70% of existing permafrost-based structures. By simulating various infrastructure types and environmental conditions, our research offers insights into failure mechanisms and evaluates structural solutions to mitigate risk. The anticipated deliverables, including a prototype runway exemplar, position this project as a critical advancement in permafrost infrastructure modeling, with applications in national security and resilience planning.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Maturing Rational Design Methodologies and Industry Consensus Engineering Standards: Critical Fastened Joints - Solar PV Industry

Critical structural joints can be seen throughout a solar array and are called upon to secure modules and keep racking assembled and able to resist large demands from winds and snow loads. In the relatively new and fast-growing solar PV industry, the important role these hardware assemblies (e.g. clips, clamps, bolts, nuts, washers) play is not well understood by product designers. Failures with critical structural joints are surprisingly common and point to the need for maturing the engineering and assembly of these joints. The wide variety of design concepts (Figure 2&2) demonstrate interesting and innovative ideas but are lacking the basics of fastener engineering seen in matured industries (e.g. transportation, buildings). Complicating the maturing process for critical structural joints is that they are one component in rack supporting structures that exhibits a systems behavior; each component will affect the other and play a key role in maintaining structural integrity. When wind loads the surface of a module, the underlying racking members deflect and twist which in turn imparts forces back into the joints and into the mounted modules. Often, these supporting rack structures exhibit high deflections and low natural frequencies which amplify the demands placed into the joints even in moderate winds. Current engineering practices and associated structural conventions view solar racking support structures as they would a high mass building that exhibit more static behaviors in wind events. Solar structures are unique from high mass buildings and require the development of solar specific industry engineering consensus standards.

14 SOLAR ENERGY↗

DOE OSTI2026

Powder‐to‐Film Conversion of Nickel Single‐Atom Catalysts into Binder‐Free and Resistant Electrodes

Although a few binder-free and self-supported single-atom electrodes have been reported, achieving mechanically robust, defect-engineered, and reproducible films that preserve atomic dispersion under electrochemical operation remains challenging. This work addresses this limitation by presenting a versatile and generalizable strategy to transform powders into standalone, defect-engineered thin films hosting atomically dispersed Ni centers within conductive 2D frameworks. The physicochemical and electronic properties of these materials are thoroughly characterized using a comprehensive set of spectroscopic and microscopic techniques and confirmed the homogeneous dispersion and monoatomic nature of the Ni centers (0.94 wt.%) on the electrode films. Electrochemical testing via cyclic voltammetry and electrochemical impedance spectroscopy under a range of experimental conditions revealed that integration of Ni single atoms markedly enhanced performance and stability compared to carbon nanotube-only electrodes, maintaining integrity after 15 h of continuous operation. This improvement is accompanied by a notable reduction in charge transfer resistance (30.50 Ω) and an increase in double-layer capacitance (295.45 µF). Post-electrochemical analyses corroborated the structural integrity and robustness of the electrodes. Overall, this work bridges atomically precise catalysis and device-level electrochemistry, opening a route toward reproducible and scalable single-atom electrodes for sensing and energy conversion.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Unsupervised learning-enabled pulsed infrared thermographic microscopy of subsurface defects in stainless steel

Metallic structures produced with laser powder bed fusion (LPBF) additive manufacturing method (AM) frequently contain microscopic porosity defects, with typical approximate size distribution from one to 100 microns. Presence of such defects could lead to premature failure of the structure. In principle, structural integrity assessment of LPBF metals can be accomplished with nondestructive evaluation (NDE). Pulsed infrared thermography (PIT) is a non-contact, one-sided NDE method that allows for imaging of internal defects in arbitrary size and shape metallic structures using heat transfer. PIT imaging is performed using compact instrumentation consisting of a flash lamp for deposition of a heat pulse, and a fast frame infrared (IR) camera for measuring surface temperature transients. However, limitations of imaging resolution with PIT include blurring due to heat diffusion, sensitivity limit of the IR camera. We demonstrate enhancement of PIT imaging capability with unsupervised learning (UL), which enables PIT microscopy of subsurface defects in high strength corrosion resistant stainless steel 316 alloy. PIT images were processed with UL spatial–temporal separation-based clustering segmentation (STSCS) algorithm, refined by morphology image processing methods to enhance visibility of defects. The STSCS algorithm starts with wavelet decomposition to spatially de-noise thermograms, followed by UL principal component analysis (PCA), fine-tuning optimization, and neural learning-based independent component analysis (ICA) algorithms to temporally compress de-noised thermograms. The compressed thermograms were further processed with UL-based graph thresholding K-means clustering algorithm for defects segmentation. The STSCS algorithm also includes online learning feature for efficient re-training of the model with new data. For this study, metallic specimens with calibrated microscopic flat bottom hole defects, with diameters in the range from 203 to 76 µm, were produced using electro discharge machining (EDM) drilling. While the raw thermograms do not show any material defects, using STSCS algorithm to process PIT images reveals defects as small as 101 µm in diameter. To the best of our knowledge, this is the smallest reported size of a sub-surface defect in a metal imaged with PIT, which demonstrates the PIT capability of detecting defects in the size range relevant to quality control requirements of LPBF-printed high-strength metals.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Mitigating Sodium Ordering for Enhanced Solid Solution Behavior in Layered NaNiO 2 Cathodes

Abstract The O‐type layered nickel oxides suffer from undesired cooperative Jahn–Teller distortion stemming from Ni 3+ ions and undergo multiple biphasic structural transformations during the insertion/extraction of large Na + ions, posing a significant challenge to stabilize the structural integrity. We present here a systematic investigation of the impact of substituting 5 % divalent (Mg 2+ ) or trivalent (Al 3+ or Co 3+ ) ions for Ni 3+ to alleviate Na + ion ordering and perturb the Jahn–Teller effect to enhance structural stability. We gauge a fundamental understanding of the Mg−O and Na−O or Mg−O−Na bonding interactions, noting that the ionicity of the Mg−O bond deshields the electronic cloud of oxygen from Na + ions. Furthermore, calculations of the Van Vleck distortion modes reveal a relaxation of NiO 6 octahedra from Jahn–Teller distortion and a reduced electron density at the interlayer with Mg 2+ substitution. Long‐range ( operando X‐ray diffraction) and short‐range (magic angle spinning nuclear magnetic resonance) structural analyses provide insights into reduced ordering, allowing a stable continuous solid solution. Overall, Mg‐substitution results in a high‐capacity retention of ~96 % even after 100 cycles, showcasing the potential of this strategy for overcoming the structural instabilities and enhancing the performance of sodium‐ion batteries.

Sada, Krishnakanth↗

DOE OSTI2024

Mitigating Sodium Ordering for Enhanced Solid Solution Behavior in Layered NaNiO 2 Cathodes

The O-type layered nickel oxides suffer from undesired cooperative Jahn–Teller distortion stemming from Ni 3+ ions and undergo multiple biphasic structural transformations during the insertion/extraction of large Na + ions, posing a significant challenge to stabilize the structural integrity. We present here a systematic investigation of the impact of substituting 5 % divalent (Mg 2+ ) or trivalent (Al 3+ or Co 3+ ) ions for Ni 3+ to alleviate Na + ion ordering and perturb the Jahn–Teller effect to enhance structural stability. Here, we gauge a fundamental understanding of the Mg−O and Na−O or Mg−O−Na bonding interactions, noting that the ionicity of the Mg−O bond deshields the electronic cloud of oxygen from Na + ions. Furthermore, calculations of the Van Vleck distortion modes reveal a relaxation of NiO 6 octahedra from Jahn–Teller distortion and a reduced electron density at the interlayer with Mg 2+ substitution. Long-range (operando X-ray diffraction) and short-range (magic angle spinning nuclear magnetic resonance) structural analyses provide insights into reduced ordering, allowing a stable continuous solid solution. Overall, Mg-substitution results in a high-capacity retention of ~96 % even after 100 cycles, showcasing the potential of this strategy for overcoming the structural instabilities and enhancing the performance of sodium-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2025

Additive manufacturing of high‐density silicon carbide ceramics through post‐processing spark plasma sintering

This research advances the field of additive manufacturing (AM) of silicon carbide (SiC) ceramics by integrating spark plasma sintering (SPS) to enhance material density, mechanical strength, and thermal properties. Traditional AM techniques struggle to achieve the high‐density SiC required for demanding applications, such as aerospace engineering, where high thermal conductivity and mechanical strength are paramount. Here, our study addresses these challenges by incorporating SPS as a post‐processing step, achieving near‐theoretical maximum densities and significantly reducing porosity, thereby resulting in outstanding thermal conductivity in SiC ceramics. We developed a specialized SiC ink optimized for 3D printing, ensuring structural integrity after deposition through tailored rheological properties. The application of SPS facilitates rapid, uniform sintering, essential for attaining superior density, mechanical properties, and thermal performance. Our experimental results, confirmed through scanning electron microscopy analysis, demonstrate significant microstructural properties, mechanical strength, and thermal conductivity, showcasing the effectiveness of integrating SPS in AM processes. This innovative approach not only expands the capabilities of AM in producing complex, high‐density ceramic structures but also broadens the potential applications of SiC in demanding environments.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Tailoring Binder Molecular Weight to Enhance Slurry-Cast NMC Cathodes for Sulfide Solid-State Batteries

We demonstrate for the first time the critical influence of binder molecular weight on the performance of slurry-cast lithium nickel manganese cobalt oxide (NMC) cathodes in sulfide-based all-solid-state batteries (SSBs). SSBs are increasingly recognized as a safer and potentially more efficient alternative to traditional Li-ion batteries, owing to the superior ionic conductivities and inherent safety features of sulfide solid electrolytes. However, the integration of high-voltage NMC cathodes with sheet-type sulfide solid electrolytes presents significant fabrication challenges. Our findings reveal that higher molecular weight binders not only enhance the discharge capacity and cycle life of these cathodes but also ensure robust adhesion and structural integrity. By optimizing binder molecular weights, we effectively shield the active materials from degradation and mechanical stress, significantly boosting the functionality and longevity of SSBs. These results underscore the paramount importance of binder properties in advancing the practical application of high-performance all-solid-state batteries.

25 ENERGY STORAGE↗

DOE OSTI2026

Hydrophobic Metal–Organic Frameworks Enable Superior High-Pressure Ammonia Storage through Geometric Design

Hydrophobic metal–organic frameworks (MOFs) are typically overlooked for ammonia storage due to weak host–guest interactions. Here, we demonstrate that four structurally analogous aluminum-based MOFs exhibit a counterintuitive behavior whereby framework geometry, rather than ligand hydrophilicity, determines high-pressure NH 3 adsorption performance. The hydrophobic CAU-23 achieved an exceptional capacity matching hydrophilic analogs despite its poor low-pressure uptake. This pressure-dependent enhancement stems from the unique 4-cis-4-trans geometry of CAU-23 compared to the purely cis arrangement of MIL-160 and KMF-1 and the alternating cis-trans configuration of MOF-303. Critically, CAU-23 retained 95% capacity over three high-pressure cycles, whereas hydrophilic MOFs suffered 39–46% irreversible losses due to strong NH 3 -framework interactions that compromise structural integrity. Grand canonical Monte Carlo simulations reveal that high pressure enables NH 3 clustering through intermolecular hydrogen bonding, bypassing the need for strong host–guest interactions. High-pressure powder X-ray diffraction measurements confirm the exceptional mechanical resilience of CAU-23, showing complete structural recovery upon decompression despite exhibiting the highest pressure sensitivity among the studied MOFs. An extended analog, HE-CAU-23, validates this design principle with further enhanced capacity. Furthermore, these findings reveal a paradigm shift toward hydrophobic MOFs with optimized geometry for high-performance and regenerable gas storage applications.

MOFs↗

DOE OSTI2025

Constructing Water‐Stable Porous Organic Salts via Suppressed Proton Integration Using Fluorinated Tetrazole Tectons

Porous organic salts (POSs) are an emerging class of materials with ordered ionic architectures, offering excellent proton transfer and water uptake properties. However, conventional POS synthesis via strong acid–base neutralization (e.g., ─SO₃H and ─NH₂) leads to extensive hydrogen bonding with water, compromising stability in aqueous and water-lean environments. Here, we address this challenge by designing POSs with hydrophobic porous channels and minimal hydrogen bonding formation. Our key innovation is the use of fluorinated tetrazole as a weak acid tecton and a tetra-substituted imidazole precursor devoid of active protons as the base. Single-crystal analysis and computational modeling reveal that the structural integrity of the synthesized POSs arises primarily from cation–anion interactions, with water confined as clusters in the pores, independent of hydrogen bonding with the scaffold. Robustness of the POS structure under aqueous and water-lean conditions is confirmed by X-ray and neutron scattering, as well as computational modeling, confirming preserved packing and crystal structures. The stability of POS is further demonstrated in aqueous iodine capture, with imidazolium cations and C–F functionalizations serving as strong adsorption sites. As a result, the approach developed herein further pushes the boundary of POS materials to withstand both aqueous and water-lean conditions.

Fluorinated tecton↗

DOE OSTI2026

Differential Privacy in Grid Kitchen: Implementation & Software Documentation

Sharing of power grid feeder models faces significant challenges due to the potential risk of exposing sensitive operational information. Traditional anonymization techniques have shown notable limitations in other sensitive domains, as evidenced by documented re-identification attacks that combine supposedly anonymized datasets with auxiliary information, raising concerns that similar vulnerabilities could affect power grid data. Consequently, there is a pressing need for a more rigorous privacy protection strategy that not only delivers formal mathematical guarantees but also preserves the analytical value of the shared models. To address this challenge, we have enhanced the Grid Kitchen framework by implementing differential privacy mechanisms within the distribution model dehydration pipeline. This implementation carefully calibrates and applies noise to sensitive attributes in feeder models according to configurable privacy levels—low, moderate, and high—each offering different balances between data utility and privacy protection. Our approach uses established noise functions (Gaussian for continuous data and Discrete Laplace for integer values) with parameters carefully calibrated so that the impact of individual data points is effectively masked in the final output. The integration leverages our Noise Catalog, which we developed to categorize feeder model properties by component type, data type, and sensitivity. This catalog guides the application of appropriate noise functions and privacy parameters ($\varepsilon$ and $\delta$) to each attribute, ensuring consistent privacy protection across the model while maintaining its structural integrity and analytical usefulness. This implementation also includes evaluation tools that allow model owners to assess the impact of privacy-preserving transformations before sharing data with external parties. This report provides documentation for the differential privacy capabilities added to the Grid Kitchen project. It includes a primer on differential privacy concepts and their importance in modern data sharing, details the architecture of our implementation, explains the privacy modes and parameter configurations, and offers practical guidance on using the code for applying differential privacy to grid feeder models. Through examples and code snippets, we demonstrate the effective application of these privacy-enhancing technologies, enabling utility operators and researchers to confidently share grid data while protecting sensitive information.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Structural characterization of ligand binding and pH-specific enzymatic activity of mouse Acidic Mammalian Chitinase

Chitin is an abundant biopolymer and pathogen-associated molecular pattern that stimulates a host innate immune response. Mammals express chitin-binding and chitin-degrading proteins to remove chitin from the body. One of these proteins, Acidic Mammalian Chitinase (AMCase), is an enzyme known for its ability to function under acidic conditions in the stomach but is also active in tissues with more neutral pHs, such as the lung. Here, we used a combination of biochemical, structural, and computational modeling approaches to examine how the mouse homolog (mAMCase) can act in both acidic and neutral environments. We measured kinetic properties of mAMCase activity across a broad pH range, quantifying its unusual dual activity optima at pH 2 and 7. We also solved high-resolution crystal structures of mAMCase in complex with oligomeric GlcNAcn, the building block of chitin, where we identified extensive conformational ligand heterogeneity. Leveraging these data, we conducted molecular dynamics simulations that suggest how a key catalytic residue could be protonated via distinct mechanisms in each of the two environmental pH ranges. These results integrate structural, biochemical, and computational approaches to deliver a more complete understanding of the catalytic mechanism governing mAMCase activity at different pH. Engineering proteins with tunable pH optima may provide new opportunities to develop improved enzyme variants, including AMCase, for therapeutic purposes in chitin degradation.

59 BASIC BIOLOGICAL SCIENCES↗