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DOE OSTI2022

Selectivity of Electrochemical Ion Insertion into Manganese Dioxide Polymorphs

The ion insertion redox chemistry of manganese dioxide has diverse applications in energy storage, catalysis, and chemical separations. Unique properties derive from the assembly of Mn–O octahedra into polymorphic structures that can host protons and nonprotonic cations in interstitial sites. Despite many reports on individual ion-polymorph couples, much less is known about the selectivity of electrochemical ion insertion in MnO 2 . In this work, we use density functional theory to holistically compare the electrochemistry of A x MnO 2 (where A = H + , Li + , Na + , K + , Mg 2+ , Ca 2+ , Zn 2+ , Al 3+ ) in aqueous and nonaqueous electrolytes. We develop an efficient computational scheme demonstrating that Hubbard-U correction has a greater impact on calculating accurate redox energetics than choice of exchange-correlation functional. Using PBE+U, we find that for nonprotonic cations, ion selectivity depends on the oxygen coordination environments inside a polymorph. When H + is present, however, the driving force to form hydroxyl bonds is usually stronger. In aqueous electrolytes, only three ion-polymorph pairs are thermodynamically stable within water’s voltage stability window (Na + and K + in α-MnO 2 , and Li + in λ-MnO 2 ), with all other ion insertion being metastable. We find Al 3+ may insert into the δ, R, and λ polymorphs across the full 2-electron redox of MnO 2 at high voltage; however, electrolytes for multivalent ions must be designed to impede the formation of insoluble precipitates and facilitate cation desolvation. We also show that small ions coinsert with water in α-MnO 2 to achieve greater coordination by oxygen, while solvation energies and kinetic effects dictate water coinsertion in δ-MnO 2 . Finally, taken together, these findings explain reports of mixed ion insertion mechanisms in aqueous electrolytes and highlight promising design strategies for safe, high energy density electrochemical energy storage, desalination batteries, and electrocatalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

The LPM effect in sequential bremsstrahlung: incorporation of “instantaneous” interactions for QCD

The splitting processes of bremsstrahlung and pair production in a medium are coherent over large distances in the very high energy limit, which leads to a suppression known as the Landau-Pomeranchuk-Migdal (LPM) effect. We continue study of the case when the coherence lengths (formation lengths) of two consecutive splitting processes overlap, avoiding soft-emission approximations. Previous work made a “nearly-complete” calculation of the effect of overlapping formation times on gluonic splittings such as g → gg → ggg (with simplifying assumptions such as an infinite QCD medium and the large-N c limit). In this paper, we extend those previous rate calculations from nearly-complete to complete by including processes involving the exchange of longitudinally-polarized gluons. In the context of Lightcone Pertubation Theory, used earlier for the “nearly-complete” calculation, such exchanges are instantaneous in lightcone time and have their own diagrammatic representation.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Relevant Additive Manufacturing Materials for Wind Industry

The purpose of this report is to equip wind industry professionals with the relevant material testing and properties of large format extrusion-based additive manufacturing processes. Discussion on the printability and processing of different classes of materials (i.e. low temperature, high temperature, thermoplastics, elastomeric, foam, etc.) is provided as well as relevant test standards and methods. Existing results for materials and properties are detailed. A companion document titled “Additive Manufacturing Design Guidelines for Wind Industry” covers the seven families of additive manufacturing, the relevance of each family to the wind industry, and design guidelines and considerations for the most relevant processes.

17 WIND ENERGY↗

DOE OSTI2025

Merging the computational design of chimeric type I polyketide synthases with enzymatic pathways for chemical biosynthesis

Synthetic biology offers the promise of manufacturing chemicals more sustainably than petrochemistry. Yet, both the rate at which biomanufacturing can synthesize these molecules and the net chemical accessible space are limited by existing pathway discovery methods, which can often rely on arduous literature searches. Here, we introduce BioPKS pipeline, an automated retrobiosynthesis tool combining multifunctional type I polyketide synthases (PKSs) and monofunctional enzymes via two complementary tools: RetroTide and DORAnet. Monofunctional enzymes are valuable for carefully decorating a substrate’s carbon backbone while PKSs are unique in their ability to iteratively catalyze carbon-carbon bond formation reactions, thereby expanding carbon backbones in a predictable fashion. We evaluate the performance of BioPKS pipeline using a previously reported set of 155 biomanufacturing candidates, achieving exact synthetic designs for 93 compounds and generating chemically similar pathways for most remaining targets. Furthermore, BioPKS pipeline can propose pathways for the complex therapeutic natural products cryptofolione and basidalin.

Chainani, Yash↗

NASA NTRS1986

Stable carbon isotope ratios in atmospheric methane and some of its sources

Ratios of C-13/C-12 have been measured in atmospheric methane and in methane collected from sites and biota that represent potentially large sources of atmospheric methane. These include temperate marshes (about -48 percent to about -54 percent), landfills (about -51 percent to about -55 percent), and the first reported values for any species of termite (-72.8 + or - 3.1 percent for Reticulitermes tibialis and -57.3 + or - 1.6 percent for Zootermopsis angusticollis). Numbers in parentheses are delta C-13 values with respect to PDB (Peedee belemnite) carbonate. Most methane sources reported thus far are depleted in C-13 with respect to atmospheric methane (-47.0 + or - 0.3 percent). Individual sources of methane should have C-13/C-12 ratios characteristic of mechanisms of CH4 formation and consumption prior to release to the atmosphere. The mass-weighted average isotopic composition of all sources should equal the mean C-13 of atmospheric methane, corrected for a kinetic isotope effect in the OH attack of CH4. Assuming the kinetic isotope effect to be small (about -3.0 percent correction to -47.0), as in the literature, the new values given here for termite methane do not help to explain the apparent discrepancy between C-13/C-12 ratios of the known CH4 sources and that of atmospheric CH4.

Tyler, Stanley C.↗

DOE OSTI2025

Fluid Mechanics Challenges in Direct-Ink-Writing Additive Manufacturing

Direct-ink writing (DIW) has rapidly become a versatile 3D fabrication method due to its ability to deposit a wide range of complex fluids into customizable 3D geometries. This review highlights key fundamental fluid mechanics and soft matter challenges across the different stages of the DIW printing process. The rheology of fluids and suspensions governs the flow behavior through narrow nozzles, posing questions about extrudability, confined flow dynamics, and clogging mechanisms. Downstream, the formation and deposition of extruded filaments involve extensional flows and potential instabilities, while postdeposition dynamics introduces complexities related to yield stress and structural stability. These stages are inherently interdependent, as optimizing material composition without considering filament stability risks compromising the final structure. As DIW applications expand through advanced ink formulations, developing fundamental fluid mechanics frameworks is essential to replace trial-and-error approaches with predictive design methodologies to enable more precise control and improved reliability of the printing process.

3D printing↗

DOE OSTI2025

Improving the Performance of Mid-T Baked Niobium Cavities through Post-Bake Surface Treatment

he Medium temperature (mid-T) baking of niobium superconducting radio-frequency cavities at 300 350 C in a vacuum furnace is known to enhance the quality factor (Q₀). However, despite this improvement, cavities treated with this process often exhibit premature quench at relatively low accelerating fields. This limitation is suspected to arise from the formation of surface contaminants, such as niobium carbides, during the furnace bake at 350 C for 3 h. To investigate the influence of potential surface contamination, this study applied an ultralight chemical removal to 1.3 GHz and 650 MHz single-cell cavities that had undergone medium-temperature baking. The removal of the top RF surface layer led to a notable improvement in the quench field and Q₀, indicating a beneficial effect of eliminating possible surface residues introduced during the bake.

Chouhan, Vijay [Fermilab]↗

DOE OSTI2025

Effect of toolpath in large-format additive manufacturing with bio-derived composites

There has been growing interest in integrating bio-derived composites into Large-format additive manufacturing (LFAM) feedstocks to reduce the use of petroleum-derived materials and reduce the overall carbon footprint of LFAM. However, these materials present unique challenges during manufacturing due to their variability, which can lead to unintended deformations and failures attributable to suboptimal process conditions. While numerical modelling has been extensively employed to simulate numerous manufacturing processes, its application in LFAM with bio-derived composites remains limited. This study addresses this gap by systematically developing a numerical model to simulate the LFAM process using bio-based materials, specifically wood fiber-reinforced polylactic acid (PLA/WF). Experimental investigations were conducted to characterise the thermal and mechanical properties of additively manufactured PLA/WF specimens. Numerical simulations were performed to predict temperature profiles and deformations during LFAM. The effect of varying infill patterns, internal structures, and tool paths on the temperature distribution and deformation of printed parts was explored using the developed model. This article aims to advance the utilisation of bio-derived composites in LFAM systems and provide a comprehensive understanding of the LFAM process. The findings offer valuable insights for optimising process parameters and enhancing the performance of LFAM with bio-based composites.

Large-format additive manufacturing↗

DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗

NASA NTRSDate not supplied

CALIGOLA: A New Spaceborne Lidar Mission

Agenzia Spaziale Italiana (ASI) and NASA are partnering on an exciting new spaceborne lidar mission known as CALIGOLA (i.e., the Cloud and Aerosol Lidar for Global Scale observations of the Ocean-Land-Atmosphere) that seeks to significantly advance our understanding of Earth’s coupled ocean-land-atmosphere systems. By flying an innovative multi-wavelength, polarization-sensitive Raman lidar that will simultaneously acquire elastic backscatter and fluorescence measurements, CALIGOLA will provide new insights into the processes that influence climate, weather, and air quality by vertically profiling microphysical and optical properties of clouds and aerosols. The mission will also probe phytoplankton biomass and zooplankton dynamics and provide observations of surface vegetation, ice, and snow. The mission is planned for launch early next decade and baselined to fly in an orbit that is compatible with NASA’s AOS-Sky mission. This formation flying configuration will enable synergistic retrievals between observations from CALIGOLA and the polarimeter and radar measurements planned for AOS-Sky and thus greatly enhance our ability to explore and characterize the intricate processes that govern the interactions between different components of the Earth system. The presentation will highlight CALIGOLA’s significant science objectives and describe the pioneering instrument that will enable us to achieve these objectives.

Chip Trepte↗

NASA NTRSDate not supplied

Celestial Mapping System for Lunar Surface Mapping and Analytics

Celestial Mapping System (CMS) is a software platform to generate virtual 3D globe for celestial bodies within our solar system. Various layers are built on top of the virtual globe to provide visualization of high resolution imagery, enable precise measurements, build analytical capabilities and broad range of functionalities to assist planetary scientists and mission planners. CMS is built using OpenJDK 11 and will run on a wide variety of platforms such as Linux, Windows, OSX, etc. It has a thick client with less overhead to access hardware resources. This allows features such as terrain profiling and distance calculations to be performed on the client and on the fly. The present focus of CMS is on developing lunar mapping tool kits to provide features such as - 3D first person view with zoom and navigational capabilities, realistic terrain visualization based on LRO data, measurement tools, Apollo landing site annotations, stereoscopic view, elevation profiles, line of sight analysis and many more. The application is developed to provide situational and domain awareness on Lunar surface, planning capabilities for equipment placements and traverse path optimization. As data becomes available, CMS has the capabilities to integrate data sets that change dynamically in real-time, which will be useful for monitoring satellites and remotely-sensed data on Lunar surface. CMS utilizes NASA WorldWind Java library and OpenGL to achieve high-performance rendering of data and measurements, and also adheres to OGC standards. CMS supports importing synthetic features in a variety of 3D, 2D, vector and raster formats. Nomenclature is pulled from USGS Moon IAU2000 database, and lunar parameters are based of the standardized IAU2000 Moon ellipsoid. GDAL (Geospatial Data Abstraction Library) was used to modify and test the accuracy of datasets before integrating into the application. Our high-resolution global elevation model was compared with the LRO LOLA DEM elevation values and tested to ensure accuracy. Celestial Mapping System has several potential use cases for NASA including subsurface lava tubes visualization and analysis, soil analysis, resource visualization and representation on 3D globe.

GIS system↗

DOE OSTI2020

Addition of Chloroform in a Solvent-in-Salt Electrolyte: Outcomes in the Microscopic Dynamics in Bulk and Confinement

Solvent-in-salt electrolytes (SISEs) are a promising alternative to the electrolytes currently used in commercial devices. Despite the SISEs’ advantages, their utilization is not yet realized due to the poor mobility of their chemical species. Here, we explore this problem by adding chloroform to a SISE formed by acetonitrile and a Li-salt. First, we performed illustrative cycling experiments to highlight the potential of this approach. Then, we focused on the description of the microscopic dynamics of the electrolytes and exposed the relevant aspects to be considered for their optimal performance. While the conductivity at low temperatures may be enhanced by the addition of chloroform, only subtle changes occur at room temperature. As revealed by molecular dynamics simulations and quasielastic neutron scattering (QENS) experiments, this effect is related to the preservation of the structure expected for a highly concentrated solution and promotion of the formation of ionic aggregates. These outcomes occur despite the increase in the overall mobility of the chemical species. The dynamics of the electrolytes in porous carbon was also investigated using QENS. In these circumstances, low concentrations of chloroform lead to diffusivities of the molecular species higher than those observed for the bulk electrolytes. As chloroform’s concentration increases, no further changes in the diffusivities are observed. Nonetheless, chloroform is mostly immobilized on the carbon surfaces and this behavior may be intensified at compositions closer to the eutectic mixture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Anion Coordination Improves High-Temperature Performance and Stability of NaPF 6 -Based Electrolytes for Supercapacitors

Electrolyte stability can be improved by incorporating complexing agents that bind key decomposition intermediates and slow down decomposition. We show that hexamethyl-phosphoramide (HMPA) extends both the thermal stability threshold of sodium hexafluorophosphate (NaPF 6 ) in dimethoxyethane (DME) electrolyte and the cycle life of double-layer capacitors. HMPA forms a stable complex with PF 5 , an intermediate in PF 6 anion thermal degradation. Unbound, this intermediate leads to autocatalytic degradation of the electrolyte solution. The results of electrochemical impedance spectroscopy (EIS) and galvanostatic cycling measurements show large changes in the cell without the presence of HMPA at higher temperatures (≥60 °C). Fourier transform infrared spectroscopy (FTIR) on the liquid and gas phase of the electrolyte shows without HMPA the formation of measurable amounts of PF 5 and HF. The complimentary results of these measurements proved the usefulness of using Lewis bases such as HMPA to inhibit the degradation of the electrolyte solution at elevated temperatures and potentially lead to improve cycle life of a nonaqueous capacitor. The results showed a large increase in capacitance retention during cycling (72% retention after 750,000 cycles). The results also provide evidence of major decomposition processes (0% capacitance retention after 100,000 cycles) that take place at higher temperatures without the additive of a thermal stability additive such as HMPA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2003

Rapid Technology Assessment via Unified Deployment of Global Optical and Virtual Diagnostics

This paper discusses recent developments in rapid technology assessment resulting from an active collaboration between researchers at the Air Force Research Laboratory (AFRL) at Wright Patterson Air Force Base (WPAFB) and the NASA Langley Research Center (LaRC). This program targets the unified development and deployment of global measurement technologies coupled with a virtual diagnostic interface to enable the comparative evaluation of experimental and computational results. Continuing efforts focus on the development of seamless data translation methods to enable integration of data sets of disparate file format in a common platform. Results from a successful low-speed wind tunnel test at WPAFB in which global surface pressure distributions were acquired simultaneously with model deformation and geometry measurements are discussed and comparatively evaluated with numerical simulations. Intensity- and lifetime-based pressure-sensitive paint (PSP) and projection moire interferometry (PMI) results are presented within the context of rapid technology assessment to enable simulation-based R&D.

Jordan, Jeffrey D.↗

DOE OSTI2022

Large-format battery anodes comprising silicon particles

Large-scale anodes containing high weight percentages of silicon suitable for use in lithium-ion energy storage devices and batteries, and methods of manufacturing the same, are described. The anode material described herein can include a film cast on a current collector substrate, with the film including a plurality of active material particles and a conductive polymer membrane coated over the active material particles. In some embodiments, the conductive polymer membrane comprises polyacrylonitrile (PAN). The method of manufacturing the anode material can include preparation of a slurry including the active material particles and the conductive polymer material, casting the slurry on a current collector substrate, and subjecting the composite material to drying and heat treatments.

25 ENERGY STORAGE↗

DOE OSTI2024

Large-format battery anodes comprising silicon particles

Evans, Tyler↗

DOE OSTI2026

Modern insights into the mechanisms of neptunium oxalate decomposition

Neptunium oxalate (Np(C 2 O 4 ) 2 ·6H 2 O) is a historically relevant solid phase used in nuclear processing as a precursor for neptunium dioxide (NpO 2 ). Although Np oxalate has been synthesized and used for NpO 2 production for decades, the thermal decomposition mechanism of this phase remains poorly understood and has not been evaluated in over 30 years. Conflicting reports in historical literature suggest either a direct conversion from anhydrous oxalate to NpO 2 or a decomposition that includes the formation of Np carbonate or oxidized Np intermediate phases. In this work, we reexamine the decomposition pathway of Np(C 2 O 4 ) 2 ·6H 2 O using thermal analysis coupled with evolved gas analysis and temperature-dependent Raman spectroscopy to elucidate decomposition mechanisms and intermediate phases using modern analytical techniques. Thermal analysis revealed a three-stage decomposition process, including dehydration below 200 °C, oxalate breakdown between 170 and 370 °C, and NpO 2 formation by 500 °C. However, an unidentified plateau in the thermal data was observed during measurements. Raman spectroscopy confirmed the stages of decomposition, and in the analysis of potential intermediate phases, no carbonate phases or Np 2 O 5 were identified. Raman data suggest that residual oxalate or nonstoichiometric oxide are present during decomposition before pure NpO 2 is formed. These findings clarify aspects of the Np oxalate decomposition mechanism and address longstanding discrepancies in the literature, with a specific focus on Np-specific materials chemistry.

Lawson, Kathryn M. [Oak Ridge National Laboratory ↗

DOE OSTI2022

Sonochemical oxidation and stabilization of liquid elemental mercury in water and soil

Over 3000 mercury (Hg)-contaminated sites worldwide contain liquid metallic Hg [Hg(0) 1 ] representing a continuous source of elemental Hg(0) in the environment through volatilization and solubilization in water. Currently, there are few effective treatment technologies available to remove or sequester Hg(0) 1 in situ. We investigated sonochemical treatments coupled with complexing agents, polysulfide and sulfide, in oxidizing Hg(0) 1 and stabilizing Hg in water, soil and quartz sand. Results indicate that sonication is highly effective in breaking up and oxidizing liquid Hg(0) 1 beads via acoustic cavitation, particularly in the presence of polysulfide. Without complexing agents, sonication caused only minor oxidation of Hg(0) 1 but increased headspace gaseous Hg(0) g and dissolved Hg(0) aq in water. However, the presence of polysulfide essentially stopped Hg(0) volatilization and solubilization. As a charged polymer, polysulfide was more effective than sulfide in oxidizing Hg(0) 1 and subsequently stabilizing the precipitated metacinnabar (β-HgS) nanocrystals. Sonochemical treatments with sulfide yielded incomplete oxidation of Hg(0) 1 , likely resulting from the formation of HgS coatings on the dispersed µm-size Hg(0) 1 bead surfaces. Sonication with polysulfide also resulted in rapid oxidation of Hg(0) 1 and precipitation of HgS in quartz sand and in the Hg(0) 1 -contaminated soil. This research indicates that sonochemical treatment with polysulfide could be an effective means in rapidly converting Hg(0) 1 to insoluble HgS precipitates in water and sediments, thereby preventing its further emission and release to the environment. We suggest that future studies are performed to confirm its technical feasibility and treatment efficacy for remediation applications.

36 MATERIALS SCIENCE↗