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NASA NTRS2012

Calculating Soil Wetness, Evapotranspiration and Carbon Cycle Processes Over Large Grid Areas Using a New Scaling Technique

Soil wetness typically shows great spatial variability over the length scales of general circulation model (GCM) grid areas (approx 100 km ), and the functions relating evapotranspiration and photosynthetic rate to local-scale (approx 1 m) soil wetness are highly non-linear. Soil respiration is also highly dependent on very small-scale variations in soil wetness. We therefore expect significant inaccuracies whenever we insert a single grid area-average soil wetness value into a function to calculate any of these rates for the grid area. For the particular case of evapotranspiration., this method - use of a grid-averaged soil wetness value - can also provoke severe oscillations in the evapotranspiration rate and soil wetness under some conditions. A method is presented whereby the probability distribution timction(pdf) for soil wetness within a grid area is represented by binning. and numerical integration of the binned pdf is performed to provide a spatially-integrated wetness stress term for the whole grid area, which then permits calculation of grid area fluxes in a single operation. The method is very accurate when 10 or more bins are used, can deal realistically with spatially variable precipitation, conserves moisture exactly and allows for precise modification of the soil wetness pdf after every time step. The method could also be applied to other ecological problems where small-scale processes must be area-integrated, or upscaled, to estimate fluxes over large areas, for example in treatments of the terrestrial carbon budget or trace gas generation.

Sellers, Piers↗

NASA NTRS2012

Method and system for efficient video compression with low-complexity encoder

Disclosed are a method and system for video compression, wherein the video encoder has low computational complexity and high compression efficiency. The disclosed system comprises a video encoder and a video decoder, wherein the method for encoding includes the steps of converting a source frame into a space-frequency representation; estimating conditional statistics of at least one vector of space-frequency coefficients; estimating encoding rates based on the said conditional statistics; and applying Slepian-Wolf codes with the said computed encoding rates. The preferred method for decoding includes the steps of; generating a side-information vector of frequency coefficients based on previously decoded source data, encoder statistics, and previous reconstructions of the source frequency vector; and performing Slepian-Wolf decoding of at least one source frequency vector based on the generated side-information, the Slepian-Wolf code bits and the encoder statistics.

Chen, Jun↗

NASA NTRS2021

Goddard Latent Heating Retrieval Algorithm for TRMM and GPM

The Goddard Convective-Stratiform Heating (CSH) algorithm has been used to retrieve latent heating (LH) associated with clouds and cloud systems in support of the Tropical Rainfall Measuring Mission (TRMM) and Global Precipitation Measurement (GPM) mission. The CSH algorithm requires the use of a cloud-resolving model (CRM) to simulate LH profiles to build look-up tables (LUTs). In this paper we describe the current V6 CSH and its differences/similarities versus the previous V5 CSH. Long-term CRM simulations are conducted to identify the impact of CRM resolution and the convective-stratiform separation method on LH structure/profiles. The TRMM and GPM Combined algorithm derived surface rainfall rates and their associated precipitation properties are the input to the CSH algorithm. Since there is no direct measurement of LH structure, the performance of the CSH V6 algorithm is examined by comparing its vertically-integrated heating (or equivalent surface rainfall rate) against the surface rainfall rate derived from the TRMM/GPM Combined algorithm. The results suggest the CSH three-month and zonal mean equivalent surface rain rates are in good agreement with the Combined rates over the ITCZ region; the agreement is best over ocean. CSH three-month and zonal mean equivalent surface rain rates are larger than the Combined rates over land in both the tropics and sub-tropics. CSH three-month mean equivalent surface rainfall rates also have local differences with the Combined rates that can be smoothed by area averaging to larger horizontal resolutions (from the CSH standard grid of 0.25° × 0.25° to 0.5° × 0.5° or 1.0° × 1.0°). CSH equivalent surface rainfall rates have more light rain rates but less larger rain rates compared to the GPM Combined surface rain rates.

Latent heating retrieval↗

NASA NTRS2021

Pre-Flight Assessment of Xenon Propellant Usage and Usage Uncertainty for the Psyche Mission

NASA’s Psyche mission will launch in 2022 and begin a 3.6-year cruise to the metallic asteroid Psyche, the largest metal asteroid in the solar system. All primary propulsion will be done with the flight-proven SPT-140 electric propulsion subsystem. The Psyche mission will feature the first use of Hall thrusters for a NASA mission, and the first use of Hall thrusters beyond cis-lunar space, which has presented some unique challenges. In this paper we describe the Psyche propellant feed system architecture, expected propellant usage for the mission, propellant gauging requirements, and challenges associated with propellant gauging. Data from two recent Maxar electric orbit-raising missions with SPT-140 thrusters are reviewed and used to assess in-flight performance. We develop a pressure-volume-temperature gauging method that incorporates the propellant temperature distributions observed in the flight data, and use this method to provide an improved quantitative understanding of in-flight propellant consumption rates and their uncertainties. The results are in excellent agreement with the results of standard Maxar gauging methods and we determine a propellant usage uncertainty of ± 7.1% 3σ based on flight telemetry. Additionally, we demonstrate that the bookkeeping method of propellant gauging accurately predicts the tank pressure flight data. This work has led to design changes in the Psyche spacecraft avionics that will further improve propellant gauging uncertainties, which is particularly important for later phases of the mission. Finally, we statistically combine the predicted propellant mass uncertainties from the two gauging methods and demonstrate that the system will meet the mission requirements for propellant uncertainty. Together, all of this work provides confidence that the Psyche mission can be successfully completed within the existing propellant budget and propellant tank capacity.

Baldwin, Jeff↗

DOE OSTI2020

Rapid Memory Footprint Access Diagnostics

Footprint and reuse distance measure temporal locality and therefore do not capture the significance of access patterns (spacial locality). A strided access pattern has the largest possible footprint but usually has the best performance. To highlight exposed memory latency, we separate footprint into strided (prefetchable) and irregular (non-prefetchable) access components and calculate the growth rate of each. To rapidly compute these footprint access diagnostics, we present two methods, whole-program and precise. Current footprint analyses can cause 200× or more slowdown with realistic inputs and are therefore impractical. Our whole-program method reduces the overhead to 10% by computing upper bounds, but still yields inter-procedural insight through a call path profile. Our precise method uses additional static analysis and profiling to refine the upper bounds for intra-procedural loop nests. We evaluate our approaches using benchmarks that vary access patterns (strided \vs unpredictable), sparsity (all words in a cache line \vs some), and reuse (varying and repeated accesses per element). Notably, for loop nests with unpredictable accesses, the precise method's accuracy is within 10% of ideal. The whole-program method has sufficient accuracy to diagnose bottlenecks.

data locality, memory footprint, footprint access ↗

NASA NTRSDate not supplied

Sleep, Sleepiness, and Performance Across Three In-Flight Bunk Rest Opportunities

Introduction: Airline pilots are required to take a rest break in a bunk during long-haul flights in an effort to reduce sleepiness during critical phases of flight. It is unclear, however, whether each rest break affords equal opportunity for sleep. We aimed to characterize sleep, sleepiness, and performance outcomes across three in-flight rest breaks during long-haul flights. Methods: Thirty-seven pilots wore actiwatches and completed sleep diaries for approximately two weeks while flying a variety of long-haul routes (n=126 flights). Self-reported in-flight bunk rest (BR) periods were used to set rest intervals and sleep was estimated within these intervals using actigraphy software (wake threshold set to medium). Pilots provided Karolinska Sleepiness Scale ratings (KSS) and performed a 5-minute psychomotor vigilance task (PVT) before landing. A linear mixed-effects model with participant included as a random effect and allowed to vary by intercept was used to assess differences between BR opportunities. Results : The majority (97%, n=122) of bunk rest periods contained sleep (as estimated by actigraphy). The mean (+/- standard deviation) sleep duration for the first, middle, and third BR opportunity was 152.8 (69.7), 149.2 (44.1), 125.2 (44.9) minutes, respectively. There was a significant effect of BR opportunity for sleep duration (F2,54 = 3.747, p=.03) and KSS (F2,44 = 7.869, p=.001). Bonferroni adjusted planned pairwise contrasts revealed that pilots using the third BR obtained significantly less sleep than in the first BR (p=.029). KSS ratings prior to landing were higher for the third BR compared to both the first (p=.001) and middle BR (p=.017). There were no significant differences for PVT speed or lapses (all p>05). Conclusion: These results suggest that the last rest break is associated with shorter sleep, lower alertness, and no differences in performance relative to the other rest breaks. Further analysis is required to determine whether the higher KSS ratings following the third rest break are associated with sleep inertia, or whether other factors may be involved.

sleepiness↗

DOE OSTI2022

Bayesian estimation of the $S$ factor and thermonuclear reaction rate for 16 O(p, γ) 17 F

The 16 O(p, γ) 17 F reaction is the slowest hydrogen-burning process in the CNO mass region. Its thermonuclear rate sensitively impacts predictions of oxygen isotopic ratios in a number of astrophysical sites, including AGB stars. The reaction has been measured several times at low bombarding energies using a variety of techniques. The most recent evaluated experimental rates have a reported uncertainty of about 7.5% below 1 GK. However, the previous rate estimate represents a best guess only and was not based on rigorous statistical methods. We apply a Bayesian model to fit all reliable 16 O(p, γ) 17 F cross section data, and take into account independent contributions of statistical and systematic uncertainties. The nuclear reaction model employed is a single-particle potential model involving a Woods-Saxon potential for generating the radial bound state wave function. The model has three physical parameters, the radius and diffuseness of the Woods-Saxon potential, and the asymptotic normalization coefficients (ANCs) of the final bound state in 17 F. Here, we find that performing the Bayesian S -factor fit using ANCs as scaling parameters has a distinct advantage over adopting spectroscopic factors instead. Based on these results, we present the first statistically rigorous estimation of experimental 16 O(p, γ) 17 F reaction rates, with uncertainties (±4.2%) of about half the previously reported values.

6 ≤ A ≤ 19↗

DOE OSTI2017

Solvothermal synthesis, electromagnetic and electrochemical properties of jellylike cylinder graphene-Mn{sub 3}O{sub 4} composite with highly coupled effect

Jellylike cylinder graphene-Mn{sub 3}O{sub 4} composite with highly coupled effect was successfully synthesized by a simple solvothermal process. Without using toxic reducing agent and expensive equipment, this method is environmental compatible and suitable for low cost mass production. High capacitance Mn{sub 3}O{sub 4} nanoparticles are homogeneously anchored on excellent conductivity graphene framework and a growth mechanism is hypothesized. Excellent electron conductivity and unique structure of Mn{sub 3}O{sub 4}-graphene composite give rise to various applications such as microwave absorber and electrode material. As a microwave absorber, the composite exhibits lowest reflection loss of −14.2 dB in the frequency range of 2–18 GHz. Good microwave absorption performance is due to the structure of the composite where conductive channels form between nano sized Mn{sub 3}O{sub 4} and high conductivity graphene with defects and dangling bonds. As for electrochemical property, Mn{sub 3}O{sub 4}-graphene composite with coupled effect shows excellent performance with highest specific capacitance of 246.7 F g{sup −1} in saturated K{sub 2}SO{sub 4} at a scan rate of 5 mV s{sup −1}. Good electrochemical property is also attributed to the structure with high utilization of Mn{sub 3}O{sub 4}, fast charge carrier transmission, and excellent electronic conductivity. This composite shows a promising application in absorbing materials and electrodes. - Graphical abstract: Graphene-Mn{sub 3}O{sub 4} composite. Display Omitted - Highlights: • Strongly coupled graphene-Mn{sub 3}O{sub 4} composite is synthesized by a solvothermal method. • Excellent microwave absorption property is ascribed to the composite structure. • Good capacitance performance is attributed to the structure and physical property. • The composite shows promising application in absorbing material, and electrode.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1999

The Effect of Penetration Depth on Thermal Contrast of NDT by Thermography

Nondestructive evaluation by Thermography (TNDE) is generally classified into two categories, the passive approach and the active approach. The passive approach is usually performed by measuring the natural temperature difference between the ambient and the material or structure to be tested. The active approach, on the other hand, requires the application of an external energy source to stimulate the material for inspection. A laser, a heater, a hot air blower, a high power thermal pulse, mechanical, or electromagnetic energy may provide the energy sources. For the external heating method to inspect materials for defects and imperfection at ambient temperature, a very short burst of heat can be introduced to one of the surfaces or slow heating of the side opposite to the side being observed. Due to the interruption of the heat flow through the defects, the thermal images will reveal the defective area by contrasting against the surrounding good materials. This technique is called transient Thermography, pulse video Thermography, or thermal wave imaging. As an empirical rule, the radius of the smallest defect should be at least one to two times larger than its depth under the surface. Thermography is being used to inspect void, debond, impact damage, and porosity in composite materials. It has been shown that most of the defects and imperfection can be detected. However, the current method of inspection using thermographic technique is more of an art than a practical scientific and engineering approach. The success rate of determining the defect location and defect type is largely depend on the experience of the person who operates thermography system and performs the inspection. The operator has to try different type of heat source, different duration of its application time, as well as experimenting with the thermal image acquisition time and interval during the inspection process. Further-more, the complexity of the lay-up and structure of composites makes it more difficult to determine the optimal operating condition for revealing the defects. In order to develop an optimal thermography inspection procedure, we must understand the thermal behavior inside the material subjected to transient heat in order to interpret the thermal images correctly. Fabrication of finite element models of characteristic defects in composite materials subjected to transient heat will enable the development of appropriate procedure for thermography inspection. Design of phantom defects could be modeled and behavior characterized prior to physically building these test parts. Since production of phantom test parts can be very time consuming and laborious, it is important to design good representative defects.

Chu, Tsuchin Philip↗

DOE OSTI2024

Understanding the heat generation mechanisms and the interplay between joule heat and entropy effects as a function of state of charge in lithium-ion batteries

The thermal performance of lithium-ion battery cells is critical for ensuring their safe and reliable operation across various applications. In this study, we employed an isothermal calorimetry method to investigate the heat generation of commercial 18650 lithium-ion battery fresh cells during charge and discharge at different current rates, ranging from 0.05C to 0.5C, and across various temperatures: 20 °C, 30 °C, 40 °C, and 50 °C. Our findings revealed a direct correlation between heat generation and current rates, indicating that higher current rates lead to increased heat generation within the cells. Conversely, we observed that heat generation remained relatively stable as the temperature rose, suggesting that temperature changes within this range may not significantly impact the heat generation of fresh cells during typical operations. Furthermore, our study explored irreversible heat generation, which depends on the applied current and overpotential, using the galvanostatic intermittent titration technique at 0.05C–0.5C and 30 °C. Additionally, electrochemical impedance spectroscopy was performed on the same cells during charge and discharge at 20 °C, 30 °C, and 40 °C to analyze cell impedance. Finally, our results indicated a consistent dependence of impedance on the state of charge and depth of discharge, with a significant increase in impedance observed at the end of the discharge process.

25 ENERGY STORAGE↗

DOE OSTI2016

Assessing Gaseous Hydrogen Assisted Fatigue Crack Growth Susceptibility of Pipeline Steel Weld Fusion Zones and Heat Affected Zones

The objective of this work was twofold: (1) measure reliable fatigue crack growth relationships for X65 steel and its girth weld in high-pressure hydrogen gas to enable structural integrity assessments of hydrogen pipelines, and (2) evaluate the hydrogen accelerated fatigue crack growth susceptibility of the weld fusion zone and heat-affected zone relative to the base metal. Fatigue crack growth relationships (da/dN versus ΔK) were measured for girth welded X65 pipeline steel in high pressure hydrogen gas (21 MPa) and in air. Hydrogen assisted fatigue crack growth was observed for the base metal (BM), fusion zone (FZ), and heat-affected zone (HAZ), and was manifested through crack growth rates reaching nearly an order of magnitude acceleration over rates in air. Addditionally, at higher ΔK values, crack growth rates of BM, FZ, and HAZ were coincident; however, at lower ΔK, the fatigue crack growth relationships exhibited some divergence with the fusion zone having the highest crack growth rates. These relative fatigue crack growth rates in the BM, FZ, and HAZ were provisional, however, since both crack closure and residual stress contributed to the crack-tip driving force in specimens extracted from the HAZ. Despite the relatively high applied R-ratio (R = 0.5), crack closure was detected in the heat affected zone tests, in contrast to the absence of crack closure in the base metal tests. Crack closure corrections were performed using the adjusted compliance ratio method and the effect of residual stress on K max was determined by the crack-compliance method. Crack-tip driving forces that account for closure and residual stress effects were quantified as a weighted function of ΔK and K max (i.e., K norm ), and the resulting da/dN versus K norm relationships showed that the HAZ exhibited higher hydrogen accelerated fatigue crack growth rates than the BM at lower K norm values.

36 MATERIALS SCIENCE↗

NASA NTRS1996

SSM/I Rain Retrievals Within a Unified All-Weather Ocean Algorithm

A new method for the physical retrieval of rain rates from satellite microwave radiometers is presented and compared to two other rainfall climatologies derived from satellites. The method is part of a unified ocean parameter retrieval algorithm that is based on the fundamental principles of radiative transfer. The algorithm simultaneously finds near-surface wind speed W, columnar water vapor V, columnar cloud liquid water L, rain rate R, and effective radiating temperature T(sub U) for the upwelling radiation. The performance of the algorithm in the absence of rain is discussed in Wentz, and this paper focuses on the rain component of the algorithm. A particular strength of the unified algorithm is its ability to 'orthogonalize' the retrievals so that there is minimum cross-talk between the retrieved parameters. For example, comparisons of the retrieved water vapor with radiosonde observations show that there is very little correlation between the water vapor retrieval error and rain rate. For rain rates from 1 to 15 mm/h, the rms difference between the retrieved water vapor and the radiosonde value is 5 mm. A novel feature of the rain retrieval method is a beamfilling correction that is based upon the ratio of the retrieved liquid water absorption coefficients at 37 GHz and 19.35 GHz. This ratio decreases by about 40% when heavy and light rain co-exist within the SSM/I footprint as compared to the case of uniform rain. This correction has the effect of increasing the rain rate when the spectral ratio of the absorption coefficients is small. Even with this beamfilling correction, tropical rainfall is still unrealistically low when the freezing level in the tropics (approx. 5 km) is used to specify the rain layer thickness. We restore realism by reducing the assumed averaged tropical rain layer thickness to 3 km, thereby accounting for the existence of warm rain processes in which the rain layer does not extend to the freezing level. Global rain rates are produced for the 1991 through 1994 period from observations taken by microwave radiometers (SSM/I) that are aboard two polar-orbiting satellites. We find that approximately 6% of the SSM/I observations detect measurable rain rates (R greater than 0.2 mm/h). Zonal averages of the rain rates show the peak at the intertropical convergence zone (ITCZ) is quite narrow in meridional extent and varies from about 7 mm/day in the winter to a maximum 11 mm/day in the summer. Very low precipitation rates (less than 0.3 mm/day) are observed in those areas of subsidence influenced by the large semipermanent anticyclones. In general, these features are similar to those reported in previously published rain climatologies. However, significant differences do exists between our rain rates and those produced by Spencer. These differences seem to be related to non-precipitating cloud water.

Wentz, Frank J.↗

DOE OSTI2024

Local convergence analysis of an inexact trust-region method for nonsmooth optimization

In Baraldi, we introduced an inexact trust-region algorithm for minimizing the sum of a smooth nonconvex function and a nonsmooth convex function in Hilbert space—a class of problems that is ubiquitous in data science, learning, optimal control, and inverse problems. Furthermore, this algorithm has demonstrated excellent performance and scalability with problem size. In this paper, we enrich the convergence analysis for this algorithm, proving strong convergence of the iterates with guaranteed rates. In particular, we demonstrate that the trust-region algorithm recovers superlinear, even quadratic, convergence rates when using a second-order Taylor approximation of the smooth objective function term.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Roadmap for the Application of Ion Beam Technologies to Challenges for the Advancement and Implementation of Nuclear Energy Technologies

The use of ion beams in interrogating materials performance for nuclear energy applications is advancing at a rapid rate. Ion irradiations have been proven to produce radiation effects data that are of direct relevance for understanding neutron-induced displacement damage. This development reflects significant and continued investment in infrastructure by the U.S. Department of Energy (DOE) as well as support of science and engineering research at universities and national laboratories. Application of ion beam irradiation methods to enhance the deployment of materials in reactors is in the spirit of the Gateway for Accelerated Innovation in Nuclear (GAIN) initiative sponsored by DOE to accelerate the deployment of innovation in the U.S. nuclear industry. Ion beam irradiation shows considerable promise for assisting in down selecting candidate materials for use in both current and advanced nuclear energy systems. Ion beams allow rapid achievement of materials damage levels not accessible by neutron irradiation in test reactors due to cost and time constraints. Ion beam studies provide data on the effects of irradiation under very specific conditions of temperature, radiation dose, and radiation dose rate that are difficult or impossible to achieve via reactor irradiation experiments. This data can be used to develop and validate detailed predictive radiation effects models for use in reactor materials research and development. Despite the current high state of the art and the maturity of quality assurance, there are still challenges to the deployment of ion beam data in support of reactor materials qualification. For the most part, these challenges arise from the lack of a detailed mechanistic understanding of potential difference between ion induced and neutron induced materials damage, which is exacerbated by difficulties in obtaining bulk physical and mechanical properties data from the micron-scale heavy ion irradiation depths. In particular, improved understanding of dose rate effects, as a function of temperature, are needed. This document offers a roadmap for the development and enhancement of current U.S. ion beam irradiation technologies within university and national laboratory settings, and especially for the deployment of new highly controlled in situ interrogation of materials during irradiation to provide dynamic and mechanistic data for model development. The status and capabilities of relevant U.S. ion beam facilities are summarized and recommended “best practices” for performing ion irradiations are described. The potential role of ion beam irradiations to assist the development and deployment of reactor materials is outlined. Key principles include developing methods for rapid and cost-effective materials selection and development, characterizing fundamental material response under irradiation, and developing a robust mechanistic understanding of microstructure evolution under irradiation (including development and validation of reliable predictive models for microstructure evolution).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1997

Bulk Growth of Wide Band Gap II-VI Compound Semiconductors by Physical Vapor Transport

The mechanism of physical vapor transport of II-VI semiconducting compounds was studied both theoretically, using a one-dimensional diffusion model, as well as experimentally. It was found that the vapor phase stoichiometry is critical in determining the vapor transport rate. The experimental heat treatment methods to control the vapor composition over the starting materials were investigated and the effectiveness of the heat treatments was confirmed by partial pressure measurements using an optical absorption technique. The effect of residual (foreign) gas on the transport rate was also studies theoretically by the diffusion model and confirmed experimentally by the measurements of total pressure and compositions of the residual gas. An in-situ dynamic technique for the transport rate measurements and a further extension of the technique that simultaneously measured the partial pressures and transport rates were performed and, for the first time, the experimentally determined mass fluxes were compared with those calculated, without any adjustable parameters, from the diffusion model. Using the information obtained from the experimental transport rate measurements as guideline high quality bulk crystal of wide band gap II-VI semiconductor were grown from the source materials which undergone the same heat treatment methods. The grown crystals were then extensively characterized with emphasis on the analysis of the crystalline structural defects.

Su, Ching-Hua↗

NASA NTRS1997

Bulk Growth of Wide Band Gap II-VI Compound Semiconductors by Physical Vapor Transport

Su, Ching-Hua↗

DOE OSTI2017

High-rate and long-life lithium-ion battery performance of hierarchically hollow-structured NiCo 2 O 4 /CNT nanocomposite

In this paper, 3D-transition binary metal oxides have been considered as promising anode materials for lithium-ion batteries with improved reversible capacity, structural stability and electronic conductivity compared with single metal oxides. Here, carbon nanotube supported NiCo 2 O 4 nanoparticles (NiCo 2 O 4 /CNT) with 3D hierarchical hollow structure are fabricated via a simple one-pot method. The NiCo 2 O 4 nanoparticles with interconnected pores are consists of small nanocrystals. When used as anode material for the lithium-ion battery, NiCo 2 O 4 /CNT exhibits enhanced electrochemical performance than that of Co 3 O 4 /CNT and NiO/CNT. Moreover, ultra-high discharge/charge stability was obtained for 4000 cycles at a current density of 5 A g –1 . The superior battery performance of NiCo 2 O 4 nanoparticles is probably attributed to the special structural features and physical characteristics, including integrity, hollow structure with interconnected pores, which providing sufficient accommodation for the volume change during charge/discharge process. Besides, the consisting of ultra-small crystals enhanced the utility of active material, and intimate interaction with CNTs improved the electron-transfer rate.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Control of Ionomer Distribution and Porosity in Roll-to-Roll Coated Fuel Cell Catalyst Layers

As fuel cells transition from the laboratory to industrial production for vehicles and other applications there is a need to understand how manufacturing processes impact the properties and, ultimately, the performance of materials. Roll-to-roll coating enables processing at meters per second speeds with physics that can be quite different from common laboratory coating methods. In this work, we have focused on the coating of catalyst layers for proton exchange membrane fuel cells. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die and gravure, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths. have focused on the coating of catalyst layers for proton exchange membrane fuel cells. Commonly, laboratory samples are prepared using spray coating or hand painting, which effectively coat many thin layers to achieve the desired catalyst layer thickness. This creates catalyst layers with uniform distributions of materials throughout the thickness of the full catalyst layer. In contrast, roll-to-roll methods, like slot die and gravure, coat the catalyst layer as a single wet film. As the film dries, ink constituents are able to segregate, leading to a heterogeneous distribution of materials through the thickness of the layer. It is also known that solvent and drying rate can affect the morphology of the catalyst layer. Thus, there is a need to understand how ink formulation and the drying process influence the distribution of materials and catalyst layer morphology. Here, we have explored the influence of solvent and drying rate on morphology of roll-to-roll coated catalyst layers. We show the development of the Kelvin probe method as a rapid screening technique for qualitative analysis of ionomer distribution. We also utilize nano X-ray computed tomography to visualize electrode structure and to quantify particle-size and pore-size distributions, thickness-dependent ionomer distribution, tortuosity, and effective transport properties. We find that solvent has a strong influence on ionomer distribution, with less of an effect on porosity. Conversely, drying temperature has a strong influence on porosity, but less influence on ionomer distribution. Finally, we utilize in situ fuel cell performance testing and other advanced diagnostics to quantify the impact of catalyst layer properties on fuel cell performance and demonstrate that roll-to-roll coating is capable of coating high performance catalyst layers in multi-meter lengths.

30 DIRECT ENERGY CONVERSION↗