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DOE OSTI2022

Operation Tumbler-Snapper

Operation Tumbler-Snapper began on April 1, 1952, when Able, a low-yield nuclear device, detonated 793 feet over the Frenchman Flat area of the Nevada Proving Ground. Able, the first of four airdrops conducted as the Tumbler phase of the Operation, provided the Department of Defense with reliable data on the relationship between height of burst and blast overpressure. Such information was vital to establishing the battlefield use of nuclear weapons. A final set of four tower detonations, the Snapper phase, provided the AEC and Los Alamos with diagnostic data on new weapon designs. Although the test series was nominally divided between the AEC and the DOD, this distinction held little meaning because two of the Tumbler effects tests, Charlie and Dog, employed experimental devices and all four of the Snapper tests involved effects experiments, including military troop maneuvers.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2025

Improving the Parameterization of Cloud and Rain Microphysics in E3SM using Novel Observationally-Constrained Bayesian Approach (Final Technical Report)

In this project, we sought to develop new cloud and rain microphysics frameworks within the Energy Exascale Earth System Model (E3SM). This work encompassed two primary avenues of research: 1) Further development of a Bayesian-based scheme called BOSS (Bayesian Observationally-constrained Statistical-physical Scheme) to represent cloud and rain microphysics, testing it in realistic high-resolution cloud models, and implementing it in E3SM; 2) Development of a methodology utilizing machine learning to enable computationally tractable use of tractable use of Markov chain Monte Carlo sampling for Bayesian parameter estimation in Earth system and cloud models. In this project, we adapted the BOSS microphysics scheme, originally formulated for rain-only, to include all liquid-phase microphysical processes for cloud and rain, in particular the processes that mediate between these two categories, for example the conversion from cloud to rain through collision and coalescence of drops. We constrained the scheme via comparison and testing against a detailed model that explicitly represents the evolution of cloud and rain particles, called a bin microphysics scheme.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Hydrochlorination of Uranium Dioxide in a Molten Salt Mixture - Phase 1: Tube Furnace Cross Flow Experiments

In 2023, Metatomic® Inc., a South Carolina based company, was awarded a Gateway for Advanced Innovation in Nuclear (GAIN) research voucher for a proposed series of experiments aimed at demonstrating the viability of a spent nuclear fuel (SNF) recycling process patented by Met atomic® Inc. For the GAIN voucher, Metatomic® Inc. selected Savannah River National Laboratory (SRNL) as a partner in executing the proposed proof-of-concept experiments. This report outlines the proof-of-concept experiments performed by SRNL for Metatomic® Inc. during Phase 1 (of 2) experimentation. The Phase 1 hydrochlorination experiments consisted of weighing UO2 into alumina crucibles with a eutectic mixture of NaCl and CsCl, heating the uranium/salt mixture to a varied temperature (550, 650, or 750 °C), and flowing anhydrous hydrogen chloride (AHCl) gas across the surface of the uranium-bearing molten salt mixture. The hydrochlorination process conditions were maintained for 4-5 hours and the percent conversion for each batch of UO2 was determined using a suite of analytical characterization techniques. The degree of UO2 conversion was found to be greatest at the highest tested temperature, ultimately achieving 32.9% conversion of UO2 to water soluble uranium-chloro species (e.g., UO2Cl2, UCl4) after exposure to AHCl for 4.25 hours at 750 °C.

Nguyen, Vinh T. [Savannah River National Laborator↗

DOE OSTI2019

Utah FORGE: Phase 2C Topical Report

This is the topical report that wraps up the work and results achieved during Utah FORGE Phase 2C. The zip file includes several folders containing (1) an overview; (2) the results; (3) the lessons learned; and (4) the conclusions. It also contains a folder containing appendices including (1) the updated permitting inventory; (2) the updated site characterization data inventory; (3) the updated conceptual geological model; and (4) the stakeholders engagement and outreach status.

15 GEOTHERMAL ENERGY↗

DOE OSTI2018

A GENERIC MICROGRID CONTROLLER

The main objective of this project was to develop and test a Generic Microgrid Controller (GMC) that provides (1) seamless islanding and reconnection of the microgrid, (2) efficient, reliable, and resilient operation of the microgrid with the required power quality, whether islanded or grid-connected, (3) existing and future ancillary services to the larger grid, (4) the capability for the microgrid to serve the resiliency needs of participating communities, (5) communication with the electric grid utility as a single controllable entity, and (6) increased reliability, efficiency and reduced emissions. The GMC developed under this project was designed to facilitate the deployment of microgrids, to be easily adapted to various microgrid configurations, and reduce up-front engineering costs associated with the design and development of microgrid controllers. Specifically, the GMC: 1. Provides a control structure amenable to accommodating an array of microgrid configurations and a portfolio of functional requirements; 2. Possesses a high level architecture that can readily be adopted by commercial suppliers; 3. Supports unlimited nesting of conforming microgrid control schemes; 4. Integrates into a full-featured Energy Management System (EMS) as a module. A select set of microgrids, operating a variety of microgrid configurations, served as “collaborating microgrid partners” in the project and assured thereby that the GMC developed under this program can readily be applied to microgrids of different sizes, and equipped with various resources, attributes, and equipment. Collaborating microgrid partners included the UCI Medical Center), the Port of Los Angeles, Port of Long Beach, and the Irvine Ranch Water District. The objectives of the project were achieved in two phases: (Phase I) Research, Development and Design (“Design”), and (Phase II) Testing, Evaluation, and Verification (“TEV”). In Phase I, specifications were developed for the GMC and a detailed test plan was established to test the functional requirements of the GMC. The GMC addresses two core functions, transition and dispatch, as well as several optional higher level functions such as economic dispatch, and renewable and load forecasting.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Zero Emission Cargo Transport (ZECT) II Demonstration: South Coast Air Quality Management District (Final Report)

The South Coast Air Quality Management District (South Coast AQMD), California Air Resources Board (CARB) and Southern California Association of Governments (SCAG) — the agencies responsible for preparing the State Implementation Plan required under the federal Clean Air Act — have agreed that attainment of federal air quality standards for the region will require a transition to the broad use of zero and near-zero emission energy sources in cars, trucks and other equipment. Accordingly, the 2012 South Coast AQMD Air Quality Management Plan, the SCAG 2012 Regional Transportation Plan, and the “Vision for Clean Air: A Framework for Air Quality and Climate Control Planning” all identify the need to immediately enact a phasing in of zero and near-zero emission technologies to meet air quality goals. In 2014, South Coast AQMD was awarded grant funding under the US Department of Energy Zero Emission Cargo Transport (ZECT) II Demonstration program to develop and demonstrate zero-emission drayage trucks for goods movement operations between the Port of Los Angeles (POLA) and Port of Long Beach (POLB) near dock rail yards and warehouses: 1) development and demonstration of zero-emission fuel cell range extended electric drayage trucks and 2) development and demonstration of hybrid electric drayage trucks. The purpose of this project was to accelerate deployment of zero emission cargo transport technologies to reduce harmful diesel emissions, petroleum consumption and greenhouse gases in the surrounding communities along the goods movement corridors that are impacted by heavy diesel traffic and the associated air pollution. Between 2014 – 2024, six ZECT II zero-emission fuel cell drayage truck platforms, including fuel cell range extended and CNG hybrid trucks, were successfully designed, developed, integrated, built, tested, and demonstrated with drayage fleet operators in transportation corridors within areas of the South Coast AQMD jurisdiction in Southern California such as in and around POLA and POLB. Portable hydrogen refueling was deployed to support the fuel cell vehicles. The project had real-time improvement with on-going debugging and optimizations while the vehicles were under demonstration. All platforms demonstrated sufficient or excess power, torque, and energy to support 82,000lbs Gross Vehicle Weight Rating and gradeability to perform their daily duty cycles. Collectively, the trucks drove over 23,000 miles during their respective demonstration phases. The ZECT II project was the first of its kind to demonstrate the commercial viability that supported the additional technology breakthroughs for Class 8 zero emission trucks and validations as well as the regulatory basis for all the zero-emission regulation that we know today, such as the Innovative Clean Transit regulation, Advanced Clean Trucks and Clean Fleet regulations.

08 HYDROGEN↗

DOE OSTI2026

Combination and interpretation of differential Higgs boson production cross sections in proton-proton collisions at $ \sqrt{s}=13 $ TeV

Precision measurements of Higgs boson differential production cross sections are a key tool to probe the properties of the Higgs boson and test the standard model. New physics can affect both Higgs boson production and decay, leading to deviations from the distributions that are expected in the standard model. In this paper, combined measurements of differential spectra in a fiducial region matching the experimental selections are performed, based on analyses of four Higgs boson decay channels (γγ, ZZ$^{(*)}$, WW$^{(*)}$, and ττ) using proton-proton collision data recorded with the CMS detector at $ \sqrt{s}=13 $ TeV, corresponding to an integrated luminosity of 138 fb$^{−1}$. The differential measurements are extrapolated to the full phase space and combined to provide the differential spectra. A measurement of the total Higgs boson production cross section is also performed using the γγ and ZZ decay channels, with a result of $ {53.4}_{-2.9}^{+2.9}{\left(\textrm{stat}\right)}_{-1.8}^{+1.9}\left(\textrm{syst}\right) $ pb, consistent with the standard model prediction of 55.6 ± 2.5 pb. The fiducial measurements are used to compute limits on Higgs boson couplings using the κ-framework and the SM effective field theory.[graphic not available: see fulltext]

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

Distinguishing Models for Mixed Halide Lead Perovskite Photosegregation via Terminal Halide Stoichiometry

Photoinduced halide segregation in mixed halide hybrid perovskites [i.e., APb(I 1–x Br x ) 3 ] represents an intrinsic instability that impedes their commercialization. Resolving this issue requires developing a microscopic understanding of the phenomenon. Key to this is distinguishing existing models of halide photosegregation by comparing their corresponding predictions to experiment. In this work, we test the temperature dependency of predicted perovskite terminal stoichiometries (x terminal ), following photosegregation, in single and double cation mixed halide perovskites. Our results show a general temperature invariance of x terminal . This largely supports the idea that band gap difference between parent and halide-segregated perovskite phases drives photosegregation. Beyond this, careful examination of temperature- and halide composition-dependent emission energies suggests an alternative explanation for the enhanced photostability of mixed cation/mixed halide perovskites, linked to band gap energy differences between parent and phase-segregated perovskite phases. Together, our results make inroads in clarifying the microscopic origin of mixed halide perovskite photosegregation and pave the way toward approaches that stabilize their use in applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

BOPTest As a Platform for Building Controls and Grid-Interactive Buildings Workforce Training

Building automation and controls are becoming increasingly complex with the emergence of Grid Integrated Efficient Buildings (GEBs) as well as new highly efficient sequences of operation and data-driven control schemes. However, there remains a significant gap in hands-on training opportunities for building operators and technicians to gain practical experience with advanced control systems in a low-risk environment. This paper presents BOPTEST (Building Optimization Performance Test) as a suitable platform for workforce training in building controls and GEB technologies. BOPTEST provides a suite of standardized building simulation test cases with a REST API, real-time control interfaces through BACnet, semantic models connecting users to building data, and built-in calculation of control metrics and performance indicators. The platform enables trainees to interact with virtual buildings using industry-standard protocols while learning how to implement and innovate control strategies. The training platform is designed to offer a structured and interactive learning experience for building engineers, helping them effectively develop, learn, and retain skills in fault identification, troubleshooting, and correction. The workflow is divided into three main phases: 1) Setup, 2) Exercise, and 3) Review, each comprising specific activities performed by either the instructor or the student. Initial pilot training sessions have yielded positive feedback from instructors and participants and demonstrates that BOPTEST effectively fills an industry need for a low-risk training resource via simulation of real building control systems, allowing trainees to gain practical experience before working in the field. The platform's ability to provide immediate performance feedback while maintaining familiar industry interfaces makes it particularly suitable for workforce development programs. This work provides a replicable model for leveraging building simulation in control education and training.

Paul, Lazlo↗

DOE OSTI2017

SECARB Report on Post-Injection In-Situ Monitoring

The Southeast Carbon Sequestration Partnership Phase III Anthropogenic Test at Citronelle Field is the United States’ largest prototype of commercial CO 2 capture from a coal-fired power station and transportation, injection, storage and monitoring. This report focuses on the results of the post-injection monitoring period for the Anthropogenic Test. Monitoring methods include both direct and indirect measurements. The Class V Experimental Permit requires extensive monitoring of injected CO 2 at the surface and at deep and shallow depths. The safety, integrity and information objectives of the CO 2 monitoring plan are in place to: (1) create and sustain wellbore integrity; (2) assure safe CO 2 injection operations; (3) verify the location and migration of the injected CO 2 plume; and (4) monitor for any CO 2 leakage. A robust suite of monitoring approaches is utilized for the in-situ monitoring and include, pressure monitoring, various seismic surveys, pulsed neutron logging, reservoir fluid sampling and injection surveys. Data and observations collected using these monitoring methods will be used in the numerical model to inform the post-injection site care monitoring plan. This report describes actions pertaining to in situ monitoring at the Anthropogenic Test Site that were undertaken during the period of September 2014 to May 2016. These monitoring techniques include the acquisition of pressure data, seismic data, pulsed neutron capture logs, reservoir fluid sampling, and tracer gas monitoring. CO 2 injection operations began on August 20, 2012 and terminated on September 1, 2014.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Conceptual design for a blanket tritium extraction test stand

Tritium breeding is fundamentally required for a sustainable fusion fuel cycle, yet the technological readiness of blanket technology lags far behind other fusion systems. Breeder concepts are divided into solid and liquid media, where solid breeders typically rely on a sweep gas, such as helium, to carry away tritium from lithium containing ceramic materials, and liquid breeders produce tritium from lithium containing eutectics (e.g., PbLi) or molten salts (FLiBe). In each case, tritium must be harvested from the breeding medium. A promising method for tritium extraction is through a vacuum permeator, in which a concentration gradient from the tritium- containing fluid promotes diffusion through a membrane with high hydrogen permeability to the vacuum. This technology has been demonstrated for hydrogen gas systems using Pd and PdAg permeators, but relatively little work has been done to test tritium extraction from PbLi. A Tritium Extraction eXperimental (TEX) loop is being designed to test tritium extraction in a vacuum permeator configuration. The system design is such that it will allow the testing of tritium extraction from both helium and PbLi. A phased approach is being taken that will allow testing of small specimens for fundamental permeation measurements, to multi-meter component testing at near-prototypic conditions. A molten PbLi loop is challenging due to the toxic and explosive nature of Pb and Li, respectively, radiological concerns by introducing tritium, and high temperatures involved in such a system. In addition, PbLi corrosion is a significant issue at high temperatures (>400C). The TEX system will not employ a neutron source for volumetric production of tritium. Herein we present the design and methods used for 1) pumping PbLi, 2) introducing deuterium or tritium into the PbLi, 3) quantifying the amount of deuterium in the loop, 4) extracting deuterium and tritium, and 5) quantifying the total amount of extracted deuterium or tritium from the permeator. In addition, the safety design for operating such a system will be discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Status of the Measurement of Proton Scattering on Carbon Nuclei in EMPHATIC for Neutrino Flux Uncertainty Reduction

In long-baseline neutrino oscillation experiments, Monte Carlo (MC) simulations based on hadron interactions and decays are used to predict the neutrino flux. The 10%-level systematic uncertainty of the predicted neutrino fluxes from these simulations is dominated by uncertainties in hadron interaction cross sections due to limited hadron scattering data. EMPHATIC aims to reduce the neutrino flux uncertainty by providing additional data. Using a table-top-sized spectrometer located at the Fermilab Test Beam Facility (FTBF), its physics program includes precise measurements of hadron scattering and production cross sections at various beam momenta and target species that are relevant for GeV-scale neutrino production. Using simulation, we have developed a simple single-track reconstruction algorithm that has a momentum resolution of 3-4\%. We will demonstrate the progress in developing one of EMPHATIC’s first track reconstruction algorithms – an important step in making a new single-track forward scattering measurement (p + C $\rightarrow$ p + C at several beam momenta) using Phase 1 data collected between 2022 and 2023.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

BOPTEST as a Platform for Building Controls and Grid-Interactive Buildings Workforce Training

Paul, Lazlo↗

DOE OSTI2020

Radiological Recovery Logistics Tool - 20161

Argonne is building and testing a tool, the Radiological Recovery Logistics Tool (RRLT), that can be used during the response and recovery from a radiological or nuclear incident to effectively allocate appropriate commercial and public works equipment to mitigate, remove, and contain radiological contamination. The requirements for this tool - as well as development of the resulting software - is overseen by a steering committee of stakeholders from DHS's National Urban Security Technology Laboratory (NUSTL), the Federal Emergency Management Agency (FEMA), and the Environmental Protection Agency (EPA). One essential requirement is for RRLT to support the efficient and appropriate allocation of resources for a radiological response. Subsequent discussions between ANL and stakeholders have solidified the nature of this support to include identification of the types of resources to be allocated. The study reported in this paper has both factored fundamental concepts and connections out of this identification process and created a Knowledge Base detailing support goals, response scenarios, and efficacy information on dozens of equipment types. In short, RRLT will dynamically apply these findings to situational conditions surrounding contamination incidents. RRLT's Domain, the model of elements, ideas and relationships with which the tool will work, draws concepts from technical reports and stakeholder vocabularies to connect response goals and scenarios to types of equipment that offer utility towards those goals in those scenarios. RRLT's Knowledge Base will contain details on dozens of equipment types and facilitate the operator's discovery and consumption of these details most pertinent to a dynamically selected subset of goals. The core of its Domain Model is based on a report authored by this team. This report [1] contains a comprehensive list of proposed equipment to accomplish various missions or scenarios that might arise after a large-scale radiological contamination incident in an urban environment or critical infrastructure. The report divides potential response and recovery efforts into five support goals: Survey and monitoring of the contaminated area; Mitigation of received dose to first responders: Decontamination (gross and final) of buildings, vehicles, roadways, parks, and other surfaces: Waste management of solid waste generated during recovery operations: and Containment of wastewater and other waste generated during the response and recovery phases. RRLT's development is driven by use cases. A use case is an intention with which a user approaches the software. Use cases are grouped into delivery increments to schedule development, testing, and presentation to stakeholders. This model partitions the system into seven increments: User Arrival and Authentication, Search and Navigation, Equipment Recommendation, Plan Management, Content Management, and Expanded Access. Once a user 15 authenticated, RRLT will present the user with a dashboard that allows them to explore or search RRLT's content. The dashboard will also include a 'Plan' panel for collecting decisions and relevant observations about an incident at hand to facilitate development of an equipment list. RRLT will offer three general modes of access to items in the knowledge base: - Keyword search for direct discovery of items, - Navigation along predetermined paths from recovery goal towards equipment types, and - Interactive guidance towards equipment types by an autonomous software agent: the Equipment Recommendation Wizard. This presentation will detail progress in the development of the RRLT and also discuss opportunities for those interested in providing feedback on its content and functionality. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Navigating thermal stability intricacies of high-nickel cathodes for high-energy lithium batteries

High-nickel oxide cathodes, LiNi x M 1−x O 2 (x ≥ 0.8), are preferred in automotive lithium batteries, but they face thermal instability challenges. Inconsistent literature reports and unstandardized testing protocols further complicate quantitative assessments of the thermal stability of these cathodes. Here, we present here a statistical thermal analysis based on the differential scanning calorimetry measurements of 15 representative cathode materials with different compositions, morphologies and states of charge. The findings reveal that each cathode has a critical state of charge that defines its safe operating limit, which is affected by the metal–oxygen bond strength and surface reactivity. The thermal runaway temperature is dictated by the layered Li 1−x NiO 2 to LiNi 2 O 4 spinel-like phase transition, which is thermodynamically determined by the metal–oxygen bond covalency and kinetically influenced by the cation mixing and particle size. Raman spectroscopy is used to predict the thermal runaway temperature on the basis of the linear relationship between them. Finally, we propose a thermal stability index to quantify cathode thermal stability as a guide for developing safer high-nickel cathodes.

batteries↗

DOE OSTI2014

High-Current Cold Cathode Employing Diamond and Related Materials

The essence of this project was for diamond films to be deposited on cold cathodes to improve their emission properties. Films with varying morphology, composition, and size of the crystals were deposited and the emission properties of the cathodes that utilize such films were studied. The prototype cathodes fabricated by the methods developed during Phase I were tested and evaluated in an actual high-power RF device during Phase II. These high-power tests used the novel active RF pulse compression system and the X-band magnicon test facility at US Naval Research Laboratory. In earlier tests, plasma switches were employed, while tests under this project utilized electron-beam switching. The intense electron beams required in the switches were supplied from cold cathodes embodying diamond films with varying morphology, including uncoated molybdenum cathodes in the preliminary tests. Tests with uncoated molybdenum cathodes produced compressed X-band RF pulses with a peak power of 91 MW, and a maximum power gain of 16.5:1. Tests were also carried out with switches employing diamond coated cathodes. The pulse compressor was based on use of switches employing electron beam triggering to effect mode conversion. In experimental tests, the compressor produced 165 MW in a ~ 20 ns pulse at ~18× power gain and ~ 140 MW at ~ 16× power gain in a 16 ns pulse with a ~ 7 ns flat-top. In these tests, molybdenum blade cathodes with thin diamond coatings demonstrated good reproducible emission uniformity with a 100 kV, 100 ns high voltage pulse. The new compressor does not have the limitations of earlier types of active pulse compressors and can operate at significantly higher electric fields without breakdown.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Experimental Evaluation of Thermal Storage Performance of a Dual-Purpose Underground Thermal Battery

A geothermal heat pump (GHP) system is an energy-efficient building heating and cooling technology with great potential for reducing energy consumption and decarbonization. However, applications of GHP are still limited due to the high cost, of which 30% is related to the cost of installing the conventional vertical bore ground heat exchangers, which are usually installed in boreholes 60 meters deep. A dual-purpose underground thermal battery (DPUTB) has been developed to offer a low-cost ground heat exchanger with a built-in thermal storage capacity. The DPUTB innovatively integrates a shallow-bore ground heat exchanger (the outer tank), which can be installed in a borehole less than 6 m deep, with thermal energy storage (TES) (the inner tank). DPUTB has the potential to reduce the cost of a ground source heat pump system while allowing shifting the electric demand of the building served by the GHP system from peak to off-peak hours of the electric grid by charging and discharging the thermal storage. A lab-scale (1:125 in volume) DPUTB prototype was built. Phase change material (PCM) was added to increase the thermal storage capacity and maintain the supply water temperature from the TES within the desired range for direct cooling operation during the discharge period. As PCMs are critical to the TES performance of the DPUTB, this study compared the influence of different PCMs (including salt hydrate and organic PCMs) on the discharge performance of the DPUTB. The thermal State of Charge (SoC) of the DPUTB was used to compare the performance resulting from using different PCMs. Test results indicate that the organic PCM (Methyl Laurate) outperforms salt-hydrate PCMs due to a lower melting temperature and a narrower melting temperature range during the phase change process. The results of this study provide a guide for PCM selection and the optimal design of DPUTB.

Wang, Lingshi↗

DOE OSTI2023

Chromium Tolerant, Highly Active and Stable Electrocatalytic Internal Surface Coating for Cathode of Commercial SOFCs (Final Report)

This project is aimed to develop a chromium (Cr) tolerant, highly active, and stable coating layer on the internal surfaces of the porous composite cathode from commercially available SOFCs. Such coating layer was developed using the additive manufacturing process of Atomic Layer Deposition (ALD) and has been applied on the cathode consisting of either an electronic conductor of LaxSr 1-x MnyO 3-δ (LSM) or mixed ionic and electronic conducting La x Sr 1-x Co y Fe 1-y O 3-δ (LSCF). PI's work has demonstrated that the internal surface of cathode from the commercial cells, can be further tailored using ALD coating to dramatically enhance the cell performance. For instance, ALD layer consisting heterostructured nano composite of nano-Pt and nano-(Mn 0.8 Co 0.2 ) 3 O 4 oxide on the internal surface of porous LSM/YSZ cathode from SOFCs, has resulted in the large reduction of the cell polarizations resistance by up to 53%, and enormous increase of power density over 370%. For the cells with LSCF/Sm 2 O 3 doped CeO 2 (SDC) cathode, the conformal layer of nano-composite consisting of superjacent CoOx and subjacent minimum amount of Pt nano-grains has resulted in the power density enhancement by 126% for the large scale industry tubular cells at 750°C, and both the performance enhancement and nanostructure of the ALD layer are stable over ~ 2000 h continuous operation performed at industry test station. In the meanwhile, those ALD coating layer developed by PI's work is also inherently Cr-tolerant, and could act as physical barrier for preventing Cr diffusion into the cathode backbone, so as to mitigate the Cr poisoning effect on the cathode. In this project, the impact of Cr on the performance of those ALD coated commercial cells has been evaluated. Based on evolution of the cell performance, the ALD coating layer chemistry and ALD coating layer thickness has been optimized to maximize the overall Cr tolerance, cell power density and cell longevity. Different ALD coating has been applied onto the internal surface of LSM/YSZ and LSCF/SDC backbone respectively. The architecture/scaffold structures on the internal surface of different cathode, designed by this project, was catalogued and analyzed using High Resolution Transmission Electron Microscopy (HRTEM), and cell power/durability performance are assured via comprehensive electrochemical performance testing in the industry operation relevant conditions. The impact of the electrochemical operation current density, the water humidity, the cell operation temperature, and cell operation duration on the Cr tolerance of ALD coated cells has been systematically investigated. There is completely different nanostructure degradation mechanisms between LSM and LSCF cells induced by Cr contamination. For the LSCF/SDC baseline cell, With the Cr source, there is no apparent Sr surface segregation phase even for the baseline cell operated for 3000 h at 750 °C. With the Cr source, there is significant amorphous (SrCr)Ox phase accumulated in the original pore region. For the commercial baseline cells, Cr contaminants on the LSM electrode severely impacted the entire cell's electrochemical performance and nanostructure degradation. Those degradations include (1). Peak power density loss of 64 % after 109 h of operation. The dramatic increase in Rp (2). They are cracking at LSM/SSZ interface, LSM grains. SSZ remains intact but with (CrMn)Ox. By contrast, ALD coating (MnCo)Ox/Pt dramatically improves the Cr resistance, as follows (1). ALD-coated cell with a power density is 280-380 % of the baseline cell, depending on the ALD layer thickness. (2). For a cell with a 20 nm thick ALD layer, there is a large performance enhancement (> 200 % power density) induced by ALD coating of Cr-tolerant Mn 0.8 Co 0.2 Ox. (3). For a cell with a 20 nm thick ALD layer, after 168 h at 750 °C power density of the ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination for 109 h. The ALD coating on the internal surface of cathode developed by this project integrated multi-functions. Those multi-functions include (1). Dramatically improving the cell power density for the commercial cells; (2). Dramatically improving contamination resistance of the cathode, for being an excellent protection coating layer sealing off Cr contamination. (3). Dramatically increasing the cell longevity by potentially preventing the microstructure evolution and grain coarsening of the cathode. Overall, this project will provide a simple solution to simultaneously enhance power density and increase the reliability, robustness, and endurance of commercial SOFCs, over the entire operating temperature range of 650-800 °C. For the inherently functional SOFC, the ALD coating of LSM based cathode mitigate the Cr-contamination. Power density of ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination. In addition to SOFCs, the novel on-demand design approach and creation of multifunctional heterogeneous architecture on the electrode surface presented in this work opens further research for their application in other types of fuel cells, batteries, and sensors for which electrochemical reactions on the surface are similarly critical.

36 MATERIALS SCIENCE↗