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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Composite Overwrapped Pressure Vessels, A Primer

Due to the extensive amount of detailed information that has been published on composite overwrapped pressure vessels (COPVs), this document has been written to serve as a primer for those who desire an elementary knowledge of COPVs and the factors affecting composite safety. In this application, the word "composite" simply refers to a matrix of continuous fibers contained within a resin and wrapped over a pressure barrier to form a vessel for gas or liquid containment. COPVs are currently used at NASA to contain high pressure fluids in propulsion, science experiments, and life support applications. They have a significant weight advantage over all metal vessels but require unique design, manufacturing, and test requirements. COPVs also involve a much more complex mechanical understanding due to the interplay between the composite overwrap and the inner liner. A metallic liner is typically used in a COPV as a fluid permeation barrier. The liner design concepts and requirements have been borrowed from all-metal vessels. However, application of metallic vessel design standards to a very thin liner is not straightforward. Different failure modes exist for COPVs than for all-metal vessels, and understanding of these failure modes is at a much more rudimentary level than for metal vessels.

McLaughlan, Pat B.↗
NASA NTRSDate not supplied

BioSentinel: To the Moon or Beyond?

BioSentinel, an Artemis-1 secondary spacecraft, will carry a biology experiment into deep space for the first time in 50 years. A 6U CubeSat form factor was utilized for the spacecraft and included technologies newly developed or adapted for operations beyond Earth orbit. This is the maiden deep-space voyage for the radio, propulsion system, electrical power system, and BioSensor payload. The spacecraft carries onboard budding yeast, Saccharomyces cerevisiae, as an analog to human cells to test the biological response to deep space radiation. Flying a secondary payload beyond LEO comes with unique challenges with respect to trajectory uncertainty and mission operations planning. BioSentinel does not carry propulsion for trajectory maneuvers, so plans for Comms and Power need to be developed for all trajectories. The nominal plan is a lunar flyby followed by an insertion into Heliocentric orbit. However, some possible scenarios include lunar eclipses that could severely impact the power budget during that phase of the mission, while others could result in a “Retrograde” hyperbola at swingby resulting in the spacecraft traveling inward toward Earth or even towards a collision with the lunar surface. BioSentinel’s final trajectory will not be known until after launch and deployment so possible scenarios need to be planned for ahead of time. This paper discusses the operational scenarios that were planned for as well as the actual execution of the mission operations including: command pass scheduling with the Deep Space Network, selecting bandwidth limits, medium gain antenna versus low gain antenna usage, and conserving power prior to a lunar eclipse. Note: Artemis-1 is planned to launch in the Spring of 2022

BioSentinel↗
DOE OSTI2020

GeoRePORT Case Study Examples: Reporting Using the Geothermal Resource Portfolio Optimization and Reporting Technique (GeoRePORT)

The Geothermal Research Portfolio Optimization & Reporting Technique (GeoRePORT) was developed with funding from the United States Department of Energy's Geothermal Technologies Office (GTO) to assist in identifying and pursuing long-term investment strategies through the development of a resource reporting protocol. GeoRePORT provides scientists and non-scientists a comprehensive and quantitative means of reporting: (1) features intrinsic to geothermal sites (project grade) and, (2) maturity of the development (project readiness). Because geothermal feasibility is not determined by any single factor (e.g. temperature, permeability, permitting), a site's project grade and readiness are evaluated on twelve independent attributes pertaining to geological, technical, or socio-economic feasibility. In this paper, we present case studies illustrating how GeoRePORT can be used to compare geological, technical, and socio-economic attributes between geothermal systems. The consistent and objective assessment protocols used in GeoRePORT allow for comparison of project attributes across unique locations and geological settings. GeoRePORT case studies outline the geological, socio-economic and technical features of four individual geothermal sites: Coso, Chena, Dixie Valley, and White Sands Missile Range. The case studies presented herein illustrate the usefulness of GeoRePORT in evaluating project risk/return, identifying gaps in reported data, evaluating R&D impact, and gathering insights on successes/failures as applicable to future projects.

40 EE - Geothermal Technologies Office (EE-4G)↗
NASA NTRS2015

Beneficial Effects of Metabolic Supression for Adoptation and Survival in Space Environment

NASA in its plans to send humans to distant destination such as Mars faces the health and physiological performance problems caused by microgravity and space radiation. While most of the environmental conditions in spacecraft during flight can be made to mimic terrestrial conditions, microgravity cannot yet be managed. This space environmental factor has a major impact on the body’s biological system forcing alterations, in order to adapt to this new environment. Most space flight and ground-based studies suggest that prolonged exposure to microgravity leads to significant skeletal muscle atrophy, bone loss, and results in suppression of total metabolism. Due to microgravity, unloaded crewmembers lose up to 1.5% of their skeletal mass and 1.8% of bone strength each month during ISS missions. Remarkably many animals, including human-size bears, which are largely inactive during the 6 to 8 months of hibernation, show no loss in bone mass and much less muscle atrophy than would be anticipated over such a prolonged period of physical inactivity. This suggests that while in a suppressed metabolic state animals have unique natural mechanisms to prevent muscle disuse and bone atrophy. The molecular mechanisms underlying these important adaptations are not yet known. Radiation exposure is the second health hazard encountered during spaceflight that can cause radiation sickness, cancer or death. This study provides new evidence that metabolic activity levels play a critical role in radioprotection. Metabolic suppression, as an adaptive response of cells to minimize damage caused by radiation, enables cells to reduce cellular dysfunction and damage, and prolong their survival despite persistent oxidative stress. Thus mechanistic understanding of metabolism offers a means for sustaining astronauts in long-duration missions. The ultimate goals of this study are to demonstrate that induced metabolic suppression in animals and humans will profoundly reduce their sensitivity to the damaging effects of radiation and microgravity as well as other kinds of stresses caused by spaceflight. The beneficial effects of suppressed metabolism induced by different factors such as temperature, nutrition, and medications, will not only mitigate the most detrimental hazards of spaceflight but also radically reduce mission life support requirements and spaceflight logistics.

Galicia, E.↗
DOE OSTI2025

First observations of edge instabilities in strongly shaped negative triangularity plasmas on DIII-D

Throughout the 2023 DIII-D negative triangularity (NT) campaign, unexpected magnetic fluctuations indicative of an edge localized instability were observed in the majority of strongly shaped (–0.55 ≤ δ ≤ –0.45) discharges. Moreover, these same fluctuations were found to be absent in weaker NT plasma shapes. Based on a database study, three separate mode behaviors are observed based primarily on the edge safety factor and normalized plasma beta β N . The main regime is the bursty state, in which short (~5 ms) magnetic bursts occur every 5–10 ms. Each burst drives a small reduction in the edge electron temperature (T e ) as measured by electron cyclotron emissions (ECE), which then rapidly recovers between the bursts. The quiescent regime appears to have governing mechanics similar to the bursty regime, but with multiple unique mode signatures observed in the magnetics. These additional modes greatly reduce the bursty nature of the plasma. Finally, a saturated state is observed in a number of discharges, particularly at early time slices. The saturated regime is often short-lived (maximum 500 ms), but can have a large impact on the dynamics of the plasma edge region, causing significant drops in electron temperature as observed in the ECE diagnostic. 2D ECE imaging (ECE-I) is utilized, showing large kink-like perturbations localized near the last closed flux surface that extend into the SOL indicative of an external kink/peeling behavior. Additionally, evidence of phase mixing and observed tearing-parity perturbations localized near the edge rational surfaces is observed in the quiescent regime plasmas. As a result, the various modes do not appear to have a large impact on global confinement but may play a role in regulating the transport of the NT edge and the observed edge gradients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Subsurface Characterization of Hydraulic Fracture Test Site-2 (HFTS-2), Delaware Basin

Hydraulic Fracturing Test Site-2 (HFTS-2) is a field-based research experiment performed in the Wolfcamp Formation of the Permian (Delaware) Basin. This paper focuses on integration, advanced geological characterization, and 3D subsurface modeling of the comprehensive HFTS-2 dataset. The study showcases a multidisciplinary reservoir characterization approach that incorporates geology, petrophysics, geochemistry, geomechanics, microseismic, and subsurface engineering analysis. Subsurface characterization of organic-rich mudstone formations requires understanding complex hydraulic fracture network growth in relation to inherent lithology, geomechanical properties, and interaction with pre-existing natural fractures. This paper presents a characterization workflow incorporating pre- and post-stimulation subsurface data, unique to the HFTS-2 dataset. The study integrated: (1) rock properties from logs, cores, and thin sections; (2) natural and hydraulic fracture descriptions from cores and image logs; (3) local and regional stresses; (4) geomechanics; (5) microseismic; (6) fiber optic (FO) and bottomhole pressure gauge (BHPG) response; and (7) produced fluids analysis. During a stimulation treatment, creation of the stimulated rock volume (SRV) is influenced by several subsurface factors. Key contributing factors include structural context, stress conditions, lithology, facies architecture, pre-existing natural fractures, and geomechanical properties. The HFTS-2 subsurface data integration indicates that the SRV is comprised of a complex juxtaposition of hydraulic fracture swarms, as evidenced by image logs analysis, core description, and microseismic monitoring. The HFTS-2 microseismic event density was used to generate 3D heat maps that serve as a representative SRV footprint, corroborated by secondary datasets. These maps were further integrated with petrophysical and geomechanical characteristics, as well as responses from FO and BHPG, to estimate the lateral and vertical dimensions of the effective fractures. The geological characterization for the HFTS-2 dataset combined with 3D modeling for petrophysical and geomechanical properties provides a strong foundation for subsurface simulation and optimization studies. Downloaded from http://onepetro.org/URTECONF/proceedings-pdf/21URTC/1-21URTC/D011S005R001/2477501/urtec-2021-5243-ms.pdf/1 by Carol Worster on 28 February 2022 URTeC 5243 The workflow improved our understanding of HFTS-2 hydraulic fracture propagation and characteristics in relation to offset pressure depletion and interaction with pre-existing natural fractures. Analysis showed that fracture geometry varies by stage and by well, and a complex fracture network is generated with varying fracture density. The multidisciplinary workflow presented herein for integration and characterization serves as a foundation to evaluate completion efficiency and estimate areal and vertical stimulation and depletion extent for the project. Furthermore, the workflow and learnings can also be transferred to other unconventional plays.

58 GEOSCIENCES↗
NASA NTRS1977

Solution to the Delta vehicle second stage pogo problem

A discussion of the pogo phenomenon observed on the Delta launch vehicle second stage is presented. The pressure-fed engine and the high frequency of the oscillation (125 Hz) required unique analysis and extensive testing to support analysis detail. In addition, the need to continue a one vehicle per month launch rate required both an immediate interim and a timely long-term solution to the problem. The development and implementation of a program involving analysis, ground test, and flight instrumentation is described. An analytical model was developed and used to investigate both structural and propulsion system modifications. The factors which influenced the final suppression system selection, the analytical predictions for that system, and flight data which validate that system's effectiveness are presented.

Markowitz, M.↗
NASA NTRS1988

Deep-reasoning fault diagnosis - An aid and a model

The design and evaluation are presented for the knowledge-based assistance of a human operator who must diagnose a novel fault in a dynamic, physical system. A computer aid based on a qualitative model of the system was built to help the operators overcome some of their cognitive limitations. This aid differs from most expert systems in that it operates at several levels of interaction that are believed to be more suitable for deep reasoning. Four aiding approaches, each of which provided unique information to the operator, were evaluated. The aiding features were designed to help the human's casual reasoning about the system in predicting normal system behavior (N aiding), integrating observations into actual system behavior (O aiding), finding discrepancies between the two (O-N aiding), or finding discrepancies between observed behavior and hypothetical behavior (O-HN aiding). Human diagnostic performance was found to improve by almost a factor of two with O aiding and O-N aiding.

Yoon, Wan Chul↗
NASA NTRS1991

Low power DIPS design for NASA missions

Conceptual designs of low power dynamic isotope power systems (DIPS) for NASA's future deep space missions are being developed to characterize the power system's unique features in the 0.5-1.0 kilowatt-electric (kWe) range. The August 1990 Mariner Mark II spacecraft design was used for the spacecraft integration study. One basic design with slight mission specific variations was developed for the Cassini, Comet Nucleus Sample Return, and Outer Planet Orbiter Probe missions. A low power DIPS flight unit offers comparable specific power values to the MOD-RTG unit with a factor-of-three improvement in radioisotope fuel requirements. This was accomplished by fully exploiting the dynamic power conversion technology available in the DIPS program.

Johnson, Richard A.↗
NASA NTRS1996

A Numerical Study of Self-Similarity in a Turbulent Plane Wake Using Large-Eddy Simulation

Turbulent wakes are known to develop self-similarly sufficiently far downstream from obstacles that generate them. It has long been assumed that the spreading rate of the wake in the self-similar regime is independent of the details of the body generating the wake, being dependent only on the total drag (or momentum deficit). This assumption seems to be in contradiction with some recent experiments. In this study we attempt to complement these experimental investigations through a numerical study of a time-developing wake. A numerical study has the advantage of eliminating many of the uncontrolled factors present in experiments and allowing precise control of initial conditions. Large-eddy simulations employing the recently developed dynamic localization model are used to extend previous results from direct numerical simulations. The large-eddy simulation results are compared to the direct numerical simulation database, wherever such comparisons are feasible, as a check of the method. Like the experiments, the large-eddy simulations suggest that non-unique self-similar states, characterized by different spreading rates and turbulent statistics, are possible and that they can be maintained for significant time periods. The study also demonstrates the predictive capability of the dynamic localization subgrid model.

Ghosal, Sandip↗
NASA NTRS2010

The Dust Management Project: Characterizing Lunar Environments and Dust, Developing Regolith Mitigation Technology and Simulants

A return to the Moon to extend human presence, pursue scientific activities, use the Moon to prepare for future human missions to Mars, and expand Earth?s economic sphere, will require investment in developing new technologies and capabilities to achieve affordable and sustainable human exploration. From the operational experience gained and lessons learned during the Apollo missions, conducting long-term operations in the lunar environment will be a particular challenge, given the difficulties presented by the unique physical properties and other characteristics of lunar regolith, including dust. The Apollo missions and other lunar explorations have identified significant lunar dust-related problems that will challenge future mission success. Comprised of regolith particles ranging in size from tens of nanometers to microns, lunar dust is a manifestation of the complex interaction of the lunar soil with multiple mechanical, electrical, and gravitational effects. The environmental and anthropogenic factors effecting the perturbation, transport, and deposition of lunar dust must be studied in order to mitigate it?s potentially harmful effects on exploration systems and human explorers. The Dust Management Project (DMP) is tasked with the evaluation of lunar dust effects, assessment of the resulting risks, and development of mitigation and management strategies and technologies related to Exploration Systems architectures. To this end, the DMP supports the overall goal of the Exploration Technology Development Program (ETDP) of addressing the relevant high priority technology needs of multiple elements within the Constellation Program (CxP) and sister ETDP projects. Project scope, plans, and accomplishments will be presented.

Hyatt, Mark J.↗
NASA NTRS2011

The Dust Management Project: Final Report

A return to the Moon to extend human presence, pursue scientific activities, use the Moon to prepare for future human missions to Mars, and expand Earth s economic sphere, will require investment in developing new technologies and capabilities to achieve affordable and sustainable human exploration. From the operational experience gained and lessons learned during the Apollo missions, conducting longterm operations in the lunar environment will be a particular challenge, given the difficulties presented by the unique physical properties and other characteristics of lunar regolith, including dust. The Apollo missions and other lunar explorations have identified significant lunar dust-related problems that will challenge future mission success. Comprised of regolith particles ranging in size from tens of nanometers to microns, lunar dust is a manifestation of the complex interaction of the lunar soil with multiple mechanical, electrical, and gravitational effects. The environmental and anthropogenic factors effecting the perturbation, transport, and deposition of lunar dust must be studied in order to mitigate it s potentially harmful effects on exploration systems and human explorers. The Dust Management Project (DMP) is tasked with the evaluation of lunar dust effects, assessment of the resulting risks, and development of mitigation and management strategies and technologies related to Exploration Systems architectures. To this end, the DMP supports the overall goal of the Exploration Technology Development Program (ETDP) of addressing the relevant high priority technology needs of multiple elements within the Constellation Program (CxP) and sister ETDP projects. Project scope, approach, accomplishments, summary of deliverables, and lessons learned are presented.

Hyatt, Mark J.↗
NASA NTRS2009

Space Transportation System Availability Relationships to Life Cycle Cost

Future space transportation architectures and designs must be affordable. Consequently, their Life Cycle Cost (LCC) must be controlled. For the LCC to be controlled, it is necessary to identify all the requirements and elements of the architecture at the beginning of the concept phase. Controlling LCC requires the establishment of the major operational cost drivers. Two of these major cost drivers are reliability and maintainability, in other words, the system's availability (responsiveness). Potential reasons that may drive the inherent availability requirement are the need to control the number of unique parts and the spare parts required to support the transportation system's operation. For more typical space transportation systems used to place satellites in space, the productivity of the system will drive the launch cost. This system productivity is the resultant output of the system availability. Availability is equal to the mean uptime divided by the sum of the mean uptime plus the mean downtime. Since many operational factors cannot be projected early in the definition phase, the focus will be on inherent availability which is equal to the mean time between a failure (MTBF) divided by the MTBF plus the mean time to repair (MTTR) the system. The MTBF is a function of reliability or the expected frequency of failures. When the system experiences failures the result is added operational flow time, parts consumption, and increased labor with an impact to responsiveness resulting in increased LCC. The other function of availability is the MTTR, or maintainability. In other words, how accessible is the failed hardware that requires replacement and what operational functions are required before and after change-out to make the system operable. This paper will describe how the MTTR can be equated to additional labor, additional operational flow time, and additional structural access capability, all of which drive up the LCC. A methodology will be presented that provides the decision makers with the understanding necessary to place constraints on the design definition. This methodology for the major drivers will determine the inherent availability, safety, reliability, maintainability, and the life cycle cost of the fielded system. This methodology will focus on the achievement of an affordable, responsive space transportation system. It is the intent of this paper to not only provide the visibility of the relationships of these major attribute drivers (variables) to each other and the resultant system inherent availability, but also to provide the capability to bound the variables, thus providing the insight required to control the system's engineering solution. An example of this visibility is the need to provide integration of similar discipline functions to allow control of the total parts count of the space transportation system. Also, selecting a reliability requirement will place a constraint on parts count to achieve a given inherent availability requirement, or require accepting a larger parts count with the resulting higher individual part reliability requirements. This paper will provide an understanding of the relationship of mean repair time (mean downtime) to maintainability (accessibility for repair), and both mean time between failure (reliability of hardware) and the system inherent availability.

Rhodes, Russel E.↗
NASA NTRS2010

Challenges in Transitioning Research Data to Operations: The SPoRT Paradigm

Established in 2002 to demonstrate the weather and forecasting application of real-time EOS measurements, the NASA Short-term Prediction Research and Transition (SPoRT) program has grown to be an end-to-end research to operations activity focused on the use of advanced NASA modeling and data assimilation approaches, nowcasting techniques, and unique high-resolution multispectral data from EOS satellites to improve short-term weather forecasts on a regional and local scale. With the ever-broadening application of real-time high resolution satellite data from current EOS and planned NPP, JPSS, and GOES-R sensors to weather forecast problems, significant challenges arise in the acquisition, delivery, and integration of the new capabilities into the decision making process of the operational weather community. For polar orbiting sensors such as MODIS, AIRS, VIIRS, and CRiS, the use of direct broadcast ground stations is key to the real-time delivery of the data and derived products in a timely fashion. With the ABI on the geostationary GOES-R satellite, the data volume will likely increase by a factor of 5- 10 from current data streams. However, the high data volume and limited bandwidth of end user facilities presents a formidable obstacle to timely access to the data. This challenge can be addressed through the use of subsetting techniques, innovative web services, and the judicious selection of data formats. Many of these approaches have been implemented by SPoRT for the delivery of real-time products to NWS forecast offices and other weather entities. Once available in decision support systems like AWIPS II, these new data and products must be integrated into existing and new displays that allow for the integration of the data with existing operational products in these systems. SPoRT is leading the way in demonstrating this enhanced capability. This paper will highlight the ways SPoRT is overcoming many of the challenges presented by the enormous data volumes of current and future satellite systems to get unique high quality research data into the operational weather environment.

Jedloved, Gary J.↗
NASA NTRS2013

SPoRT: Transitioning NASA and NOAA Experimental Data to the Operational Weather Community

Established in 2002 to demonstrate the weather and forecasting application of real-time EOS measurements, the NASA Short-term Prediction Research and Transition (SPoRT) program has grown to be an end-to-end research to operations activity focused on the use of advanced NASA modeling and data assimilation approaches, nowcasting techniques, and unique high-resolution multispectral data from EOS satellites to improve short-term weather forecasts on a regional and local scale. With the ever-broadening application of real-time high resolution satellite data from current EOS, Suomi NPP, and planned JPSS and GOES-R sensors to weather forecast problems, significant challenges arise in the acquisition, delivery, and integration of the new capabilities into the decision making process of the operational weather community. For polar orbiting sensors such as MODIS, AIRS, VIIRS, and CRiS, the use of direct broadcast ground stations is key to the real-time delivery of the data and derived products in a timely fashion. With the ABI on the geostationary GOES-R satellite, the data volumes will likely increase by a factor of 5-10 from current data streams. However, the high data volume and limited bandwidth of end user facilities presents a formidable obstacle to timely access to the data. This challenge can be addressed through the use of subsetting techniques, innovative web services, and the judicious selection of data formats. Many of these approaches have been implemented by SPoRT for the delivery of real-time products to NWS forecast offices and other weather entities. Once available in decision support systems like AWIPS II, these new data and products must be integrated into existing and new displays that allow for the integration of the data with existing operational products in these systems. SPoRT is leading the way in demonstrating this enhanced capability. This paper will highlight the ways SPoRT is overcoming many of the challenges presented by the enormous data volumes of current and future satellite systems to get unique high quality research data into the operational weather environment.

Jedlovec, Gary J.↗
NASA NTRS2013

Method to Increase Performance of Foil Bearings Through Passive Thermal Management

This invention is a new approach to designing foil bearings to increase their load capacity and improve their reliability through passive thermal management. In the present case, the bearing is designed in such a way as to prevent the carryover of lubricant from the exit of one sector to the inlet of the ensuing sector of the foil bearing. When such passive thermal management techniques are used, bearing load capacity is improved by multiples, and reliability is enhanced when compared to current foil bearings. This concept has recently been tested and validated, and shows that load capacity performance of foil bearings can be improved by a factor of two at relatively low speeds with potentially greater relative improvements at higher speeds. Such improvements in performance with respect to speed are typical of foil bearings. Additionally, operation of these newly conceived bearings shows much more reliability and repeatable performance. This trait can be exploited in machine design to enhance safety, reliability, and overall performance. Finally, lower frictional torque has been demonstrated when operating at lower (non-load capacity) loads, thus providing another improvement above the current state of the art. The objective of the invention is to incorporate features into a foil bearing that both enhance passive thermal management and temperature control, while at the same time improve the hydrodynamic (load capacity) performance of the foil bearing. Foil bearings are unique antifriction devices that can utilize the working fluid of a machine as a lubricant (typically air for turbines and motors, liquids for pumps), and as a coolant to remove excess energy due to frictional heating. The current state of the art of foil bearings utilizes forced cooling of the bearing and shaft, which represents poor efficiency and poor reliability. This invention embodies features that utilize the bearing geometry in such a manner as to both support load and provide an inherent and passive cooling mechanism. This cooling mechanism functions in such a way as to prevent used (higher temperature) lubricant from being carried over from the exit of one sector into the entry of the next sector of the foil bearing. The disclosed innovation is an improved foil bearing design that reduces or eliminates the need for force cooling of the bearing, while at the same time improving the load capacity of the bearing by at least a factor of two. These improvements are due to the elimination of lubricant carryover from the trailing edge of one sector into the leading edge of the next, and the mixing of used lubricant with the surrounding ambient fluid.

Bruckner, Robert↗
DOE OSTI2021

VTO_2021_APR_LLNL_Ye

Traditional batteries are composed of two-dimensional films that are stacked and/or rolled. Thin film batteries display high power density while their thick film counterparts show good energy density, but it has proven difficult to concurrently achieve both within these planar form factors. In addition, conventional Li-ion batteries based on liquid organic electrolytes or gel polymer electrolytes have raised severe safety concerns due to the intrinsic flammable properties of the organic electrolytes. They are also not ideal for the use of high energy density metallic lithium (Li) anodes due to Li dendrite growth, or sulfur cathodes due to shuttling effects that result in fast capacity fade. There is an urgent need to develop safe, high-performance solid-state batteries (SSBs) with advanced electrolyte and separator technologies. Although in recent years a series of superionic conductors have been developed for electrolytes and separators, their performance does not satisfy demanding criteria due to large impedance from poor solid electrolyte-electrode contact and questionable electrochemical and mechanical stability. Unlike the well-established roll-to-roll fabrication of conventional Li-ion batteries, the processing of SSBs is unique due to the brittleness of solid-state electrolytes (SSEs). The commercially available or lab-developed SSE discs are usually very thick (hundreds of micrometers to millimeters) to overcome their brittle nature, which unfortunately increases the cell impedance and accounts for the majority of the overall cell weight and volume, leading to dramatically decreased power and energy densities. In this project, we will investigate 3D printing techniques to overcome safety, fabrication, mechanical, and electrochemical issues in SSBs. 3D printing builds complex structures in a layer-by-layer fashion, which allows rapid production of hierarchical architectures, gradient and multi-material structures, and multi-component assemblies. 3D printing is an emerging area that could fundamentally transform energy storage devices. For example, 3D printing can produce batteries with arbitrary form factors to fit a product’s specific volume requirements and can create interwoven electrode arrangements over a wide range of length scales to improve transport and increase power density for a given energy density. For SSBs, 3D printing may dramatically reduce the separator thickness from ~1 mm (by hydraulic pressing) to tens of micrometers or less. In addition, the interfacial contact area between the electrolyte and the electrode may be increased via 3D interdigitated designs. Hence, we expect a significant reduction of the overall cell impedance and enhancement of both energy and power densities of SSBs by harnessing an array of 3D printing technologies being developed at Lawrence Livermore National Laboratory (LLNL).

25 ENERGY STORAGE↗