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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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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

EWTN: Quantifying Mass Transport to Enable Water Electrolyzer Architectures with Low Flow-Rate Sensitivity

To develop cost-effective and high-performing polymer electrolyte water electrolyzers (PEWEs) for gigawatt-scale applications, researchers have focused on reducing precious metal catalyst loadings and optimizing porous transport layers. However, the performance of PEWEs is also affected by system architecture. Mass transport losses are dependent on localized architecture and material interactions. In-situ measurements, such as current density distribution maps have demonstrated advantages in understanding the intricate characteristics and influence of two-phase flow within PEWEs. This study proposes the parameter of effective water transport number (EWTN) as a quantitative tool to investigate such current density distribution (CDD) measurements for PEWEs. Results show that higher flow-rates have EWTN values of 0.95 and above, indicating no mass transport limitations; while lower flow-rates with large gradients CDD have EWTN values between 0.6-0.8, indicating mass transport limited conditions. The new analysis also identified a correlation between mass transport losses due to bubble accumulation, membrane hydration, and ohmic overpotentials. To address these limitations, an unitized pin-type LGDL/flow-field design was developed, which effectively prevents local gas phase accumulation, resulting in improved mass transport characteristics. The results of this work show reduced flow-rate sensitivity with the pin-type architecture and ∼13% increased performance at 0.24 ml / min / cm 2 .

Electrochemistry↗
DOE OSTI2024

Predicting the Rate of Degradation Related to Oxygen Electrode Delamination in Solid Oxide-Ion Electrolyzers

One of the leading causes for the performance degradation in H 2 -producing solid oxide electrolytic cells (SOECs) is the gradual delamination of oxygen electrode (OE) from the electrolyte under a strong anodic polarization. Identification of the key factor that controls the rate of OE delamination is of paramount importance to achieve long-term stable operation of SOECs. Here we show from thousands of hours of testing data that the exchange current density (i°) of OE can be leveraged as a predictor for the rate of delamination. To obtain i°, we apply DC-biased electrochemical impedance spectroscopy on a three-electrode symmetrical cell to measure polarization resistance (R p ) of OE as a function of current density (i) and time (t). The collected R p -i-t raw data are then converted to overpotential ( η )-i-t, from which i° is extracted from the “low-field” approximation. An analytical relationship between i° and time-to-delamination (TTD) is further established from the established i°-i-t relationship. We show that under a constant anodic polarization current density i, the greater the ratio i/i°, the faster the delamination. Therefore, we conclude that the exchange current density of an OE, i°, can be used to predict the rate of OE degradation in solid oxide-ion electrolyzers.

25 ENERGY STORAGE↗
DOE OSTI2024

Nano Scale Poly(vinylidene chloride-co-acrylonitrile) Protection for Reversible and Stable Mg Anode Interface

This study investigates the efficacy of a polymer coating, PVdC-co-AN, in enhancing the stability and reversibility of the electrochemical Mg anode interface. Coated electrodes, immersed in a 0.25 M Mg(TFSI) 2 −0.50 M MgCl 2 /dimethoxyethane (DME) electrolyte, exhibit notable improvements. Cyclic voltammetry demonstrates consistent behavior with the coated electrode, while the uncoated electrode changes dramatically. During extended open circuit potential conditions, the coated electrode maintains much higher coulombic efficiency (93%) compared to the uncoated electrode (62%). Galvanostatic cycling test over 200 cycles further show the benefits of the PVdC-co-AN coating, decreasing the overpotential of Mg plating and improving long-term stability. The coated electrodes also demonstrate improved rate capability at higher current densities. Surface analysis reveals differences in the formation of byproducts between the coated and uncoated electrodes, indicating a more stable and uniform interface in the former. Nuclear magnetic resonance (NMR) spectroscopy suggests that the polymer influences ion mobility through tuning the solvation environments which results in better kinetics and fewer byproducts. In summary, the study affirms that the PVdC-co-AN coating significantly improves the stability and performance of Mg electrochemistry, offering a promising advancement for practical battery applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Shorting at Long Duration: Impact of Extended Discharge Capacity on Battery Solid Electrolytes

Long-duration energy storage (LDES) is critical to a stable, resilient, and decarbonized electric grid. While batteries are emerging as important LDES devices, extended, high-power discharges necessary for cost-competitive LDES present new materials challenges. Here, focusing on a new generation of low-temperature molten sodium batteries, we explore here unique phenomena related to long-duration discharge through a well-known solid electrolyte, NaSICON. Specifically, molten sodium symmetric cells at 110°C were cycled at 0.1 A cm -2 for 1-23 h discharges. Longer discharges led to unstable overpotentials, reduced resistances, and decreased electrolyte strength, caused by massive sodium penetration not observed in shorter duration discharges. Scanning electron microscopy informed mechanisms of sodium penetration and even “healing” during shorter-duration cycling. Importantly, these findings show that traditional, low-capacity, shorter-duration tests may not sufficiently inform fundamental materials phenomena that will impact LDES battery performance. This case highlights the importance that candidate LDES batteries be tested under pertinent long-duration conditions.

25 ENERGY STORAGE↗
DOE OSTI2024

Pioneering Microporous Layers for Proton-Exchange-Membrane Water Electrolyzers via Tape Casting

The imperative shift towards decarbonization necessitates the production of clean hydrogen through water electrolysis, powered by renewable energy sources. Among electrolyzer technologies, proton-exchange-membrane (PEM) systems emerge as a promising option for large-scale hydrogen generation due to their modular design and rapid response, aligning well with the intermittency of renewable energy. In this study, we employ a tape casting method to fabricate microporous layers (MPLs), both as a single layer and as a bilayer over commercial porous transport layers (PTLs), to further enhance performance of water electrolyzers. We demonstrate that microporous layers require adequate pore sizes to facilitate gas removal, preventing gas flooding and preserving electrolyzer performance. Our single layer microporous layers exhibit lower overpotentials compared to commercial sintered Ti PTLs by 142 mV at 4 A·cm ⁻2 . Moreover, we show that having an effective microporous layer enhances electrolyzer performance irrespective of the substrate used, offering avenues for cost reduction. We also investigate novel PTL structures with reduced tortuosity and integrated MPL fabricated via phase inversion tape casting, resulting in a performance enhancement of 92 mV. Our findings unravel the critical role of microporous layer structures and their impact on electrolyzer performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Anodic Hydrogen Generation from Benzaldehyde on Au, Ag, and Cu: Rotating Ring-Disk Electrode Studies

Aldehydes are selectively oxidized to carboxylates on group 11 metals at low potentials (<0.4 V vs. RHE) in alkaline media. This process can occur by a pathway that generates H 2 gas from the aldehyde, known as electro-oxidative dehydrogenation (EOD) or anodic hydrogen production. The EOD process occurs with transfer of only one electron per aldehyde, whereas typical oxidation with discharge of hydrogen to form water is a two-electron process. Here, we study the catalytic activity and selectivity toward H 2 of Au, Ag, and Cu electrodes using benzaldehyde with rotating disk and ring-disk electrode (RDE/RRDE) techniques. The average number of electrons per benzaldehyde molecule obtained via H 2 detection by RRDE agrees with that obtained via Koutecký-Levich analysis conducted at various rotation rates. We find that Au and Ag have much higher H 2 and benzoate formation rates than Cu, but that Cu can perform the reaction at about 0.2 V lower overpotentials. On all three materials, benzaldehyde oxidation has high selectivity to anodic H 2 (one-electron pathway) below ∼0.5 V vs. RHE, but, with increasing potential, the selectivity shifts to H-oxidation forming water (two-electron pathway).

Ramos, Nathanael C. (ORCID:0000000247210350)↗
DOE OSTI2025

CO 2 Electrolysis Using Metal-Supported Solid Oxide Cells with Infiltrated Pr 0.5 Sr 0.4 Mn 0.2 Fe 0.8 O 3-$δ$ Catalyst

Electrochemical conversion of CO 2 to CO is demonstrated with symmetric-structured metal supported solid oxide cells (MS-SOC). Perovskite Pr 0.5 Sr 0.4 Mn 0.2 Fe 0.8 O 3-δ (PSMF) and Pr 6 O 11 catalysts were infiltrated into the MS-SOC cathode and anode, using 3 cycles with firing at 850 °C and 8 cycles with firing at 800 °C, respectively. Upon reduction during operation, the perovskite PSMF was transformed to Ruddlesden–Popper structure with a highly efficient electrocatalytic activity. The impact of operating temperature (600–800 °C) and overpotential (0–1.8 V) on the CO 2 conversion was investigated. The highest CO 2 conversion of 57.2% was achieved at 750 °C and 1.8 V. During extended operation for 150 h at 750 °C and 1.2 V, a cell demonstrated relatively stable performance, with initial current density of 535 mA cm -2 and CO 2 conversion of 23%. Degradation mechanisms were studied by posttest characterization.

25 ENERGY STORAGE↗
DOE OSTI2025

Mechanistic and Mitigation-Strategy Insights into NaCl and CaCl 2 Contamination of Proton-Exchange-Membrane Water Electrolysis Using Continuum Modeling

Cationic contaminants are detrimental to proton-exchange-membrane water electrolyzers (PEMWEs). To obtain insight, a 1-D, nonisothermal, multiphase continuum cell model including cationic contamination is developed. Simulations of steady-state cell performance predict decreased performance due to an increase in kinetic overpotential associated with the hydrogen-evolution reaction, which was attributed to decreased protonic-activity within the cathode catalyst layer from proton supplantation with contaminant cations. The accumulation and extent of cation exchange in the cathode catalyst layer depends on the operating current density due to migration. Simulations of cell recovery of potential suggest that a contaminated cell can recover approximately 78% (450 mV) with 24 h of constant current density operation at 2 A cm –2 , with higher current densities accelerating reduced recovery times. Parametric studies show that anode-side acidification at lower current densities inhibit cation contaminant adsorption, and cathode-side acidification at larger current densities facilitate the expulsion of adsorbed cations; for a cathode-side pH of 6 and 5, the cell can recover an additional 10% and 100% performance, respectively. Overall, the model serves as a framework for modeling other aspects of PEMWE systems to address durability and performance aspects, which can assist in improving the viability of the technology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Editors’ Choice—Rapid Deactivation Convolutes Electrochemical CO 2 Reduction Selectivity Measurements on Gold Rotating Ring Disk Electrodes

Voltammetric measurements of electrochemical CO 2 reduction reaction (CO 2 RR) selectivity on rotating ring disk electrodes (RRDE) are a rapid and sensitive method for quantifying an electrocatalyst’s selectivity, i.e. faradaic efficiency (FE). This method has been applied to polycrystalline Au electrocatalysts where a Au disk electrode catalyzes both the CO 2 RR and hydrogen evolution reaction while the concentric Au ring electrode selectively senses CO by oxidizing CO back to CO 2 . Such measurements enabled fundamental mechanistic studies but suffer from poor inter-laboratory reproducibility. This work identifies causes of variability in RRDE selectivity measurements by comparing protocols with different electrochemical methods, reagent purities, and glassware cleaning procedures. We observed FE CO decrease by 56% during 5 min chronoamperometry measurements, a phenomenon that is not readily apparent in voltammetric scans due to their dynamic nature. Electroplating of electrolyte impurities onto the disk and ring surfaces were identified as a major contributor to Au deactivation. Additionally, the oxygen reduction reaction may lead to higher disk currents in inadequately purged electrolytes, causing an apparent underestimation of FE CO at low overpotentials. Lastly, we propose operational bounds for CO 2 RR selectivity measurements on Au using the RRDE method and provide suggestions on steps for improving the accuracy of this technique.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Is the Chemisorbed CO 2 in Ionic Liquid Electrolytes Active for Electrochemical Utilization? A Case Study on Carboxylate and Carbamate Speciation

This study examines the activity of chemisorbed CO 2 species in the microenvironment formed by bifunctional ionic liquids (ILs) in the reactive capture and conversion (RCC) of CO 2 to CO on silver. Comparative electroanalytical measurements with imidazolium based ILs were performed to probe the impact of electrostatic interactions, anion and cation basicity, and hydrogen bonding on RCC. Particularly, ILs with 1-ethyl-3-methylimidazolium ([EMIM]+) and 1-ethyl-2,3-dimethylimidazolium ([EMMIM]+) cations and aprotic heterocyclic anions of 2-cyanopyrrolide ([2-CNpyr]) and 1,2,4-triazolide ([124-Triz]) were examined for RCC. It was found that anion–CO 2 carbamate complexes facilitate RCC at significantly lower overpotentials compared to cation–CO 2 carboxylate complexes. Additionally, [EMIM]+ was found to better stabilize anion–CO 2 complexes at the interface than [EMMIM]+. Furthermore, it was found that 2-CNpyrH that naturally forms during CO 2 absorption competes for electrode surface adsorption with the anion–CO 2 carbamate complex, thereby reducing the electrochemical activity of the anion–CO 2 complex. These results highlight the importance of IL structure in tuning the interfacial interactions and suggest that ILs with anion-dominated CO 2 chemisorption enhances CO 2 utilization in RCC applications.

Coskun, Oguz Kagan [Case Western Reserve Univ., Cl↗
DOE OSTI2025

Ion Transport in Concentrated Crosslinked Solid Polymer Electrolytes

Crosslinking polymers is a common approach to create mechanically stable solid materials such as polymer electrolytes for lithium batteries. In conventional liquid electrolytes, the solvent molecules move freely to accommodate the field-induced motion of ions. However, in crosslinked polymer electrolytes, the rearrangement of polymer segments is constrained by the deformation limits of the network. Herein, we develop a new transport model that accounts for both the formation of concentration gradients and the elasticity of the electrolyte. The elasticity is incorporated by adding an additional term related to the entropy of crosslinked strands to the electrochemical potential of the salt. The resulting Crosslink Model contains two adjustable parameters: $\mathcal{N}$, the average number of monomers in a strand, and λ crit , the maximum strain the network can sustain. These solid-like constraints produce singularities in the governing transport equations, fundamentally altering the concentration profiles. Plateaus in salt concentrations emerge near the electrodes, and network elasticity introduces a strain overpotential. When compared to a Baseline Model ($\mathcal{N}$ → ∞, equivalent to concentrated solution theory), which predicts steepest gradients near the electrodes, both models yield similar current–voltage relationships. Model predictions are compared to electrochemical data for a poly(ethylene oxide)-based crosslinked polymer electrolyte.

Patel, Vivaan [University of California, Berkeley,↗
DOE OSTI2026

From Powder to Power: Tailored Pre-Milling Strategy that Optimizes Microstructure for Efficient Hydrogen Evolution

The hydrogen evolution reaction (HER) plays a critical role in enabling large-scale electrolytic hydrogen production and advancing future technologies and fuel production. Among non-precious metals, NiMo-based catalysts are particularly attractive due to their capability to promote both water dissociation and hydrogen adsorption in alkaline media. However, conventional NiMo catalysts often suffer from incomplete alloying, particle aggregation, weak metal–support interactions, and surface oxidation, which significantly limit active site utilization, electronic conductivity, and long-term stability. Herein, we report a scalable, solid-state, two-step ball milling strategy for constructing an efficient NiMo/C catalyst for the HER. Pre-milling the metal precursors prior to carbon incorporation promotes efficient solid-state activation, leading to the formation of uniformly alloyed, ultrafine, and defect-rich Ni–Mo nanoparticles with robust metal–carbon interfacial anchoring. Benefiting from this integrated structural design, the optimized NiMo/C catalyst exhibits low overpotentials and Tafel slopes, reduced charge-transfer resistance, and excellent durability under alkaline conditions. Comprehensive structural and surface analysis reveal that the enhanced HER performance can be attributed to the synergistic interplay of homogeneous Ni–Mo alloying, uniform nanoparticle dispersion on a defect-rich carbon scaffold, enhanced accessibility of catalytically active sites, and optimized electronic coupling that stabilizes the catalyst surface. This work highlights the two-step solid-state ball milling strategy as a simple, robust, and scalable route for the preparation of effective and durable non-precious metal HER electrocatalysts, offering practical insights toward large-scale and inexpensive hydrogen production.

Yang, Xiaoxuan [Oak Ridge National Laboratory (ORN↗
DOE OSTI2026

Non-Invasive Electrode Impedance Estimation for Optimized Charge Profile Parameterization of Lithium-Ion Batteries

This work presents a non-invasive method for parameterizing a physically motivated equivalent circuit model of lithium-ion batteries using operando electrochemical impedance spectroscopy and time-domain data. The proposed model consists exclusively of linear circuit elements, enabling computationally efficient simulation and real-time implementation on battery management system chips. By integrating frequency- and time-domain measurements, the model accurately estimates internal states such as the negative electrode potential, achieving a root mean square error of 12.3 mV during fast charging validation. Parameterization requires only rate tests with sinusoidal perturbations at three different ambient temperatures, making the approach experimentally accessible. The model reveals key insights into battery behavior, including rate-dependent overpotentials primarily governed by charge transfer kinetics at the positive electrode, and temperature-dependent impedance contributions from both charge transfer and solid-state diffusion processes. Validation using reference electrodes confirms the model’s ability to detect lithium plating onset and reproduce impedance behavior across a wide range of operating conditions. The approach enables in situ optimization of fast charging profiles and lays the foundation for future extensions incorporating aging effects and plating dynamics.

25 ENERGY STORAGE↗
DOE OSTI2017

Communication — Modeling polymer-electrolyte fuel-cell agglomerates with double-trap kinetics

A new semi-analytical agglomerate model is presented for polymer-electrolyte fuel-cell cathodes. The model uses double-trap kinetics for the oxygen-reduction reaction, which can capture the observed potential-dependent coverage and Tafel-slope changes. An iterative semi-analytical approach is used to obtain reaction rate constants from the double-trap kinetics, oxygen concentration at the agglomerate surface, and overall agglomerate reaction rate. The analytical method can predict reaction rates within 2% of the numerically simulated values for a wide range of oxygen concentrations, overpotentials, and agglomerate sizes, while saving simulation time compared to a fully numerical approach.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Structure Sensitivity of Formic Acid Electrooxidation on Transition Metal Surfaces: A First-Principles Study

Formic acid presents several advantages for use as a fuel in fuel cells. We present a first-principles based analysis of electrooxidation trends for formic acid on the close-packed facets of eight fcc metals: Au, Ag, Cu, Pt, Pd, Ni, Ir, and Rh, and four hcp metals: Co, Os, Ru, and Re. To explore the structure sensitivity of this reaction on the fcc metals, we also studied the open (100) facet of these eight metals. We find that the open facets of Au, Ag, Cu, Pt, and Pd are more energy-efficient (i.e. require less overpotential) for formic acid electrooxidation when compared to their close-packed facets. The opposite is true for the stronger-binding metals: Ni, Ir, and Rh. Using the free energy of adsorbed CO* and OH* as reactivity descriptors, we cast the thermochemistry of the reaction network into phase diagrams showing regions of rate-determining steps, together with their calculated free energies. This allows the identification of bimetallic alloys, potentially possessing improved electrocatalysis for formic acid electrooxidation, compared to Pt or Pd. We discuss the need for anode catalysts for direct formic acid fuel cells (DFAFCs) to diminish CO* poisoning, by promoting the formation of formate instead of carboxyl intermediate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Electrochemical Charge Transfer Reaction Kinetics at the Silicon-Liquid Electrolyte Interface

Since the gravimetric lithiation capacity of silicon is roughly ten times that of graphite, while their mass densities are comparable, for the same particle size the current density required to cycle a silicon electrode at a given C-rate is about ten times greater than that of graphite. Depending on the magnitude of the corresponding Butler-Volmer exchange current density, j o , such high current densities may cause the charge transfer kinetics at the silicon-electrolyte interface to become rate limiting. Previously reported values of j o for Si differ by about 10 orders of magnitude. Here we report j o measurements using electrochemical impedance spectroscopy (EIS) for single crystal electronically conductive silicon wafers with well-defined (100) and (111) orientations and active surface areas. The electrochemical cycling regime was designed to avoid artifacts due to stress-induced surface cracking of Si upon lithiation. The exchange current density of the silicon-electrolyte interface is found to be 0.1 ± 0.01 mA/cm 2 when using electrolyte consisting of 1 M LiPF 6 in EC/DMC (1/1 by wt) + FEC (10 wt%) + VC (2 wt%). Furthermore, these results are then used to illustrate the dependence of kinetic overpotential on particle size and C-rate for silicon compared to lower volumetric capacity compounds such as graphite.

25 ENERGY STORAGE↗
DOE OSTI2016

Understanding Performance Limitations to Enable High Performance Magnesium-Ion Batteries

We developed a mathematical model in order to investigate the performance limiting factors of Mg-ion battery with a Chevrel phase (Mg x Mo 6 S 8 ) cathode and a Mg metal anode. Furthermore, the model was validated using experimental data from the literature [Cheng et al., Chem. Mater., 26, 4904 (2014)]. Two electrochemical reactions of the Chevrel phase with significantly different kinetics and solid diffusion were included in the porous electrode model, which captured the physics sufficiently well to generate charge curves of five rates (0.1C–2C) for two different particle sizes. Limitation analysis indicated that the solid diffusion and kinetics in the higher-voltage plateau limit the capacity and increase the overpotential in the Cheng et al.’s thin (20-μm) electrodes. The model reveals that the performance of the cells with reasonable thickness would also be subject to electrolyte-phase limitations. Finally, the simulation also suggested that the polarization losses on discharge will be lower than that on charge, because of the differences in the kinetics and solid diffusion between the two reactions of the Chevrel phase.

25 ENERGY STORAGE↗
DOE OSTI2014

Design of Membrane-Encapsulated Wireless Photoelectrochemical Cells for Hydrogen Production

Membrane-encapsulated devices are attractive for solar-driven hydrogen production, as their design mitigates problems with concentration overpotentials, gas bubbles, and safety inherent in liquid electrolyte water-splitting devices. However, the competing processes such as heat, water, gas, and ion transport make it nontrivial to design such devices. Here, we show analytical expressions and associated design spaces for critical membrane dimensions and material properties required for stable and efficient gas, heat, proton, and water transport. The best condition for stable gas transport in thin film or gas channels is given by the critical Damköhler number. The maximum heating of the device is governed by the Heating and Nusselt numbers, which can be tuned to the desired level. The optimal dimensions of the device, to operate under tolerable ohmic losses, correspond to the maximum value of scaled Power-loss factor. An optimal device architecture is proposed for stable and efficient operation. © 2014 The Electrochemical Society.

Singh, Meenesh R↗