Search NASA⌕ Search

SEARCH · Search NASA

Results for “Safety Performance Indicators”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Results of ISO/TS 6336-22 Evaluating Full Contact Zone: Preprint

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears — Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

gearbox↗
DOE OSTI2022

Results of ISO/TS 6336-22 Evaluating Full Contact Zone

ISO/TS 6336-22 (Calculation of load capacity of spur and helical gears - Part 22: Calculation of micropitting load capacity) is the ISO technical specification containing a proposal for calculations of the risk of micropitting in gear sets. Micropitting is a Hertzian fatigue phenomenon that appears as ultra-fine cracking and pitting on the flanks of gear teeth. Since progressive micropitting can lead to macropitting and flank damage, critical applications such as wind turbines, marine drives, and high-speed gear drives seek to accurately predict whether their designs are susceptible to this damage. ISO/TS 6336-22 assesses micropitting risk through a safety factor which is calculated as the minimum specific film thickness in the contact zone divided by a permissible specific film thickness. In the previous paper, the calculations were performed using the simplified method (Method B) that evaluates points on the path of contact. This was done for three gear sets that experienced micropitting in operation. The minimum specific film thickness for the two field cases was very high, which indicates that the gears were operating in the full elastohydrodynamic lubrication (EHL) regime. A more accurate calculation for these cases (Method A) calculates the specific film thickness across the entire contact zone. This paper applies this Method to the case study from the previous paper. The results are compared to micropitting observed in operation. Results are also compared to the results of the previous paper. Conclusions are made regarding the accuracy of both Methods compared to the field cases and relative to each other.

gearbox↗
DOE OSTI2022

Evidence of Nonlinear Seismic Effects in the Earth from Downhole Distributed Acoustic Sensors

Seismic velocities and elastic moduli of rocks are known to vary significantly with applied stress, which indicates that these materials exhibit nonlinear elasticity. Monochromatic waves in nonlinear elastic media are known to generate higher harmonics and combinational frequencies. Such effects have the potential to be used for broadening the frequency band of seismic sources, characterization of the subsurface, and safety monitoring of civil engineering infrastructure. However, knowledge on nonlinear seismic effects is still scarce, which impedes the development of their practical applications. To explore the potential of nonlinear seismology, we performed three experiments: two in the field and one in the laboratory. The first field experiment used two vibroseis sources generating signals with two different monochromatic frequencies. The second field experiment used a surface orbital vibrator with two eccentric motors working at different frequencies. In both experiments, the generated wavefield was recorded in a borehole using a fiber-optic distributed acoustic sensing cable. Both experiments showed combinational frequencies, harmonics, and other intermodulation products of the fundamental frequencies both on the surface and at depth. Laboratory experiments replicated the setup of the field test with vibroseis sources and showed similar nonlinear combinations of fundamental frequencies. Amplitudes of the nonlinear signals observed in the laboratory showed variation with the saturating fluid. These results confirm that nonlinear components of the wavefield propagate as body waves, are likely to generate within rock formations, and can be potentially used for reservoir fluid characterization.

58 GEOSCIENCES↗
DOE OSTI2020

Analysis of Respirator Cartridge Performance Testing on Hanford Tank A-101

Washington River Protection Solutions (WRPS) conducted tests on two types of chemical cartridges for use in air purifying respirators (APR) to determine the period of time that the cartridges would provide adequate performance1 to protect workers when exposed to a mixture of Chemicals of Potential Concern (COPCs) from vapors emanating from the headspace of tank A-101 on the Hanford Site. The Occupational Safety and Health Administration (OSHA) identifies cartridge testing as a valid approach for establishing a cartridge change schedules.[3] Testing is commonly applied in situations where mixtures of COPCs exist, and where other approaches, such as manufacturer recommendations and modeling, are less reliable. The tests were designed and conducted to ensure measurement and/or control of the key variables OSHA identified as important to estimate cartridge service life, including temperature, humidity, COPC concentration, breathing rate, and cartridge adsorption capacity. Testing was conducted over a period from July 22-24, 2016, using headspace vapors from Hanford tank A-101 under static conditions2 fed to a respirator cartridge test stand developed by WRPS in collaboration with HiLine Engineering (Richland, Washington). Multipurpose respirator cartridges, SCOTT 7422-SD1 and 7422-SC1 (SCOTT Safety, Monroe, North Carolina) were assessed on separate days with A-101 headspace vapors. Sample media (sorbent tubes) were used to collect samples of the vapor stream entering and exiting the respirator cartridge, and were subsequently analyzed for COPC concentrations. Pacific Northwest National Laboratory was tasked with conducting an independent analysis of the analytical results and making recommendations based on the results for respiratory cartridge performance and service life. Key conclusions from the assessment of the 59 COPCs in this study are described below: • Based on d measured cartridge inlet vapor concentrations from tank A-101 headspace, both ammonia and N-Nitrosodimethylamine (NDMA) exceeded their Occupational Exposure Limits (OEL).3 These measurements were generally consistent with maximum A-101 headspace measurements previously obtained for these two compounds. • Ammonia had respirator cartridge outlet concentrations that exceeded 10% of the OEL for both cartridges tested, indicating breakthrough for each. For the SCOTT 7422-SD1 cartridge, ammonia appeared to breakthrough above 10% of its OEL after 2 hours. For the SCOTT 7422-SC1 cartridge, ammonia breakthrough appeared to occur after 8 hours. 1 “Adequate performance” refers to the breakthrough criteria used in this analysis—that is, sustained cartridge outlet concentrations above 10% of the OEL. For some COPCs, an alternate threshold has been applied when necessary due to higher detection limit (DL)/reporting limit (RL) values for specific compounds. Ultimately, Industrial Hygiene professionals will use these results along with specific hazard assessments to determine service life and cartridge use that provides the necessary performance. 2 These tests were conducted under static conditions absent waste-disturbing activities in the subject tank or tank farm. 3 Occupational Exposure Limits accepted for Hanford Tank Farm use are based on OELs established by a U.S. governmental agency or national professional organization (e.g., OSHA, National Institute for Occupational Safety and Health, American Conference of Governmental Industrial Hygienists), or if no U.S. OEL exists, standard toxicological practices are applied to develop OELs using non-U.S. exposure limits, other established OELs for chemical surrogates when available, or other standard procedures. The OEL for NDMA was established in 2005 based on the MAK (Maximale Arbeitsplatzkonzentration) Commission standard adopted in Europe. iv • Despite respirator inlet measurements for NDMA that were in excess of its OEL, all corresponding outlet measurements, from both respirator cartridges, were below analytical DL 1 for the

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2021

Evaluation of Tritium Behavior in Forest Vegetation for the Purpose of Determining Appropriate Non-Zero Deposition Velocities for Tritium Oxide

Modeling and field measurements have been conducted between 2019 and 2021 to assess the practicality of using a non-zero deposition velocity for safety basis estimates of tritium oxide fate and transport modeling. A model was developed which used a complex deposition algorithm designed to assess how tritium oxide would mix based on the turbulent motions and wind speed effects that the forest canopy has on the atmosphere. The model was driven based on measurements of wind and turbulence taken from the Aiken AmeriFlux Tower which measures these properties at five levels located within and just above the forest. The model was then validated against a series of field experiments which were designed to test the model predictions and estimate the deposition velocity occurring over the forest environment at the Savannah River Site. The field releases used deuterium oxide as a surrogate for tritium oxide and was released as a fine mist which rapidly evaporated, creating a gaseous tracer in the atmosphere. Using air samplers, the elevations in deuterium concentration in the air relative to background measurements was assessed and then modeled. Generally, the numerical model tended to underpredict the amount of deuterium being mixed from above the canopy to the forest floor, indicating that the predictions it provides are still conservative relative to what was measured during the field experiments. Across a suite of modeling runs, the 95 th and 99 th percentile deposition velocities were estimated to be 1.2 and 0.7 cm s -1 , respectively. Estimated deposition velocities in the 2021 field experiments, which specifically assessed a release above the forest canopy and its mixing to the surface, predicted deposition velocities ranging from 1.75 to 6.61 cm s -1 . While these field releases do not cover all possible meteorological conditions, it seems appropriate to use a non-zero deposition velocity when performing safety-basis modeling of tritium oxide. The recommendation presented in this report is to use 1.0 cm s -1 . This is between the 95 th and 99 th percentile value estimated from the modeling study, suggesting it should be appropriate for the majority of release scenarios given the model’s apparent conservatism relative to field measurements.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Simulated Impact of Shortened Strings in Commercial and Utility-Scale Photovoltaic Arrays

The deliberate removal of photovoltaic modules from a string can occur for various reasons encompassing maintenance, measurements, theft, or failure, reducing that string length relative to others when replacement modules are not available and there are not any viable alternative makes and models that could be inserted. This phenomenon, delineated in our prior experimentally validated research, manifests two significant effects: (1) a shift in the ideal maximum power point and (2) the induction of potentially substantial reverse currents in the shortened strings at open-circuit voltage, VOC. However, the scalability and asymptotic limits of these observed behaviors concerning array size remained undetermined. In this study, we elucidate the operational dynamics of such arrays by manipulating two mismatch-contributing variables in simulated arrays of up to 900 strings: the number of removed modules per string (indicative of the level of mismatch, ranging up to 5) and the quantity of shortened strings (1 to 60). Simulation outcomes underscore that mismatch severity impacts array operation more than the proportion of shortened strings. This research delves into the practical ramifications of operating with shortened strings, including implications for low-irradiance operation and the manifestation of deleterious reverse currents (>35 A in specific cases), emphasizing the need for careful array configuration for optimal performance and safety in these implementations.

Energy & Fuels↗
DOE OSTI2020

Updates to the n+ 63,65 Cu Evaluations in the Resolved Resonance Region [Slides]

This presentation discusses the motivation and background of the n+ 63,65 Cu Evaluations in the Resolved Resonance Region which is to study the interaction of neutrons with copper as it is important in nuclear applications since critical assembly configurations include metallic copper as reflector. In support to the U.S. Department of Energy (DOE) Nuclear Criticality Safety Program (NCSP), measurements and related evaluations of 63,65 Cu isotopes were selected to improve the agreement with the benchmarks and to assess the importance of the angular distribution data for reactor calculations. Previous and current evaluation work is supported by an experimental campaign initiated before 2010, the 63,65 Cu R-matrix analysis generated resonance parameters up to 300 keV. However, due to outstanding issues in the benchmark performance, ENDF/B-VIII.0 library released a truncated set of resonance parameters up to 100 keV. The goal of this work is to generate an updated set of resonance parameters in the 100-300 keV range to improve the benchmark performance of 63,65 Cu isotopes. In conclusion, R-matrix analysis to update 63,65 Cu evaluations was performed to simultaneously improve benchmark performance and extend the RRR to 300 keV. The benchmark calculations suggest the increased capture cross sections are beneficial, however, further investigation of the measured capture data is needed to understand the large normalization scaling factor needed to improve the reactivity. Also, the copper-reflected benchmarks indicate the need to further investigate angular distributions and extension of RRR to 300 keV is aided well by level statistics considerations. Work to refine the fit of individual resonances is ongoing.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

Phenotypic and comparative genomic analysis of two Lactobacillus amylolyticus strains from naturally fermented tofu whey

Summary The differences in aspects of morphology, fermentation and probiotic characteristics between Lactobacillus amylolyticus L5 (Lam1.5) and L6 (Lam1.6) isolated from naturally fermented tofu whey were investigated by phenotypic and comparative genomic analysis. The results indicated that morphological difference between two strains may attribute to the mutation of ftsW and ftsK genes responsible for cell division. The optimum growth temperatures of Lam1.5 and Lam1.6 were different, and the acid‐producing ability of Lam1.6 was stronger than that of Lam1.5. And the growth rate of Lam1.6 exhibited better growth performance than that of Lam1.5 in MRS with initial pH 3.0–5.0. Besides, Lam1.5 was proved to be safe to be used in fermented food with safety evaluation. In respect of probiotic traits, Lam1.5 displayed the same performance in tolerance of intestinal juice, antimicrobial activity and adhesion properties as that of Lam1.6. However, Lam1.5 was more sensitive to simulated gastric juice than Lam1.6 at pH 2.5 and 3.0, which might be due to its long‐rod shape and lack of K+‐ATPase and Na+‐H+ antiporters. This study unveiled morphological and physiological differences between Lam1.5 and Lam1.6, raising the potential effect of ftsW and ftsK on the morphological development of lactobacilli that further affects their metabolic properties.

Fei, Yongtao↗
DOE OSTI2025

A Novel, Low-Cost, Portable Device for Counterfeit and Noncompliant Refrigerant Detection

The increasing prevalence of counterfeit refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) systems, including compromised equipment performance, safety hazards, and environmental non-compliance. This report details the development of a novel, cost-effective, and portable detection device designed to accurately identify counterfeit refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing users with clear visual indicators for refrigerant authenticity.Laboratory validation demonstrated the device’s high accuracy (exceeding 95%) in detecting unauthorized refrigerant blends. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks such as the American Innovation and Manufacturing (AIM) Act, enhances safety in HVACR operations, and mitigates the risks associated with counterfeit refrigerants. Future developments will focus on expanding refrigerant detection capabilities, integrating machine learning for enhanced accuracy, implementing cost-reduction strategies to improve accessibility and market adoption, and optimizing system packaging for enhanced field portability.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

A Novel, Low-Cost, Portable Device for Counterfeit and Noncompliant Refrigerant Detection

The increasing prevalence of counterfeit refrigerants presents significant risks to Heating, Ventilation, Air Conditioning, and Refrigeration (HVACR) systems, including compromised equipment performance, safety hazards, and environmental non-compliance. This report details the development of a novel, cost-effective, and portable detection device designed to accurately identify counterfeit refrigerants. The device utilizes a controlled gas sampling and analysis system within a sealed chamber, ensuring precise measurements while maintaining safety through a purging mechanism. The system features a high-sensitivity sensor integrated with an onboard control module that analyzes gas composition in real-time, providing users with clear visual indicators for refrigerant authenticity. Laboratory validation demonstrated the device’s high accuracy (exceeding 95%) in detecting unauthorized refrigerant blends. Key advantages include affordability, ease of use, rapid response time, and compatibility with a wide range of refrigerants. This solution supports compliance with regulatory frameworks such as the AIM Act, enhances safety in HVACR operations, and mitigates the risks associated with counterfeit refrigerants. Future developments will focus on expanding refrigerant detection capabilities, integrating machine learning for enhanced accuracy, implementing cost-reduction strategies to improve accessibility and market adoption, and optimizing system packaging for enhanced field portability.

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

Complexity of segregation behavior at localized deformation sites formed while in service in a 316 stainless steel baffle-former bolt

Here, post-irradiation evaluation was performed on a 316 stainless steel baffle former bolt harvested after 40 years of service in a pressurized water reactor. Microstructure analysis revealed the presence of defect-free dislocation channels and strain-induced twins, indicative of loading at a stress level close to yield stress at least once while in service. Primary radiation-induced Ni/Si precipitates were destroyed during channel and twin formation, and secondary, significantly coarser Ni/Si precipitates formed along newly formed Σ3 boundaries during the continued irradiation. Additionally, an elevated phosphorus level was observed inside the strain-induced twin. Complex chemistry inside the strain-induced feature may overlap with dislocation pileups and impact localized corrosion, material long-term performance, and safety.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Microreactor Core Transportation Cask Model Description for Criticality Safety Validation Basis Assessment (Rev. 2)

Criticality safety analyses are completed on transportation casks used for microreactor whole core shipment to provide examples of models and analyses to industry, regulators, and nuclear community at large to be used in verification and validation analyses of similar applications. The microreactors considered are based on a Gas-Cooled Microreactor (GCMR) and a Heat-Pipe Microreactor (HPMR), both utilize HALEU fuel in the form of TRISO particles and various other design options considered in industry microreactor designs. Variant design options of GCMR and HPMR were also investigated to provide a wider application range for each technology. Criticality safety analyses for the GCMR and HPMR packages were performed using the CSAS6 sequence of SCALE 6.3.2 with the ENDF/B-VII.1-based continuous energy neutron libraries. Different scenarios were investigated, including normal operation and water flooded conditions to represent nominal and hypothetical accident scenarios. Sensitivity and similarity analyses are also performed using the TSUNAMI sequence of SCALE 6.3.2, and the similarity analysis uses all the experiments from the ICSBEP Handbook with High Enriched Uranium (HEU), Intermediate and mixed Enriched Uranium (IEU) and Low Enriched Uranium (LEU) systems. Many ICSBEP experiments were found marginally similar, with similarity index (ck) values greater than 0.8, to the GCMR and HPMR cask models, especially in flooded conditions that may be more constraining due to reduced reactivity margins. Some experiments using TRISO fuel particles and graphite moderator, including the recent THETA and Deimos experiments from LANL, together with some IRPhEP experiments, were also used for the similarity analyses. These TRISO-fueled and graphite moderated experiments behaved similarly to the GCMR models, with maximum ck value greater than 0.9, but they are less similar to the HPMR models. This observation indicates that additional critical experiments might be needed to further validate the criticality safety models, especially for heat-pipe based microreactor transport packages and for non-flooded transportation configurations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Overcharge-to-thermal-runaway behavior and safety assessment of commercial lithium-ion cells with different cathode materials: A comparison study

In this paper, overcharge behaviors and thermal runaway (TR) features of large format lithium-ion (Li-ion) cells with different cathode materials (LiFePO 4 (LFP), Li[Ni 1/3 Co 1/3 Mn 1/3 ]O 2 (NCM111), Li[Ni 0.6 Co 0.2 Mn 0.2 ]O 2 (NCM622) and Li[Ni 0.8 Co 0.1 Mn 0.1 ]O 2 (NCM811)) were investigated. The results showed that, under the same overcharge condition, the TR of LFP Li-ion cell occurred earlier compared with the NCM Li-ion cells, indicating its poor overcharge tolerance and high TR risk. However, when TR occurred, LFP Li-ion cell exhibited lower maximum temperature and mild TR response. All NCM Li-ion cells caught fire or exploded during TR, while the LFP Li-ion cell only released a large amount of smoke without fire. According to the overcharge behaviors and TR features, a safety assessment score system was proposed to evaluate the safety of the cells. In short, NCM Li-ion cells have better performance in energy density and overcharge tolerance (or low TR risk), while LFP Li-ion cell showed less severe response to overcharging (or less TR hazards). For NCM Li-ion cells, as the ratio of nickel in cathode material increases, the thermal stability of the cathode materials becomes poorer, and the TR hazards increase. Such a comparison study on large format Li-ion cells with different cathode materials can provide deeper insights into the overcharge behaviors and TR features, and provide guidance for engineers to reasonably choose battery materials in automotive applications.

25 ENERGY STORAGE↗
DOE OSTI2021

Seismic Performance of Deeply Embedded Conceptual Advanced Reactors: Three-Dimensional Nonlinear Soil-Structure Interaction Analyses

The U.S. Nuclear Regulatory Commission’s functional containment concept provides advanced nuclear power plant designers with more flexibility in terms of the civil/structural design if the appropriate set of barriers for prevention of radioactive material release exist. Some of the conceptual advanced reactor structures, without the traditional pressure boundaries of large containment structures, are proposed to be deeply embedded or buried into soil. This approach is expected to provide (1) lesser seismic demands on the structures and safety-critical structures, (2) eased regulatory efforts and overall design against other external hazards such as aircraft impact, and (3) overall cost savings. Further, one of the important aspects of assessing the technical and economic viability of deeply embedding advanced reactor buildings is to assess the seismic performance with the understanding of effects with material and geometric nonlinearities. This study investigates the seismic response of deeply embedded or buried advanced reactors by conducting three-dimensional nonlinear soil-structure interaction analyses. Although the results indicate that there is a general trend of decreased seismic response with increased embedment depths, the change in the dynamic environment with different embedment depths and the nonlinear environment under high-intensity seismic inputs may result in increased peak response at increased embedment depths.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Quantitative Analysis of Origin of Lithium Inventory Loss and Interface Evolution over Extended Fast Charge Aging in Li Ion Batteries

During the extreme fast charging (XFC) of lithium-ion batteries, lithium inventory loss (LLI) and reaction mechanisms at the anode/electrolyte interface are crucial factors in performance and safety. Determining the causes of LLI and quantifying them remain an essential challenge. We present mechanistic research on the evolution and interactions of aging mechanisms at the anode/electrolyte interface. We used NMC 532 /graphite pouch cells charged at rates of 1, 6, and 9 C up to 1000 cycles for our investigation. The cell components were characterized after cycling using electrochemical measurements, inductively coupled plasma optical emission spectroscopy, 7 Li solid-state nuclear magnetic resonance spectroscopy, and high-performance liquid chromatography/mass spectrometry. The results indicate that cells charged at 1 C exhibit no Li plating, and the increase of SEI thickness is the dominant source of the Li loss. In contrast, Li loss in cells charged at 9 C is related to the formation of the metallic plating layers (42%) the SEI layer (38.1%) and irreversible intercalation into the bulk graphite (19%). XPS analysis suggests that the charging rate has little influence on the evolution of SEI composition. The interactions between competing aging mechanisms were evaluated by a correlation analysis. In conclusion, the quantitative method established in this work provides a comprehensive analytical framework for understanding the synergistic coupling of anodic degradation mechanisms, forecasting SEI failure scenarios, and assessing the XFC lithium-ion battery capacity fade.

25 ENERGY STORAGE↗
DOE OSTI2025

Glovebox Fires Phase 1: Simulations of Open Burner Experiments

Understanding the duration of a fire required to breach a glovebox via glove ports and/or windows within a facility is important in developing mitigation strategies for safety. To facilitate this understanding, both simulation and experiments are utilized. The approach is to first validate the Computation Fluid Dynamics (CFD) code, Fire Dynamics Simulator (FDS), with experimental data collected by New Mexico Tech (NMT) and then perform simulations of full-scale rooms containing gloveboxes to assess numerous scenarios which would otherwise be cost-prohibitive experimentally. This report provides comparison to first-phase experiments involving a fire without a glovebox. A subsequent report will provide comparison to experiments involving a glovebox. The results indicate good agreement with FDS tending to over predict the pre-mixed and diffusion-mode tests by 6% and 10%, respectively.

42 ENGINEERING↗
DOE OSTI2026

Identifying Bounds of Inorganic Content in Solventless Processing of Hybrid Solid Electrolytes

Solid-state lithium batteries require safe, robust electrolytes to enable higher energy densities and improved safety over conventional cells. Hybrid polymer–ceramic electrolytes are a promising solution, combining the processability of polymers with the high ionic conductivity and mechanical strength of inorganic fillers. In this work, we demonstrate a solventless, UV-curing method to produce hybrid solid electrolytes using a poly(ethylene glycol) dimethyl ether (PEGDME)-based photocurable matrix incorporating Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP) or Li 7 La 3 Zr 2 O 12 (LLZO) ceramic electrolyte. Inorganic filler loadings up to ∼55 wt.% could be successfully incorporated via this process which was the highest inorganic content at which the slurry remains processable and cured into a uniform film. The resulting UV-cured composite electrolytes remain flexible and exhibit room-temperature ionic conductivities on the order of 10 −4 S·cm −1 , along with notably improved lithium-ion transference numbers compared to conventional polymer electrolytes. Similar performance and processing limits were observed for both LAGP and LLZO, indicating that ceramic filler chemistry does not significantly affect the UV-curing process or the electrolyte's ion transport properties in this regime. Eliminating solvents from fabrication not only simplifies processing and mitigates environmental concerns but also enables higher solid contents that enhance mechanical strength and help suppress lithium dendrite formation. In conclusion, this scalable approach thus paves the way for manufacturing robust composite solid electrolytes for next-generation solid-state batteries (SSBs).

Batteries↗