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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Comparison of Single-Phase Convection in Additive Manufactured Versus Traditional Metal Foams

Abstract Metal foams have been often used for thermal management due to their favorable characteristics including high specific surface area (SSA), high thermal conductivity, and low relative density. However, they are accompanied by shortcomings including the significant contact resistances due to attachment method, as well as the need for characterization of foam parameters such as pore diameter and SSA. Additive manufactured (AM) metal foams would eliminate the substrate/foam thermal resistance, decrease the need for pre-usage characterization, and allow for tailoring structures, while also taking advantage of the characteristics of traditionally manufactured foams. A commercial, aluminum foam (nominally 5 pores per inch (PPI), 86.5% porosity) was analyzed using X-ray microcomputed tomography, and a custom-designed metal foam based on the cell diameter and porosity of the commercial sample was subsequently manufactured. Reduced domain computational fluid dynamics/heat transfer (CFD-HT) models were compared against experimental data. Postvalidation, the flow behavior, effect of varying attachment thermal conductivities, and thermal performance were numerically investigated, demonstrating the usefulness of validated pore-scale models, as well as the potential for improved performance using AM metal foams over traditionally manufactured foams.

Engineering↗
DOE OSTI2022

Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation

Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.

42 ENGINEERING↗
DOE OSTI2021

Bayesian Poroelastic Aquifer Characterization From InSAR Surface Deformation Data. 2. Quantifying the Uncertainty

Uncertainty quantification of groundwater (GW) aquifer parameters is critical for efficient management and sustainable extraction of GW resources. These uncertainties are introduced by the data, model, and prior information on the parameters. We develop a Bayesian inversion framework that uses Interferometric Synthetic Aperture Radar (InSAR) surface deformation data to infer the laterally heterogeneous permeability of a transient linear poroelastic model of a confined GW aquifer. The Bayesian solution of this inverse problem takes the form of a posterior probability density of the permeability. Exploring this posterior using classical Markov chain Monte Carlo (MCMC) methods is computationally prohibitive due to the large dimension of the discretized permeability field and the expense of solving the poroelastic forward problem. However, in many partial differential equation (PDE)-based Bayesian inversion problems, the data are only informative in a few directions in parameter space. For the poroelasticity problem, we prove this property theoretically for a one-dimensional problem and demonstrate it numerically for a three-dimensional aquifer model. Here we design a generalized preconditioned Crank-Nicolson (gpCN) MCMC method that exploits this intrinsic low dimensionality by using a low-rank-based Laplace approximation of the posterior as a proposal, which we build scalably. The feasibility of our approach is demonstrated through a real GW aquifer test in Nevada. The inherently two-dimensional nature of InSAR surface deformation data informs a sufficient number of modes of the permeability field to allow detection of major structures within the aquifer, significantly reducing the uncertainty in the pressure and the displacement quantities of interest.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Albedo of crops as a nature-based climate solution to global warming

Abstract Surface albedo can affect the energy budget and subsequently cause localized warming or cooling of the climate. When we convert a substantial portion of lands to agriculture, land surface properties are consequently altered, including albedo. Through crop selection and management, one can increase crop albedo to obtain higher levels of localized cooling effects to mitigate global warming. Still, there is little understanding about how distinctive features of a cropping system may be responsible for elevated albedo and consequently for the cooling potential of cultivated lands. To address this pressing issue, we conducted seasonal measurements of surface reflectivity during five growing seasons on annual crops of corn-soybean–winter wheat ( Zea mays L.- Glycine max L. Merrill - Triticum aestivum L. ; CSW) rotations at three agronomic intensities, a monoculture of perennial switchgrass ( Panicum virgatum L. ), and perennial polycultures of early successional and restored prairie grasslands. &#xD;We found that crop-species, agronomic intensity, seasonality, and plant phenology had significant effects on albedo. The mean±SD albedo was highest in perennial crops of switchgrass (0.179±0.04), intermediate in early successional crops (0.170±0.04), and lowest in a reduced input corn systems with cover crops (0.154±0.02). The strongest cooling potentials were found in soybean (-0.450 kg CO 2 e m -2 yr -1 ) and switchgrass (-0.367 kg CO 2 e m -2 yr -1 ), with up to -0.265 kg CO 2 e m -2 yr -1 of localized climate cooling annually provided by different agroecosystems. We also demonstrated how diverse ecosystems, leaf canopy, and agronomic practices can affect surface reflectivity and provide another potential nature-based solution for reducing global warming at localized scales.

Lei, Cheyenne (ORCID:0000000272746309)↗
DOE OSTI2026

Conus-Wide Mapping of Water Availability and Cost

Background: New demands for water can be satisfied through a variety of source options. In some basins surface and/or groundwater may be available through permitting with the state water management agency (termed unappropriated water), alternatively water might be purchased and transferred out of its current use to another (termed appropriated water), or non-traditional water sources can be captured and treated (e.g., wastewater). The relative availability and cost of each source are key factors in the development decision. Unfortunately, these measures are location dependent with no consistent or comparable set of data available for evaluating competing water sources. With the help of water managers, water availability was mapped for over 2500 watersheds throughout CONUS. These values are unique in that they account for institutional factors (i.e., water rights, compacts, treaties, instream flows) that locally limit water use. Five water sources were individually examined, including unappropriated surface water, unappropriated groundwater, appropriated water, municipal wastewater and brackish groundwater. Associated costs to acquire, convey and treat the water, as necessary, for each of the five sources were estimated. These metrics were developed to support regional water planning and policy analysis with initial application to electric transmission planning in the western US. Problem: These data were originally developed in 20141 and updated in 20182. New datasets on which these data depend have been published. As such, there is need to update the water availability and cost data. There is also need to map this same data to a county resolution and to publish the data in a more accessible place. Organization of the dataset: Data are organized according to five primary water sources: • Unappropriated fresh surface water • Unappropriated fresh groundwater • Appropriated water • Recycled wastewater, and • Brackish water

Tidwell, Vincent [Pacific Northwest National Labor↗
DOE OSTI2020

Urbanization drives convergence in soil profile texture and carbon content

Urban development has driven extensive modification of the global landscape. This shift in land use and land cover alters ecological functioning, and thereby affects sustainable management agendas. Urbanization fundamentally reshapes the soils that underlay landscapes, and throughout the soil profile, extends impacts of urbanization far below the landscape surface. The impacts of urbanization on deeper soils that are beyond the reach of regular land management are largely unknown, and validation of general theories of convergent ecosystem properties are thwarted by a dearth of both level of measurement effort and the substantial heterogeneity in soils and urban landscapes. Here, we examined two soil properties with strong links to ecological functioning—carbon and mineral-fraction particle size—measured in urban soils, and compared them to their pre-urbanization conditions across a continental gradient encompassing global soil diversity. We hypothesized that urbanization drove convergence of soils properties from heterogeneous pre-urban conditions towards homogeneous urban conditions. Based on our observations, we confirm the hypothesis. Both soil carbon and particle size converged toward an intermediate value in the full data distribution, from pre-urban to urban conditions. These outcomes in urban soils were observed to uniformly be fine textured soils with overall lower carbon content. Although these properties are desirable for supporting urban infrastructure (e.g. buildings, pipes), they constrain the potential to render ecosystem services. Since soil profile texture and carbon content were convergent and observed across 11 cities, we suggest that these property profiles can be used as a universal urban soil profile to: 1) provide a clear prediction for how urbanization will shift soil properties from pre-urban conditions, 2) facilitate the adoption of commonly-accepted soil profiles for process models, and 3) offer a reference point to test against urban management strategies and how they impact soil resources.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Reservoir Sediment Management and Monitoring Database

Overview This dataset compiles dam sediment management and monitoring information from surveys, case studies, and journal articles. Additionally, features described by the National Inventory of Dams (i.e., presence of sluice gates) are included to indicate known infrastructure features that may address sediment releases. The location and description of records from downstream monitoring gages are catalogued in order to help with tracking conditions over time (e.g., before and after management actions, as operations change, etc.). The data help address national scale understanding of challenges and solutions related to the accumulation of sediment behind a dam as well as downstream passage. Sediment trapping causes problems as it reduces storage capacity, disrupts dam and reservoir function, impedes access for recreation, alters water quality/habitat conditions, and contributes to riverbank and coastal erosion within the reservoir. Data compilation from a variety of sources is a first step towards assessing system-wide efficacy of management solutions. This dataset was developed under the Water Power Technologies Office funded effort which began as a Seedling on Reservoir Sedimentation Data, and was supported by the Reservoir Sedimentation Modeling Framework and Data Analysis project. These projects have addressed challenges in describing sediment transport, trapping, and management at dams throughout the US. Methodology An outer join on dams/reservoirs with surveys and survey reports (documented in the RESSED database, USBR or USACE databases, project websites, etc.) with the National Inventory of Dams, based on the NIDID to determine dams with documented management and/or sluice gates. Additional dams with documented management activity were identified through review of technical articles from the past 25 years in Journal of Hydrology, Journal of Water Resources Planning and Management, Geomorphology, Journal of Hydraulic Engineering, Water, Journal of Cleaner Production, International Journal of Sediment Research, Nature Scientific Reports, Earth Surface Processes and Landforms, and Environmental Science and Pollution Research. Individual records were created for each survey or management activity documented. To evaluate downstream sediment monitoring records, the nhdPlusTools and dataRetrieval packages in R were used to find gages within 10km of each dam in the management database. Length of record and location of matched gages were retrieved for those parameters relevant to sediment concentration or total sediment discharge.

Hansen, Carly [ORNL] (ORCID:0000000193280838)↗
DOE OSTI2024

Exploring CO 2 reduction and crossover in membrane electrode assemblies

Electrochemical CO 2 reduction (CO 2 R) using renewable electricity is a key pathway toward synthesizing fuels and chemicals. In this study, multi-physics modeling is used to interpret experimental data obtained for CO 2 R to CO using Ag catalysts in a membrane electrode assembly. The one-dimensional model is validated using measured CO 2 crossover and product formation rates. The kinetics of CO formation are described by Marcus–Hush–Chidsey kinetics, which enables accurate prediction of the experimental data by accounting for the reorganization of the solvent during CO 2 R. Further, the results show how the performance is dictated by competing phenomena including ion formation and transport, CO 2 solubility, and water management. The model shows that increasing the ion-exchange capacity of the membrane and surface area of the catalyst increases CO formation rates by >100 mA cm –2 without negatively impacting CO 2 utilization. Here we provide insights into how to manage the trade-off between productivity and CO 2 utilization in CO 2 electrolyzers.

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

AmeriFlux FLUXNET-1F US-Ne2 Mead - irrigated maize-soybean rotation site

This is the AmeriFlux Management Project (AMP) created FLUXNET-1F version of the carbon flux data for the site US-Ne2 Mead - irrigated maize-soybean rotation site. This is the FLUXNET version of the carbon flux data for the site US-Ne2 Mead - irrigated maize-soybean rotation site produced by applying the standard ONEFlux (1F) software. Site Description - The study site is one of three fields (all located within 1.6 km of each other) at the University of Nebraska Eastern Nebraska Research, Extension and Education Center near Mead, Nebraska. This site is irrigated with a center pivot system. Prior to the initiation of the study, the irrigated site had a 10-yr history of maize-soybean rotation under no-till management. A tillage operation (disking) was done just prior to the 2001 planting to homogenize the top 0.1 m of soil, incorporate P and K fertilizers, as well as previously accumulated surface residues. Since this tillage operation, the site has been under no-till management in a maize-soybean rotation (maize odd years and soybean even years). There was a brief period due to an intercomparison study from 2010 to 2013 when fall conservation tillage was performed and maize (not soybean) was planted in 2010 and 2012. The management reverted to a strictly no-till maize-soybean crop rotation after 2014.

Suyker, Andy [University of Nebraska - Lincoln]↗
DOE OSTI2020

Lessons Learned from Demolition of Hanford's Plutonium Finishing Plant - 20507

U.S. Department of Energy (DOE) contractor CH2M Hill Plateau Remediation Company (CHPRC), a Jacobs owned company, is making significant progress demolishing the Plutonium Finishing Plant (PFP), which has long been known as one of the most hazardous buildings in the DOE Environmental Management Complex (DOE Complex). The facility is located on the Hanford Site and produced plutonium metal during the Cold War. Production was stopped in 1989, the facility was formally shut down in 1996, and material processing was completed in 2004. After approximately 25 years of demolition preparations, open-air demolition of the main portions of the Hazard Category II nuclear facility began in November 2016. To prepare the PFP for demolition, CHPRC employees performed some of the most hazardous work across the DOE Complex. In addition to extensive demolition preparations, including a wide-reaching communication strategy across the Hanford Site, CHPRC implemented robust controls and monitoring during demolition, and when necessary, adjusted demolition practices and sequence to maintain employee safety and project efficiency. Demolition of the main PFP building began in November 2016. The technical complexity, high hazards and radiological concerns have all led to a difficult demolition environment. Following a spread of contamination at the project site beyond the radiological boundaries in December 2017, work was halted and a recovery plan was generated to allow the demolition work to continue. After the implementation of additional controls and concurrence from regulatory agencies and DOE, the demolition was ready to resume work and reinitiated in August 2018. There are a number of lessons learned from the demolition activities and recovery plan process. This paper allows CHPRC and DoE's Richland Operations Office (RL) to share lessons learned and progress to date with other challenging and hazardous projects across the DOE Complex. Understanding the risk acceptance level is critical to execution of any open-air demolition project and is unique to each facility. Four key lessons learned from this project include: 1) plan execution issues, 2) stakeholder communication issues, 3) watching for summit fever and 4) minimizing exposed contaminated surfaces during demolition. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Capillary-Enhanced Two-Phase Micro-Cooler Using Copper-Inverse-Opal Wick with Silicon Microchannel Manifold for High-Heat-Flux Cooling Application

In this work, we demonstrate a two-phase capillary-fed boiling micro-cooler that consists of a ~ 25-..mu..m-thick copper inverse opal (CIO) porous wicking structure for high-heat-flux boiling and a silicon 3D-manifold for distributed liquid delivery and vapor extraction across a 0.5 cm x 0.5 cm heated area. At low inlet water mass flow rates of 1.5 to 1.9 g(min)-1, the micro-cooler displays nearly two-phase boiling with exit vapor quality ~ 1 and a high critical heat flux (CHF) of 253 to 320 W cm-2 with low superheat of ~ 10 degrees C resulting in a thermal resistance of boiling ~ 0.025 cm2 degrees C W-1 or heat transfer coefficient of 0.4 MW m-2 degrees C-1. For higher flow rates of 5, 10, and 15 g(min)-1, the micro-cooler exhibits a hybrid single-phase and two-phase cooling regime where the contribution of the sensible heat (single-phase) cooling is linearly added to that of the two-phase cooling. For the highest flow rate of 15 g(min)-1, the CHF is increased to ~ 500 W cm-2 resulting in an overall thermal resistance of ~ 0.18 cm2 degrees C W-1. However, the two-phase heat transfer effectiveness, which estimates the utilization level of the inlet mass flow rate for two-phase boiling, is reduced to ~ 0.11. To achieve the best cooling system performances, the micro-cooler must operate entirely within the two-phase boiling regime (exit vapor quality or two-phase heat transfer effectiveness ~ 1). Ideally, the "coolant" should be delivered near its saturation temperature (~ 100 degrees C for water), which provides significant advantages for the energy-efficient operation of data centers and power electronics. We present detailed analysis with Infrared and high speed camera images at various inlet flow rates and heat fluxes to understand complex heat transfer in the micro-cooler. Furthermore, a conjugate thermofluidic simulation model, which incorporates the physics of capillary-fed boiling in a porous copper layer, agrees well with the experimental data.

capillary-enhanced boiling↗
DOE OSTI2023

Using temperature and flow fields to detect gas leakage from canisters containing spent nuclear fuel: Applications to RAMM-TM

The multi-physics STAR-CCM+ code has been used to simulate the temperature and flow fields in canister gas leakage experiments conducted by using a 1/4.5-scale model storage cask. The simulations were conducted at Argonne National Laboratory’s Laboratory Computing Resource Center, utilizing high-performance computing resources. Development of STAR-CCM+ simulation models for the 1/4.5-scale model cask is described herein, followed by validation of the simulation results against experimental data. Canister depressurization and thermal response during gas leakage are discussed, along with analyses of the leakage path and allowable leakage rate. The insights gained from the STAR-CCM+ simulations and leakage analyses will help guide future experiments and actual industry applications of Argonne’s Remote Area Modular Monitoring system for canister surface temperature measurement (RAMM-TM) to enable effective aging management of spent fuel during extended dry storage, as well as help reduce risks to public safety and health and protect the environment.

Canister gas leakage↗
DOE OSTI2021

Fabrication of Quasi-Random Photonic Crystals for Ultrathin Solar Cells

Quasi-random structures for light management present an intermediate ordering between a completely random rough surface and a perfect ordered photonic crystal. They are attractive for broadband applications due to their power spectral density. This makes them excellent candidates for photovoltaic applications. Here we present preliminary fabrication results creating quasi-random structures using a self-assembly approach based on polymer blends and wet etching. We are able to create patterns with average lattice constant of five to two microns. This structure is proposed to be used as a rear patterning layer for ultrathin GaAs cells for better sustainability and radiation- hard devices.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2021

Flow Assisted Evaporative Cooling for Electric Motor

This paper examines a novel concept of flow assisted latent heat driven two-phase evaporative cooling (EC) confined in-between slot liner and active-winding of electric motor. Wicking micro-structure enhanced PDMS liner axially sucks coolant in the form of thin film between the PDMS liner and active-winding and eventually enables thin film evaporation on the outer surface of the active-winding. Therefore, EC based thermal management eliminates contact resistance between the winding and slot-liner and, enhances the heat extraction from the winding without compromising the electro-magnetic performance. Two-way coupled electro-magnetic (EM) – computational fluid dynamics/heat transfer (CFD/HT) and EM - lumped parameter thermal network (LPTN) models have been developed to assess the electro-thermal performance of the EC under steady and transient conditions. Taking a case study of a 125 kW jacket cooled BMW i3 motor and dielectric coolant FC-84, EC is shown to be capable of handling a maximum steady state rms current density of 26 A/mm2 at a evaporative heat transfer coefficient of 5,000 W/m2.K, which is about 78.7% higher compared to the traditional jacket cooling (JC). In case of EC, a maximum steady state and transient rms current density of 30 A/mm2 (106.2% higher compared to the JC), and 40.8 A/mm2 have been realized by using high thermal conductivity epoxy (1.9 W/m.K) impregnation material. Thermal performance of the EC is also assessed and compared with JC over a dynamic drive cycle. Lastly, a motorette testing has been performed to demonstrate the applicability of the proposed EC method and to validate the developed modeling framework.

42 ENGINEERING↗
DOE OSTI2023

Editorial: Sorption processes in nuclear waste management: data knowledge management and new methodologies for data acquisition/prediction

A fundamental approach to Nuclear Waste Repository research involves the collection of experimental data in a laboratory setting, development of empirical and/or mechanistic numerical models representing those observations, and application of these models (or Reduced Order Models) into reactive transport and performance assessment models as predictive tools for informing society of impacts and risks associated with nuclear waste repository scenarios (Stevens et al., 2020). Therefore, the assimilation and interpretation of experimental data must take advantage of both new data and the rich historical data available in the literature and apply novel modeling approaches to improve predictive tools, particularly from the standpoint of uncertainty quantification, for nuclear waste repository performance assessment (Zavarin et al., 2022).

sorption↗
DOE OSTI2025

Experimental characterization of a triply periodic minimal surface PCM-to-air thermal energy storage device

Here, the expansion of energy production has intensified research into thermal energy storage (TES) to manage variability and improve system efficiency. Heat exchanger design is critical to achieving high power densities in TES systems. This study presents a high-surface-area phase change material (PCM)-to-air heat exchanger fabricated via resin-based stereolithography with a novel gyroid-based geometry tailored for enhanced performance. Material properties of the commercial PCM and resin were characterized using analytical techniques. A controlled air loop was used to evaluate heat transfer and pressure drop at various flow rates and inlet temperatures. Results show a strong dependence on the inlet temperature difference (ΔT) relative to the PCM melting point. During charging at the highest flow rate, increasing the inlet air temperature from ΔT = 5 °C to 20 °C above the melting point increased the average heat transfer rate by 187%. During discharging, decreasing the inlet temperature by the same ΔT below the melting point led to a 232% increase. Notably, the high-surface-area design enabled nearly symmetric charging and discharging behavior, a novel result for PCM-based TES systems which are often restricted by natural convection and other effects. The overall heat transfer coefficient was calculated and compared to values from standard design correlations. The maximum thermal effectiveness reached 95% at ΔT = 20 °C and a moderate flow rate of 34 m 3 /h. Peak coefficients of performance (COP) of 7 during charging and 6.4 during discharging were observed at ΔT = 20 °C and a low flow rate of 20 m 3 /h. These results demonstrate the viability of additively manufactured geometries for advanced TES applications.

25 ENERGY STORAGE↗
DOE OSTI2026

Spontaneous crack healing in calcite reveals the influence of dynamic strain evolution and surface chemistry

The mechanics of fracture healing in calcite remain poorly constrained yet are fundamental to managing fluid transport in geothermal reservoirs and hydrocarbon systems. Here, we apply microfocused synchrotron Laue X-ray diffraction and infrared spectroscopy to investigate subcritical crack healing in a 1 mm-thick calcite crystal subjected to controlled loading in a double-torsion device. Over a 44-hour period following load removal, we map the evolution of residual strain fields surrounding the crack tip and observe a progressive increase in compressive strain perpendicular to the crack plane accompanied by infrared spectroscopic signatures that reveal enhanced accumulation of water at the healed interface. The correlation between strain evolution and surface chemistry suggests that spontaneous crack healing in calcite is driven by dynamic anelastic relaxation coupled with irreversible fluid-mineral interactions. These findings offer insight into time-dependent crack closure processes in carbonates and highlight the role of chemically-mediated plasticity in subsurface fracture evolution.

materials science↗
DOE OSTI2025

Additive Manufacturing of Thermal Energy Storage Composites with Microencapsulated Phase Change Materials Supported in a Multipolymer Matrix

Additive manufacturing (AM) techniques to directly integrate phase change materials (PCMs) are of interest for efficient thermal energy storage (TES) architectures. Complex, high surface-to-volume ratio composites embedded with PCM can improve thermal management with reduced material waste for customizable device fabrication. Reducing feature sizes of TES-integrated heat exchangers using AM can increase heat transfer without thermal conductivity enhancement. Here, composite AM materials containing 60 wt% microencapsulated phase change materials (MEPCM) are fabricated using off-the-shelf printers at common speeds and resolutions. High MEPCM loading in filaments is achieved with powder extrusion using two polymers, thermoplastic-polyurethane (TPU) and polycaprolactone (PCL), that mediate flexibility and rigidity for effective extrusion and printing without filament fracture or buckling. Furthermore, with PCL and TPU at 20 wt% each and 60 wt% MEPCM (P 20 T 20 M 60 ), smooth, form-stable filaments are consistently printed. Powder-based extrusion displays negligible damaging effects on the MEPCM. Printed P 20 T 20 M 60 demonstrates 105 J/g of energy storage with no degradation through 250 thermal cycles, within 5% of the theoretical storage enthalpy. Combining PCL/TPU shows good interfacial adhesion between print layers and produces high surface area objects, like 15% gyroids, and dense, 100% infilled pucks. Prints are also scalable to a 900 cm 3 honeycomb heat exchanger with an estimated 9 Wh energy storage.

25 ENERGY STORAGE↗