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DOE OSTI2025

Nanoscopic strain evolution in single-crystal battery positive electrodes

Single-crystal Ni-rich layered oxides (SC-NMC) with a grain-boundary-free configuration have effectively addressed the long-standing cracking issue of conventional polycrystalline Ni-rich materials (PC-NMC) in lithium-ion batteries, prompting a shift in optimization strategies. However, continued reliance on anisotropic lattice volume change—a well-established failure indicator in PC-NMC—as a metric for understanding strain and guiding compositional design for SC-NMC becomes controversial. Here, in this study, by leveraging multiscale diagnostic techniques, we unravelled the distinct nanoscopic strain evolution in SC-NMC during battery operation, challenging the conventional composition-driven strategies and mechanical degradation indicators used for PC-NMC. Through particle-level chemomechanical analysis, we reveal a decoupling between mechanical stability and lattice volume change in SC-NMC, identifying that structural instability in SC materials is primarily driven by multidimensional lattice distortions induced by kinetics-driven reaction heterogeneity and progressively deactivating chemical phases. Using this mechanical failure mode, we redefine the roles of cobalt and manganese in maintaining mechanical stability. Unlike cobalt’s detrimental role in PC-NMC, we find cobalt to be critical in enhancing the longevity of SC-NMC by mitigating localized strain along the extended diffusion pathway, whereas manganese exacerbates mechanical degradation.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Fe-rich X-ray amorphous material records past climate and persistence of water on Mars

X-ray amorphous material comprises 15-73 wt.% of sedimentary rocks and eolian sediments in Gale crater. This material is variably siliceous and iron rich but aluminum poor. The presence of volatiles is consistent with the existence of incipient weathering products. To better understand the implications of this material for past aqueous conditions on Mars, here we investigate X-ray amorphous material formation and longevity within terrestrial iron rich soils with varying ages and environmental conditions using bulk and selective dissolution methods, X-ray diffraction, and transmission electron microscopy. Results indicate that in situ aqueous alteration is required to concentrate iron into clay-size fraction material. Cooler climates promote the formation and persistence of X-ray amorphous material whereas warmer climates promote the formation of crystalline secondary phases. Iron rich X-ray amorphous material formation and persistence on Mars are therefore consistent with past cool and relatively wet environments followed by long-term cold and dry conditions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Impacts of molecular architecture on the radiation-induced degradation and reaction kinetics of hydrophobic diglycolamides with the solvated electron and the dodecane radical cation

Given their proposed use as trivalent actinide–lanthanide separation ligands, the role of molecular architecture on the radiation robustness of diglycolamide (DGA) molecules has been investigated. This study examined three prototypical molecules with differences in their aliphatic chain architecture: N,N,N′,N′-tetra(n-octyl)diglycolamide (TODGA), N,N,N′,N′-tetra(2-ethylhexyl)diglycolamide (T2EHDGA), and N,N′-dimethyl-N,N′-dioctyldiglycolamide (DMDODGA). Rate coefficients and activation parameters are reported for the reactivity of each DGA with the solvated electron (e solv − ) and the corresponding dodecane radical cation (RH˙ + ) over the temperature range of 10.0 to 44.1 °C. These measurements indicate that DMDODGA is the most chemically reactive with both transient radicals, which may be attributed to this molecule's more accessible backbone. Complementary gamma dose accumulation studies (≤ 600 kGy) under envisioned process conditions—50 mM DGA in n-dodecane solvent—afforded dose constants for the loss of DGA of d = (3.41 ± 0.07) × 10 −3 , (4.19 ± 0.09) × 10 −3 , and (4.65 ± 0.09) × 10 −3 kGy −1 for T2EHDGA, DMDODGA, and TODGA, respectively. These dose constants indicate that varying DGA architecture affords subtle differences in chemical reactivity, leading to varying rates of radiolytic degradation under envisioned actinide–lanthanide separation conditions. However, more ambitious DGA frameworks, such as modifying the backbone, branching of the aliphatic chains, and/or changing the size of the chain may be required for larger gains in radiolytic longevity while optimizing actinide–lanthanide selectivity.

Arrhenius parameters↗

DOE OSTI2026

Chemical and morphological evolution of hybrid conversion coatings in low-Earth orbit space environment

Understanding how protective coatings respond to the harsh low-Earth orbit (LEO) environment is essential for ensuring the safety, longevity, and cost-effectiveness of spacecraft. In particular, identifying environmentally friendly, non-chromate alternatives that can maintain performance under such conditions has both technological and regulatory significance. This study investigates the environmental stability of zirconium-based hybrid conversion coatings with Cu additives (Cu10 and Cu20) applied to cold-rolled steel, tested in the Materials International Space Station Experiment (MISSE) outside the International Space Station (ISS). Chemical and morphological analyses were carried out using a combination of electron microscopy and X-ray spectroscopy techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy with energy-dispersive X-ray spectroscopy (STEM-EDS), X-ray photoelectron spectroscopy (XPS), and X-ray absorption near-edge structure (XANES) spectroscopy. After exposure outside the ISS, all coatings remained structurally intact, with all exhibiting a uniform Zr-rich matrix and embedded Cu-rich clusters, while a thin Si-rich surface layer developed from interaction with space environments. Depth-resolved XPS showed a layered structure with CuO on the surface, Cu 2 O, and partial Zr(IV) reduction near Cu-rich sites, evidence of Atomic Oxygen (AO)-driven surface oxidation. These results demonstrate that Cu–Zr coatings maintain their chemical integrity and microstructure in harsh space environments, offering a non-chromate alternative for long-term aerospace protection. These insights provide valuable guidance for developing next-generation protective coatings that combine environmental sustainability with the reliability required for future aerospace and orbital applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

The CXSFIT spectral fitting code: Past, present and future

Magnetically confined plasma experiments generate a wealth of spectroscopic data. The first step toward extracting physical parameters is to fit a spectral model to the often complex spectra. The CXSFIT (Charge eXchange Spectroscopy FITting) spectral fitting code was originally developed for fitting charge exchange spectra on JET from the late 1980s onward and has been further developed over decades to keep up with the needs of the users. The primary use is to efficiently fit a large number of spectra with many constrained Gaussian spectral lines of which the physical parameters can be coupled in a user-friendly manner. More recent additions to the code include time-dependent couplings between parameters, flexible background subtraction, and a non-linear coupling scheme between fit parameters. The latter was a pre-requisite for implementing Zeeman and motional Stark effect multiplets in the library of spectral features. The ability to save and replay “fit recipes,” even when multiple iterations are required, has ensured the traceability of the results and is one of the keys to the longevity and success of the code. The code is also in use on other tokamaks (AUG, ST-40) and to fit data from other spectroscopic diagnostics on JET. In this paper, we document the current capabilities and philosophy behind the structure of the code, including some of the algorithms used to calculate spectral features numerically efficiently. We also provide an outline of how CXSFIT could be transferred into a framework that would be able to meet the spectral fitting requirements of future devices, such as ITER.

Delabie, Ephrem G.↗

DOE OSTI2025

Runaway electron-induced plasma facing component damagein tokamaks

This Roadmap article addresses the critical and multifaceted challenge of plasma facing component (PFC) damage caused by runaway electrons (REs) in tokamaks, a phenomenon that poses a significant threat to the viability and longevity of future fusion reactors such as ITER and DEMO. The dramatically increased RE production expected in future high-current tokamaks makes it very difficult to avoid or mitigate REs in such devices when a plasma discharge terminates abnormally. Preventing damage from the intense localised heat loads they can cause requires a holistic approach that considers plasma, REs and PFC damage. Despite decades of progress in understanding the physics of REs and the thermomechanical response of PFCs separately, their complex interplay remains poorly understood. This document aims to initiate a coordinated, interdisciplinary approach to bridge this gap by reviewing experimental evidence, advancing diagnostic capabilities, and improving modelling tools across different scales, dimensionalities, and fidelities. Key topics include RE beam formation and transport, damage mechanisms in both brittle and metallic PFCs, and observed effects in major facilities such as JET, DIII-D, WEST and EAST. The Roadmap emphasises the urgency of predictive, high-fidelity modelling validated against well-diagnosed controlled experiments, particularly in the light of recent changes in ITER’s wall material strategy and the growing importance of private sector fusion initiatives. Each section of the Roadmap article is written to provide a concise overview of one area of this multidisciplinary subject, with an assessment of the status, a look at current and future challenges, and a brief summary. The ultimate goal of this initiative is to guide future mitigation strategies and design resilient components that can withstand the intense localised loads imposed by REs, thus ensuring the safe and sustainable operation of the next generation of fusion power plants.

Ratynskaia, Svetlana [KTH Royal Inst. of Technolog↗

DOE OSTI2025

Image registration for accurate electrode deformation analysis in operando microscopy of battery materials

Operando imaging techniques have become increasingly valuable in both battery research and manufacturing. However, the reliability of these methods can be compromised by instabilities in the imaging setup and operando cells, particularly when utilizing high-resolution imaging systems. The acquired imaging data often include features arising from both undesirable system vibrations and drift, as well as the scientifically relevant deformations occurring in the battery sample during cell operation. For meaningful analysis, it is crucial to distinguish and separately evaluate these two factors. To address these challenges, we employ a suite of advanced image-processing techniques. These include fast Fourier transform analysis in the frequency domain, power spectrum-based assessments for image quality, as well as rigid and non-rigid image-registration methods. These techniques allow us to identify and exclude blurred images, correct for displacements caused by motor vibrations and sample holder drift and, thus, prevent unwanted image artifacts from affecting subsequent analyses and interpretations. Additionally, we apply optical flow analysis to track the dynamic deformation of battery electrode materials during electrochemical cycling. This enables us to observe and quantify the evolving mechanical responses of the electrodes, offering deeper insights into battery degradation. Together, these methods ensure more accurate image analysis and enhance our understanding of the chemomechanical interplay in battery performance and longevity.

Sun, Tianxiao↗

DOE OSTI2024

Rapid Characterization and Statistical Analysis of High-Volume Field-Harvested Photovoltaic Connectors

Photovoltaic (PV) installations heavily depend on connectors for efficient module and string interconnections without requiring skilled labor. Yet this seemingly innocuous component of PV systems is a leading cause of module failures, multiple high-profile fires, and lawsuits in the PV industry. This work aims to answer critical questions regarding why connectors fail and the contributing factors to their failure. The study involves collecting and analyzing more than 17,000 field-harvested connectors from various solar installations across the United States. The vast dataset, which includes connector metadata, visual inspections, and resistance measurements, provides unprecedented insight into the state of health of PV connectors across the US, including the geographic locations, connector types, and installation practices most prone to failures. The work presented here describes a novel rapid characterization method for processing large numbers of connectors and is supported by parallel forensic analysis to discern the root causes of failures as well as a levelized cost of lifetime model to determine the economic ramifications of connector failure. Ultimately, the findings may inform PV developers about the best practices to extend connector longevity and lead to more resilient and reliable PV systems.

connectors↗

DOE OSTI2025

A Hybrid Fuel Cell and Battery Storage Power Management for Grid-Interactive EV Charging Station

With the increasing adoption of renewable energy sources in grid-interactive Electric Vehicle (EV) charging stations, the role of energy storage systems has become critical. While large energy storage systems have mitigated the intermittency of renewable energy, integrating multi-source energy management with prioritized charging can further enhance the reliability of charging stations (CS). This paper presents a decentralized energy management (DEM) approach combining battery energy storage (BES) and fuel cell (FC) systems using a rule-based line resistance correction droop (LRCD) control technique. The proposed droop control dynamically adjusts the gain to balance the state-of-charge (SoC) of the BES, enhancing power support longevity and improving battery life under varying capacity conditions by reducing current stress. Additionally, the paper addresses the challenges of using fuel cells in linear regions to optimize efficiency and manage various charging scenarios. The CS integrates unity power factor grid interaction, and power support for auxiliary loads, maintaining harmonic distortion within 5% during grid islanding. The approach evaluates DC bus voltage regulation under various scenarios of PV array power fluctuations and dynamic load variations, in both grid-connected and standalone operations. In conclusion, the proposed control strategy is validated on a laboratory prototype through various dynamic load variation and grid islanding scenarios.

Khalid, Mohd [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2024

STUDIES ON PIPELINE POLYETHYLENES IN HYDROGEN GAS ENVIRONMENTS USING IN-SITU AND EX-SITU CHARACTERIZATION METHODS

Polymeric materials are commonplace in the natural gas infrastructure as distribution pipes, coatings, seals, and gaskets. Under the auspices of the U.S. Department of Energy HyBlend program, one of the means to reduce greenhouse gas emissions is with replacing natural gas, either partially or completely, with hydrogen. This approach makes it imperative that we conduct near-term and long-term materials compatibility research in these relevant environments. Insights into the effects of hydrogen and hydrogen gas blends on polymer integrity can be gained through both ex-situ and in-situ analytical methods. Our work represented here highlights a study of the behavior of pipeline polyethylene (PE) materials, including HDPE (Dow 2490 and GDB50) and MDPE (Ineos and legacy Dupont Aldyl A), when exposed to hydrogen by means of in-situ X-ray scattering and ex-situ Raman spectroscopy techniques. Samples were tested in ex-situ hydrogen and argon gas environments and in-situ hydrogen environments to identify differences due to permeation and solubility of these gases. These methods complemented each other because Raman spectroscopy could capture permanent effects after materials were removed from gaseous environments, and in-situ X-ray scattering analysis collected real-time data to elucidate the impact of the gas environment on polymer microstructure. Data collected revealed that the aforementioned polymers did not show significant changes in crystallinity and microstructure under the exposure conditions tested. Our findings from these studies will help establish real-time effects caused by hydrogen gas transport through pipeline polyethylenes by way of its influence on polymer structure and chemistry, which is directly related to pipeline mechanical strength and longevity of service.

Hydrogen materials compatibility, Natural gas pipe↗

DOE OSTI2025

Atomic layer deposited aluminum nitride for interface protection of lithium germanium thiophosphate solid electrolytes

Lithium germanium thiophosphate (LGPS) is an attractive solid-state electrolyte material due to its exceptionally high ionic conductivity (~1.2 × 10 –2 S cm –1 ), comparable to many organic liquid electrolytes commonly used in batteries. Despite the high conductivity of LGPS, the susceptibility of LGPS to deleterious degradation reactions has impeded its commercial adoption into solid-state batteries. In particular, the poor voltage stability of LGPS with high-voltage cathode or lithium metal potentials often results in dramatically increasing cell impedance during galvanic cycling. Here, we use aluminum nitride (AlN) as a protection layer for Li metal anode, applied directly to the LGPS at 250 °C using plasma-enhanced atomic layer deposition, to enhance cell performance by preventing LGPS-Li metal reactions. We compare the surface chemistry and electrochemical cycling performance of atomic layer-deposited AlN grown using both plasma N 2 and NH 3 precursors. Galvanostatic cycling and electrochemical impedance spectroscopy show that AlN-coated LGPS cells perform better than bare LGPS cells in contact with Li metal anodes, with the AlN able to improve cycling longevity by over a factor of 3 in certain cases. Finally, we utilize x-ray photoelectron spectroscopy (XPS) line scans to highlight the slow room-temperature reactivity between AlN and evaporated lithium metal, and a computational model is built to aid further XPS analysis.

25 ENERGY STORAGE↗

DOE OSTI2026

Oil-impregnated densified wood veneer with high electrical insulation enabled by nanosized oil channels

Growing energy demands and renewable integration are stressing the aging power grid infrastructure. Lignocellulosic oil-impregnated paper is widely used in power transformers but suffers from critical limitations, such as low dielectric strength, mechanical strength, and thermal conductivity, causing premature transformer failures. Here, we demonstrate a superior electrically insulating oil-impregnated paper design using the naturally anisotropic structure of densified wood veneer to achieve nanosized channels of oil that efficiently disrupt electrical breakdown pathways. The developed oil-impregnated densified wood (ODW) creates aligned cellulose fibers with 166 ± 87–nanometer oil nanochannels, achieving record dielectric strength of 105 kilovolts per millimeter. The structure also delivers a mechanical strength of up to 384 megapascals and a thermal conductivity of 0.33 watts per meter per kelvin, enabling enhanced longevity upon thermal aging tests. The ODW could replace conventional transformer insulation to enhance power transformer performance and improve lifetime. Moreover, its anisotropic oil-filled nanochannel design offers a general strategy for hybrid dielectrics in medium- and high-voltage applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Impact of the LiPF6 Concentration on the Interfacial Charge Transfer and Fast-charging Capabilities of Lithium-Ion Batteries

Fast-charging lithium-ion batteries (LIB) demand optimized electrolyte formulations to balance ionic conductivity, viscosity, and interfacial charge transfer kinetics. This study examines how LiPF 6 concentration shapes solvation structure, desolvation energy, charge transfer activation energy, and solid electrolyte interphase (SEI) properties, which are critical for fast-charging performance. Using Raman spectroscopy, electrochemical cycling, X-ray photoelectron spectroscopy, and atomistic modeling, we analyze how varying LiPF 6 concentrations impact interfacial and bulk transport properties. Our findings show that increasing LiPF 6 concentration alters lithium solvation structures, reduces desolvation energy, and accelerates charge transfer at the electrode interface. Higher concentrations lower the activation energy for charge transfer and suppress excessive SEI growth, improving interfacial kinetics. However, concentrations above a certain threshold increase viscosity and reduce ionic conductivity, limiting transport efficiency. These results offer insights into electrolyte solvation and interfacial charge transfer mechanisms, providing guidelines for designing next-generation fast-charging LIB electrolytes with enhanced efficiency, stability, and longevity.

Son, Seoung-Bum [Argonne National Laboratory (ANL)↗

DOE OSTI2025

Multiscale Modeling Framework for Lithium Nucleation in 3D Porous Carbon Anodes

Porous carbon scaffolds offer a promising route for mitigating non-uniform lithium (Li) plating to enhance the safety and longevity of Li metal batteries. However, the influence of microstructural morphology on Li nucleation is not well understood. Here, we present a multiscale modeling framework to investigate how the porous microstructure of carbon materials affects Li nucleation behavior. Ab initio molecular dynamics simulations quantify the nucleation energy barriers of Li on graphene as a function of Li content, surface curvature, and applied potential, providing key parameters for a classical nucleation theory (CNT) model. From macroscale half-cell simulations, we obtained Li concentration and electrical potential profiles to define boundary conditions for mesoscopic simulations. At the mesoscale, three distinct synthetic 3D microstructures with different porosities and characteristic feature sizes are generated to resolve local distributions of Li flux, current density, and mechanical stress. These outputs are integrated into the CNT model to map spatial variation in nucleation rates. Our findings reveal trade-offs between suppressing nucleation rates and achieving spatial uniformity, offering design guidelines for optimizing porous carbon anodes to balance nucleation control and mechanical integrity.

Materials science↗

DOE OSTI2025

On Stability and Electrochemical Performance of 316 Stainless Steel in Wastewater: Implications for Resource Recovery

Electrochemical nutrient recovery systems rely on stable electrode materials capable of operating in chemically complex wastewater environments. We investigated corrosion resistance and interfacial electrochemical behavior of 316 stainless steel (SS316) in a synthetic wastewater matrix representative of centrate streams, a key knowledge gap in electrochemical phosphorus recovery. A comprehensive suite of electrochemical techniques (chronoamperometry, cyclic voltammetry, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS)) and surface characterization methods (scanning electron microscopy, X-ray diffraction) were employed. Results revealed that wastewater containing typical ionic constituents (such as PO 4 3- , NH 4 + , and divalent cations) exhibited enhanced cathodic activity and the formation of a more stable, protective surface film on SS316 that mitigated chloride-induced corrosion. In contrast, SS316 in the NaCl solution showed significant susceptibility to passive layer breakdown and localized corrosion. Time-resolved EIS further confirmed improved interfacial stability and restricted charge transfer in WW over time, in stark contrast to the progressive passive layer degradation in NaCl. Surface analyses corroborated these findings, showing limited surface attack in WW compared to distinct localized corrosion features in NaCl. These findings indicate that competing ionic species in WW effectively mitigate chloride aggressiveness, enhance SS316 stability, and demonstrate improved electrode longevity and reliability for sustainable wastewater-based electrochemical phosphorus recovery applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Sensor Data Analytics and Data Quality Assessment Software

The proposed framework derives a set of quality metrics to provide critical insights into and tracking of grid operations, sensor performance, sensor longevity, and event statistics. Power grid engineers can utilize this information to identify problems with existing sensor locations and problematic power grid assets including generators, transmission lines, load centers, and substations. This information can also be used to identify unexpected/abnormal behavior of power grid components, improve power grid observability, and operational monitoring, and thus enhance real-time decision-making support system. Power grid planners can utilize this information to augment existing sensing architecture with new sensors and improve the observability of the network.

Mahapatra, Kaveri↗

DOE OSTI2024

Atmospheric Variability Drives Anomalies in the Bering Sea Air–Sea Heat Exchange

Abstract High latitudes, including the Bering Sea, are experiencing unprecedented rates of change. Long-term Bering Sea warming trends have been identified, and marine heatwaves (MHWs), event-scale elevated sea surface temperature (SST) extremes, have also increased in frequency and longevity in recent years. Recent work has shown that variability in air–sea coupling plays a dominant role in driving Bering Sea upper-ocean thermal variability and that surface forcing has driven an increase in the occurrence of positive ocean temperature anomalies since 2010. In this work, we characterize the drivers of the anomalous surface air–sea heat fluxes in the Bering Sea over the period 2010–22 using ERA5 fields. We show that the surface turbulent heat flux dominates the net surface heat flux variability from September to April and is primarily a result of near-surface air temperature and specific humidity anomalies. The airmass anomalies that account for the majority of the turbulent heat flux variability are a function of wind direction, with southerly (northerly) wind advecting anomalously warm (cool), moist (dry) air over the Bering Sea, resulting in positive (negative) surface turbulent flux anomalies. During the remaining months of the year, anomalies in the surface radiative fluxes account for the majority of the net surface heat flux variability and are a result of anomalous cloud coverage, anomalous lower-tropospheric virtual temperature, and sea ice coverage variability. Our results indicate that atmospheric variability drives much of the Bering Sea upper-ocean temperature variability through the mediation of the surface heat fluxes during the analysis period. Significance Statement A long-term ocean warming trend and a recent increase in marine heatwaves in the Bering Sea have been identified. Previous work showed that anomalies in the exchange of heat between the ocean and the atmosphere were the primary driver of Bering Sea temperature variability, but the processes responsible for the heat exchange anomalies were unknown. In this work, we show that the atmosphere is the primary driver of anomalies in the Bering Sea air–sea heat exchange and therefore plays an important role in altering the thermal state of the Bering Sea. Our results highlight the importance of understanding more about how the ocean and the atmosphere interact at high latitudes and how this relationship will be affected by future climate change.

Hayden, Emily E. [a College of Earth, Ocean, and A↗

DOE OSTI2024

Identification and time evolution of thionyl chloride (SOCl 2 ) radiolysis products

In this study, innovative solutions are needed to reduce the amount of high-level waste generated by used nuclear fuel recycling strategies to support the widespread adoption of sustainable nuclear fission energy technologies. To this end, a new sulfur chloride-based process has been developed to recycle zirconium alloy-based materials, which make up a significant fraction of high-level radioactive waste. To support the continued development of this process, we present new data on the potential reaction pathways over time of the products arising from the gamma and electron beam radiolysis of neat thionyl chloride (SOCl 2 ). Interrogation of the gamma irradiated liquid by Raman spectroscopy provided more conclusive identification of the SOCl 2 degradation products, specifically sulfur dichloride (SCl 2 ), molecular chlorine (Cl 2 ), sulfur dioxide (SO 2 ), and sulfuryl chloride (SO 2 Cl 2 ). In comparison, the high dose rate (~10 7 Gy s -1 ) electron beam irradiations formed significantly more degradation products. For both cobalt-60 gamma and electron beam irradiations, the observed degradation products were found to evolve as a function of time post-irradiation via the same reaction pathways, with indication of a solvent regeneration mechanism. These findings are fortuitous for process development, as such a mechanism would be beneficial for process longevity and cost effectiveness.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗