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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 145 records · Page 8

Physics-Informed Machine-Learning Prediction of Curie Temperatures and Its Promise for Guiding the Discovery of Functional Magnetic Materials

High-performance permanent magnets with a high Curie temperature, containing less critical materials, are integral to zero-carbon energy solutions. We built a machine-learning model trained over available experimentally measured Curie temperature values to predict the T C of multicomponent magnetic materials. We chose two compositions from a pseudo-binary (Zr 1–x Ce x )Fe 2 system, namely, (Zr 0.16 Ce 0.84 )Fe 2 and (Zr 0.94 Ce 0.06 )Fe 2 , to experimentally validate the ability of our model to predict the Curie temperature of novel compounds. We also provided a detailed discussion on the correlation of the Curie temperature with the de Gennes scaling factor in rare-earth intermetallic compounds and its breakdown below a certain rare-earth content. The electronic structure calculations (density of states and Fermi surface) were performed using the density functional theory on selected compounds (Zr 0.16 Ce 0.84 )Fe 2 and (Zr 0.94 Ce 0.06 )Fe 2 to understand the electronic origin of a strong magnetic exchange. We found that the change in the electronic density of states and electron/hole fillings at the Fermi level directly correlate with the Curie temperature. Notably, our model was able to capture these key electronic structure trends, which show that physics-informed machine learning can play a crucial role in designing new high-performance magnets with improved properties for environmentally sustainable applications.

36 MATERIALS SCIENCE↗

Wedge-Shaped Hopper Design for Milled Woody Biomass Flow

The bioenergy industry has been challenged by unstable flow and transport of milled biomass in material handling operations. Handling issues such as hopper clogging and auger jamming are attributed to knowledge gaps between existing handling units designed for bulk solids and their suitability for milled biomass with high compressibility. This work investigates various flow behaviors of granular woody biomass in wedge-shaped hoppers. Herein, hopper flow physical experiments and numerical simulations are conducted to study the influence of the critical material attributes and critical processing parameters on the flow pattern, arching, and throughput. The results show that (1) the preferred flow pattern, mass flow, can be achieved by controlling the material’s internal friction angle, hopper inclination, and hopper wall friction; (2) hopper arching, governed by the competing gravity-driven force against flow resistance from material internal friction and material–wall friction, can be controlled by the hopper wall friction angle and the inclination angle; and (3) flow throughput can be accurately estimated from our empirical equation with inputs of hopper outlet geometry and particle-scale to bulk-scale material attributes. This study elucidates woody biomass flow physics and provides guidance for industrial equipment design.

09 BIOMASS FUELS↗

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs ) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam).During this project ,samples of high-purity recycled NMC hydroxide (~2kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

99 GENERAL AND MISCELLANEOUS↗

Cost Competitive Process of Battery Grade Oxides Preparation from Aged LIBS

The increasing demand for lithium-ion batteries (LIBs) is driving development of advanced recycling and refining methods. In this project, new cathode active materials are prepared from recycled lithium battery materials and subsequently electrochemically evaluated in coin cells. In detail, scrap LIBs were mechanically processed into a metal rich black mass, then reductive acid leached into an aqueous metal solution, and finally high-purity metal hydroxide precursor materials were prepared by selective electrochemical flow precipitation. Closed-loop LIB recycling into active electrode materials will enable US manufacturers to break their reliance on foreign sources of critical materials. For example, electroextraction process used here has potential to significantly reduce chemical & water use as compared to traditional metallurgic techniques. To this end, electroextracted materials refined from used batteries were collected and processed to be tested as precursor cathode active material (pCam). During this project , samples of high-purity recycled NMC hydroxide (~2 kg each) were received from Nth Cycle. In the first received batch some impurities like cadmium, calcium, and sodium are present in quantities that would negatively impact battery performance. Nth Cycle indicated that the impurities such as cadmium are present due to poor battery separation and co-shredding of NiCd batteries with with LIB. Cadmium was not present in the two subsequent batches as Nth Cycle processed cadmium free black mass. Thus, effective recycled battery sorting is critical to closed-loop LIB recycling into active electrode materials.

25 ENERGY STORAGE↗

AVCOAT Density Characterization for Orion Multi-Purpose Crew Vehicle

The Orion Multi-Purpose Crew Vehicle (MPCV) will transport four crew members to and from lunar-class orbital destinations. The first orbital Exploration Flight Test (EFT-1) is scheduled for December 2014 and will provide valuable data on several systems, including the heat shield. The heat shield material is AvcoatTM, a mid-density ablator. Specifically, the heat shield contains a fiberglass-phenolic honeycomb structure filled with an ablative epoxy novolac resin. Post-flight characterization of the EFT-1 thermal protection system will be conducted in order to study the material response and measure the char front of the material. Avcoat density profiling will be conducted to study three critical material zones: char, pyrolysis, and virgin states as a function of material depth. As part of a ground test campaign, Avcoat coupons are tested at the NASA Ames Research Center Arc Jet Complex. The test campaign is set forth to study material response based on environments, perform Avcoat material density characterization, and compare the char depths from the HEAT sensor and density profiling studies. These investigations will then be compared to flight data in order to improve upon TPS material response models.

AVCOAT↗

Education and Workforce Development for Critical Minerals and Materials Supply Chains (Workshop Report)

The Advanced Materials and Manufacturing Technologies Office (AMMTO) aims to improve the efficiency, productivity, environmental impact, and competitiveness of the manufacturing sector. Education and workforce development (EWD) efforts are essential for AMMTO to achieve these goals, and for this reason the current and future EWD landscape in the critical minerals and materials (CMM) sector requires renewed attention.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Sustainable Direct Recycling of Lithium-Ion Batteries via Solvent Recovery of Electrode Materials

Separation of electrode materials from their current collectors is an enabling step toward recovering critical materials from spent lithium-ion batteries. In this study, a highly efficient, cost-effective, and environmentally sustainable separation process was developed for that purpose. Ethylene glycol, a vital commodity chemical as an antifreeze and polymer precursor, is used to delaminate electrode materials at low temperatures in seconds without altering the crystalline structure and morphology of active electrode materials. The recovered current collectors were intact without any corrosion. The authors also found that the solvent could be continuously reused, leading to the development of a closed-loop ecosystem and lithium-ion battery circular economy. The ultrafast delamination was driven by the competitive inhibition of binding through the weakening of hydrogen bonding. The ethylene glycol-based separation is a sustainable electrode recovery process that paves the way for battery recycling.

25 ENERGY STORAGE↗

Moving closer to experimental level materials property prediction using AI

Abstract While experiments and DFT-computations have been the primary means for understanding the chemical and physical properties of crystalline materials, experiments are expensive and DFT-computations are time-consuming and have significant discrepancies against experiments. Currently, predictive modeling based on DFT-computations have provided a rapid screening method for materials candidates for further DFT-computations and experiments; however, such models inherit the large discrepancies from the DFT-based training data. Here, we demonstrate how AI can be leveraged together with DFT to compute materials properties more accurately than DFT itself by focusing on the critical materials science task of predicting “formation energy of a material given its structure and composition”. On an experimental hold-out test set containing 137 entries, AI can predict formation energy from materials structure and composition with a mean absolute error (MAE) of 0.064 eV/atom; comparing this against DFT-computations, we find that AI can significantly outperform DFT computations for the same task (discrepancies of $$>0.076$$ > 0.076 eV/atom) for the first time.

36 MATERIALS SCIENCE↗

Life-cycle analysis of lithium chemical production in the United States

To achieve its ambitious national decarbonization goals, the United States has incentivized the domestic production of materials critical to decarbonization technologies, including lithium-ion batteries (LIBs). These materials include battery-grade lithium chemicals (Li-chemicals), for which the U.S. is encouraging domestic production from resources (sedimentary clays and low Li-content brines (LLCBs)) that differ substantially from conventional sources (Salar brines and spodumene ores). Here, we conduct the first-ever comparative life-cycle analysis of Li-chemical production from all alternative resources (in the U.S.) and conventional sources based on data from company literature for U.S.-related production efforts. Two energy sources (electricity and natural gas), four material inputs (HCl, NaOH, Na 2 CO 3 , and CaO), and process carbon emissions dominate the life-cycle impacts (≥90% share) of U.S.-based Li-chemical production. Comparatively, the life-cycle impacts of alternative sources-based Li-chemicals lie between those for Li-chemical production from Salar brines and from spodumene ores. At the battery level, the shift in Li-chemical sourcing causes a notable change in LIB's life-cycle impacts (by ~5–15%), independent of the cathode chemistry employed. Our study highlights the relevance of a decarbonized electric grid and the capture and sequestration of process carbon emissions generated during Li-chemical and upstream material production in decarbonizing Li-chemical production from alternative sources. Further decarbonization would necessitate using decarbonized material inputs and a shift away from natural gas towards renewable energy for alternative resource-based Li-chemical production processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Materials (FY 2022 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2022. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗

Materials (FR 2023 Annual Progress Report)

This document summarizes the progress of VTO Materials R&D projects supported during the fiscal year 2023. The Propulsion Materials portfolio is closely aligned with other VTO subprograms to identify critical materials needs for next-generation high-efficiency powertrains for both heavy- and light-duty vehicles. The Lightweight Materials portfolio works closely with industry through the U.S. DRIVE Partnership to understand light-duty vehicle structural weight-reduction goals and identify technical challenges that prevent the deployment of lightweight materials.

33 ADVANCED PROPULSION SYSTEMS↗

Impact of Nd ions on the chemical kinetic behavior of radiolytic transients in molten LiCl-KCl-NdCl3 salt mixtures

Pyrochemical reprocessing technologies can be used to recover valuable materials from used nuclear fuel (UNF), such as uranium. However, other critical materials, such as fission product neodymium, are challenging to recover from molten chloride eutectic mixtures (LiCl-KCl) due to the presence of multivalent states (Nd2+/Nd3+), disproportionation reactions, and re-dissolution in the molten chloride salt. Understanding, predicting, and controlling these processes is further complicated by the presence of ionizing radiation fields, for which little is known on the interaction of neodymium ions with the radiolytic transients (es– and Cl2.–) in molten LiCl-KCl salt mixtures. Here, chemical kinetics, from integrated electron pulse irradiation and transient absorption spectroscopy, are presented for the reaction of Nd3+ ions with es– and Cl2.– as a function of temperature (400–600 ?).

36 - MATERIALS SCIENCE↗

An Abrasive Wear Model of Knife Milling to Predict the Impact of Material Properties and Milling Parameters on Knife Edge Recession

A workable analytical abrasion model that relates critical knife-mill process parameters (geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) was formulated to model wear of knives in knife-milling systems. Results of the model were compared to experimental observations of the edge recession of knives used in a knife mill marketed by Eberbach. Results showed good agreement between the predicted and measured shape of a worn knife and showed that a quality-by-design approach can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

36 MATERIALS SCIENCE↗

Addressing Inherent Challenges to Chemical Relithiation of Cycled End‐of‐Life Cathode Materials

Recycling end‐of‐life (EOL) lithium‐ion batteries (LIBs) is important to retain valuable resources from critical materials present in EOL battery waste. Direct recycling methods offer an opportunity to recover intact valuable cathode materials with minimal re‐processing. An important step of the direct recycling process is relithiation which is used to restore lithium content to EOL cathode materials. However, little has been done to study how preprocessing steps such as washing or binder removal may affect relithiation methods in the direct recycling process. Here, the evolution of fluorine byproducts left over from preprocessing steps during a low‐temperature chemical redox mediator relithiation process is tracked. A facile washing step is presented as a solution for mediating adverse effects of surface contamination on the chemical relithiation performance. The structure, lithium content, and electrochemical performance of relithiated EOL NMC 622 material that underwent a pre‐relithiation washing step to remove fluorine byproducts is shown to match that of pristine NMC 622. In this work, it is showed that redox mediator relithiation as a part of a direct recycling process is a promising low energy method that can be applied to EOL material with inherent surface impurities if the proper pre‐relithiation processing steps are implemented.

25 ENERGY STORAGE↗

Cobalt–Nickel Exchange in Exfoliated Battery Layered Cathode Sheets with Application to Recycling

With the emerging dominance of electric vehicles (EV) in the transportation sector, recycling or upcycling spent battery materials will be required to reduce EV costs, lessen waste, and ease critical material supply chain issues for EV batteries. Here, motivated by work in the literature describing the exfoliation of layered oxides, first‐principles calculations are performed to show that Li x CoO 2 , if exfoliated into nanosheets, can readily undergo transition metal cation exchange in aqueous media. The substitution of Co 3+ or Co 4+ cations inside the sheet by Ni 2+ is associated with modest reaction barriers (Δ G* ≈ 0.3–0.7 eV) and is at most mildly endothermic (Δ G ≈ 0.2–0.3 eV). In contrast, previous battery degradation studies have shown that Co 3+ diffusion is strongly inhibited inside bulk layered oxides. This suggests that processing spent layered oxides as nanosheets can provide a potentially low‐energy‐cost pathway to altering the transition metal and/or dopant stoichiometry, which can be used toward developing new room‐temperature upcycling routes for cathodes from end‐of‐life batteries.

battery recycling↗

International Meeting on Fuel Cell and Electrolyzer Quality Control: Summary Report

Quality control (QC) for both polymer electrolyte membrane fuel cell and electrolysis membrane electrode assembly (MEA) materials is a key challenge for scale-up and cost reduction. Developing methods for detecting defects, as well as measuring critical material properties and understanding the impact of as-manufactured variations in these materials on cell performance and lifetime, are critical barriers. To help address these needs, the National Research Council Canada (NRC), Fraunhofer Institute for Solar Energy Systems (ISE), and the National Renewable Energy Laboratory (NREL) have organized and facilitated a series of workshops on the topic, bringing together industry, academia, and research institutions from North America and Europe. Prior workshops in Canada and Germany have focused on the status of quality tool capabilities and identification of needed developments for fuel cells. These meetings have garnered an excellent response and follow-on attendance, with over 100 unique attendees.

30 DIRECT ENERGY CONVERSION↗

Nano- and Earth-Science-inspired Electric Vehicle Battery Recycling to Secure Battery Supply Chain

With the expected growth of electric vehicles (EV) in the transportation sector, recycling or upcycling spent battery materials will be required to reduce EV costs, lessen waste, and ease critical material supply chain pressure for EV battery applications. “Direct” recycling or upcycling is an alternative to current industrial approaches. Many challenges remain for viable direct battery upcycling, including upgrading the transition metal ratio in the costliest component (cathode oxide); separation of transition metal ions in the exit stream; battery disassembly; improving cathode exfoliation which can lead to a new way of direct recycling; and lithium metal anode recycling -- including safety concerns. We devise and deploy a suite of methods to deal with these challenges. The results pave the way to future work on battery recycling, in areas of technological/commercial readiness level ranging from basic research to large-scale commercialization.

25 ENERGY STORAGE↗