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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,603 records · Page 89
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Investigating Fast Scanning Calorimetry and Differential Scanning Calorimetry as Screening Tools for Thermoset Polymer Material Compatibility with Laser-Based Powder Bed Fusion

As additive manufacturing (AM) technology has developed and progressed, a constant topic of research in the area is expanding the library of materials to be used with these techniques. Among AM methods that utilize polymers, laser-based powder bed fusion (PBF-LB) has preferentially used thermoplastic polymers as its starting materials, but the deposition and material joining method employed in PBF-LB may also be compatible with powdered thermoset polymer precursors as feedstocks. To assess the compatibility of candidate thermosetting polymers and PBF-LB, characterization techniques and protocols that link fundamental material behavior to material behavior in the processing environment are needed. Therefore, the objectives of this work are to compare the curing behavior measured with two different calorimetry techniques that can operate in different heating rate regimes, differential scanning calorimetry (DSC) and fast scanning calorimetry (FSC), and to assess the capabilities of these techniques to act as materials screening tools for PBF-LB. A commercial polyester powder coating is used as a model material to evaluate the potential of obtaining complimentary information for material screening through a combination of calorimetry methods, and its non-isothermal curing behavior is measured at heating rates between 5 °C/min and 7500 °C/min. Curing exotherms are observed with both calorimetry techniques, and comparing the enthalpy associated with curing shows that incomplete curing occurs at higher heating rates, with relative conversion values of approximately 30%. The curing data are fit with two isoconversional models, Friedman and Starink, which show a reduced activation energy at higher heating rates as well, signifying a lower barrier to curing at the conditions used in the FSC experiments. Overall, the results of this work indicate that using these two calorimetry techniques as tiered screening tools can provide valuable information about how curing may proceed in PBF-LB and inform materials selection and design activities for additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2017

High-Performance Transition Metal Phosphide Alloy Catalyst for Oxygen Evolution Reaction

Oxygen evolution reaction (OER) is a pivotal process in many energy conversion and storage techniques, such as water splitting, regenerative fuel cells, and rechargeable metal-air batteries. The synthesis of stable, efficient, non-noble metal-based electrocatalysts for OER has been a long-standing challenge. In this work, a facile and scalable method to synthesize hollow and conductive iron–cobalt phosphide (Fe–Co–P) alloy nanostructures using an Fe–Co metal organic complex as a precursor is described. The Fe–Co–P alloy exhibits excellent OER activity with a specific current density of 10 mA/cm 2 being achieved at an overpotential as low as 252 mV. The current density at 1.5 V (vs reversible hydrogen electrode) of the Fe–Co–P catalyst is 30.7 mA/cm 2 , which is more than 3 orders of magnitude greater than that obtained with state-of-the-art Fe–Co oxide catalysts. Our mechanistic experiments and theoretical analysis suggest that the electrochemical-induced high-valent iron stabilizes the cobalt in a low-valent state, leading to the simultaneous enhancement of activity and stability of the OER catalyst.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Scalable focused ion beam creation of nearly lifetime-limited single quantum emitters in diamond nanostructures

The controlled creation of defect centre—nanocavity systems is one of the outstanding challenges for efficiently interfacing spin quantum memories with photons for photon-based entanglement operations in a quantum network. Here we demonstrate direct, maskless creation of atom-like single silicon vacancy (SiV) centres in diamond nanostructures via focused ion beam implantation with ~32 nm lateral precision and <50 nm positioning accuracy relative to a nanocavity. We determine the Si+ ion to SiV centre conversion yield to be ~2.5% and observe a 10-fold conversion yield increase by additional electron irradiation. Low-temperature spectroscopy reveals inhomogeneously broadened ensemble emission linewidths of ~51 GHz and close to lifetime-limited single-emitter transition linewidths down to 126±13 MHz corresponding to ~1.4 times the natural linewidth. Furthermore, this method for the targeted generation of nearly transform-limited quantum emitters should facilitate the development of scalable solid-state quantum information processors.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Single-atom Zr promoter boosts oxygen activation on ceria-supported Pt catalysts

Activation of surface lattice oxygen and chemisorbed oxygen on catalyst surfaces constitutes a pivotal step in heterogeneous oxidative catalysis. Herein, we report a strategy for enhancing oxygen activation by rational design of catalysts with single-atom promoters. Single-site Zr species in CeO 2 (Zr 1 -CeO 2 ) are synthesized using the atom-trapping method. The Zr 1 -CeO 2 -supported Pt catalyst exhibits enhanced catalytic performance over the CeO 2 -supported Pt catalyst in the oxidation of CO, C 3 H 8 , and C 3 H 6 , achieving significantly lower T 50 values (temperature required to reach 50% conversion). This enhanced catalytic activity is attributed to the formation of an asymmetric Zr 1 -O-Pt 1 structure, which favors the activation of the adjacent surface lattice oxygen and chemisorbed molecular oxygen. This work exemplifies that incorporating single-site atoms into oxide support facilitates oxygen activation, providing new insights into the role of atomically dispersed promoters in heterogeneous catalysis.

Science & Technology - Other Topics↗
DOE OSTI2020

Attosecond pulse shaping using a seeded free-electron laser

Attosecond pulses are central to the investigation of valence- and core-electron dynamics on their natural timescales. The reproducible generation and characterization of attosecond waveforms has been demonstrated so far only through the process of high-order harmonic generation. Several methods for shaping attosecond waveforms have been proposed, including the use of metallic filters, multilayer mirrors and manipulation of the driving field. However, none of these approaches allows the flexible manipulation of the temporal characteristics of the attosecond waveforms, and they suffer from the low conversion efficiency of the high-order harmonic generation process. Free-electron lasers, by contrast, deliver femtosecond, extreme-ultraviolet and X-ray pulses with energies ranging from tens of microjoules to a few millijoules. Recent experiments have shown that they can generate subfemtosecond spikes, but with temporal characteristics that change shot-to-shot. In this paper we report reproducible generation of high-energy (microjoule level) attosecond waveforms using a seeded free-electron laser. We demonstrate amplitude and phase manipulation of the harmonic components of an attosecond pulse train in combination with an approach for its temporal reconstruction. The results presented here open the way to performing attosecond time-resolved experiments with free-electron lasers.

47 OTHER INSTRUMENTATION↗
DOE OSTI2017

Rapid and Low Temperature Densification of Gadolinia Doped Ceria Barrier Layers by Photonic Curing

Nanohmics successfully demonstrated the viability of photonic sintering as a method to form densified gadolina doped ceria (GDC) barrier layers. Photonic sintering utilizes short pulses (millisecond regime) of broad spectrum light from a xenon flash lamp to convert densely packed nanoparticle thin films to bulk films through the absorption of optical energy and its subsequent conversion to heat; this results in grain ripening and/or melt and reflow the particles. The transformation of GDC nanoparticle thin films to bulk materials was accomplished by formulating various GDC nanoparticle “inks”, spin casting or tape casting these inks onto yttria stabilized zirconia (YSZ) substrates, brief low temperature (~700°C) bake outs to remove organic binders/plastisizers, and photonically sintering these substrates with a variety of conditions and sintering aids.

03 NATURAL GAS↗
DOE OSTI2018

Control of Interface- and Mesoscopic Structure in High Performance Organic Solar Cells: Towards a Predictive Device Paradigm [and earlier project titles]. Final Technical Report for DE-FG02-98ER45737

This document represents the cumulative, final technical report for Grant No. DE-FG02-98ER45737, the title of which has changed with each funding period, but the research pursued is within a coherent overall theme of methods and technique developments that exploit contrast at the carbon absorption edge to characterize complex organic materials and the use of these synchrotron radiation-based methods for important research challenges in polymer physics and Materials Science. The last three funding periods focused on organic devices and in particular organic solar cells (OSCs), owing to their extra-ordinarily complex morphology, yet high potential as a cheap and printable power-conversion technology.

14 SOLAR ENERGY↗
DOE OSTI2019

Development of mathematical model and simulation tool for the high capacity production of carbon fiber

Weight reduction in the transportation is the most effective way for reducing fuel consumption. Carbon fiber composites have been increasingly used by automotive manufacturers in vehicle nonstructural and structural parts. Larger penetration of carbon fiber-based materials requires very large quantities of fiber at a low price, and of consistently high quality. The advancements in carbon fiber technology that are required to achieve this production scale-up and cost reduction, are very challenging. The most expensive production step is the conversion of textile-grade polyacrylonitrile (PAN) precursor to carbon fiber. The conversion takes place in three main stages: stabilization, low and high temperature carbonization. Most of the research to date has focused on the stabilization of the PAN precursors and oxidized PAN fibers. Comparingly little effort has been dedicated to the investigation of processing conditions during low temperature (LT) carbonization. During this stage of fiber conversion, the largest fiber mass loss occurs, and the fundamental carbon fiber structure and material properties are established. The understanding of the conversion processes in the LT furnace, and the effects of spatial and temporal variations of the LT process parameters on the carbon fiber properties are necessary to identify possible process improvements and cost savings. The objective of this research was to develop computational models for gas flow and energy transport in the gas and fiber phases of the LT furnace, and to couple them with the fiber conversion process models. The model is implemented in the three-dimensional framework that enables analysis of process condition variations in all directions. The formulation is based on modified transport equation to simulate steady state conditions and thus significantly reduce computational effort associated with transient methods. The model is implemented in open source computational fluid dynamics (CFD) code OpenFOAM. The model has been demonstrated on a prototype carbon fiber LT furnace and can be extended to other geometries and process conditions. Extensions to other physical effects, such as accounting evolution of multiple gas species, and fiber tensioning are straightforward. The model uses High Performance Computing (HPC) capabilities of OpenFOAM and can be implemented on multi-processor workstations or mid-size computer clusters common in the industrial setting.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Chemical Recycling of Plastic Waste to Higher Value Lubricants

The aim of this project was to develop scalable methods to convert plastic waste to petrochemical-equivalent feedstocks and demonstrate their utility in lubricant base oil and wax applications. These objectives were partially accomplished, by scaling up the synthesis of platinum-on-strontium titanate catalysts to twenty gram batches, scaling up the conversion of plastic waste to twenty-five grams of plastic, producing high-melt waxes and characterizing their properties, and demonstrating the purification of high-melt waxes. High-melt waxes are one petrochemical-equivalent feedstock that can be made from plastic waste, consisting of a hard wax with a melt point above 65 C. They are used as ingredients in hot melt adhesives, coatings, and cosmetics. Producing a petrochemical-equivalent feedstock from plastic waste provides an advantage in lower carbon footprint and manufacturing cost, as the waste feedstock costs less than crude oil.

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

“Green” Fabrication of High-performance Transparent Conducting Electrodes by Blade Coating and Photonic Curing on PET for Perovskite Solar Cells

This study presents an innovative material processing approach to fabricate transparent conducting electrodes (TCEs) on polyethylene terephthalate (PET) substrates using blade coating and photonic curing. The hybrid TCEs consist of a multiscale Ag network, combining silver metal bus lines and nanowires, overcoated by an indium zinc oxide layer, and then photonically cured. Blade coating ensures film uniformity and thickness control over large areas. Photonic curing, a non-thermal processing method with significantly lower carbon emissions, enhances the conductivity and transparency of the coated layers. Our hybrid TCEs achieve an average transmittance of (81 ± 0.4)% referenced to air ((90 ± 0.4)% referenced to the PET substrate) in the visible range, an average sheet resistance of (11 ± 0.5) Ω sq−1, and an average surface roughness of (4.3 ± 0.4) nm. We benchmark these values against commercial PET/TCE substrates. Mechanical durability tests demonstrate <3% change in resistance after 2000 bending cycles at a 1 in radius. The scalable potential of the hybrid TCE fabrication method is demonstrated by high uniformity and excellent properties in 7 in × 8 in large-area samples and by performing the photonic curing process at 11 m min−1. Furthermore, halide perovskite solar cells fabricated on these hybrid TCEs achieve average and champion power conversion efficiencies of (10.5 ± 1.0) % and 12.2%, respectively, and significantly outperform devices made on commercial PET/TCEs. This work showcases our approach as a viable pathway for high-speed “green” manufacturing of high-performance TCEs on PET substrates for flexible optoelectronic devices.

Bonner, Justin C↗
DOE OSTI2025

Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)

Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.

25 ENERGY STORAGE↗
DOE OSTI2022

Enabling practical nanoparticle electrodeposition from aqueous nanodroplets

The rapid rise of technology in the modern world has led to an increased demand for energy. Consequently, it is essential to increase the efficiency of current energy-producing systems due to the poor activity of their catalysts. Nanoparticles play a significant role in energy storage and conversion; however, electrodeposition of nanoparticles is difficult to achieve due to surface heterogeneities, nanoparticle diffusion layer overlap, and the inability to electrodeposit multi-metallic nanoparticles with stoichiometric control. These problems can be solved through nanodroplet-mediated electrodeposition, a technique where water nanodroplets are filled with metal salt precursors that form stable nanoparticles when they collide with a negatively-biased electrode. Further, this method has demonstrated control over nanoparticle size and morphology, displaying a wide variety of applications for the generation of materials with excellent catalytic properties. Historically, the cost of nanodroplet-mediated electrodeposition experimentation is prohibitive because practitioners use 0.1 M to 0.5 M tetrabutylammonium perchlorate (TBAP) dissolved in the oil phase (∼10 mL). Such high concentrations of electrolytes have been used to lower ohmic drop and provide ions to maintain charge balance during electrodeposition. Here, we show that supporting electrolyte is not necessary for the oil phase. In fact, one can use a suitable salt (such as lithium perchlorate) in the aqueous phase to achieve nanoparticle electrodeposition. This simple change, grounded in an understanding of ion transfer, drives down the cost per experiment by nearly three orders of magnitude, representing a necessary step forward in enabling practical nanoparticle electrodeposition from water nanodroplets. This approach is a promising procedure for future cost-effective energy conversion systems relying on electrocatalytic nanoparticles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Nanostructured carbon as highly efficient and stable anodes for ethylene production and power generation in protonic ceramic electrochemical cells

Protonic ceramic electrochemical cells (PCECs) have the potential in reducing the energy input and carbon emissions in ethylene production from ethane dehydrogenation. The performance of conventional perovskite-based anode materials for ethane conversion in PCECs is limited by their low active surface area and proneness to coke deposition. In this work, for the first time, we demonstrate the use of aligned carbon nanotube forests (CNTFs) as a novel anode material for an ethane fueled PCEC to co-produce ethylene and electricity. The CNTF electrode was grown on the electrolyte by the chemical vapor deposition (CVD) method. Highly dispersed iron carbide nanoparticles are formed in situ on the CNTFs during the CVD process, acting as highly active catalysts for ethane dehydrogenation. The novel PCECs show superior catalytic and electrochemical performances to that using conventional perovskite-based anodes. The cell also exhibits excellent durability and anti-coking abilities within 100 h test. This work showcases the promising application of nanostructured carbon, a new class of non-perovskite materials, as the multifunctional electrode materials for PCECs.

03 NATURAL GAS↗
DOE OSTI2019

US-India Consortium for Development of Sustainable Advanced Lignocellulosic Biofuel Systems

This multi-institutional project had as it main objectives to develop a fully integrated platform for the production of advanced biofuels, specifically butanol, from sustainably produced switchgrass and biomass sorghum and to develop economic models that could guide the establishment of a crop to fuel value chain. The project was organized into three work packages: (1) WP1 Feedstock Development and Supply. Activities in this WP resulted in the development of improved biomass sorghum cultivars and biomass hybrids that generate high yields of biomass with limited inputs of water, fertilizer and agri-chemicals and that display less recalcitrance to enzymatic saccharification at the biorefinery; the identification of physiological responses and genes associated with sorghum’s tolerance to water logging as the basis for the development of biomass sorghums that can be cultivated on land prone to flooding; the identification of water-logging tolerant switchgrass genotypes among existing germplasm; the identification of management practices that maximize switchgrass biomass yield (fertilizer applications, harvest regimens) on commercial farms on different types of soil in Missouri. (2) WP2 Biorefinery Technologies. This WP included the development of a recombinant E. coli strain able to convert fermentable sugars derived from biomass sorghum and switchgrass to butyrate as a precursor for the advanced biofuel butanol. Butanol is toxic to most microbes, so that yields tend to be low. In contrast, butyrate can be produced in high titer and high yield by several naturally occurring bacteria, but these species are strictly anaerobic, which complicates commercial production. Our strategy involved developing a recombinant strain of E. coli able to produce high yields and high titers of butyrate. The butyrate can then be reduced to butanol via chemical conversion. In addition, a techno-economic analysis of converting sorghum and switchgrass biomass to ethanol was conducted based on data obtained at a pilot biorefinery. These data combined with small-scale butanol production data were used as the basis for a techno-economic analysis of biomass-to-butanol conversion. Furthermore, the biorefinery stillage was evaluated as a source of fertilizer or soil amendment. In contrast to the use of biochar as a soil amendment, stillage resulted in enhanced microbial activity in the soil and release of CO2. Stillage was determined to be a suitable feedstock for biogas production in an anaerobic digester. Biorefinery lignin can be blended with polymers to create novel UV-resistant materials promising for application in outer space, and as a source of organic acids for use in plastics. These applications offer opportunities to create value from the biorefinery residues. (3) WP3. This WP focused on development of economic models that can help define the most successful strategy for implementing biofuel production from bioenergy crops. Southeastern Missouri was determined to be the best location for a bio-butanol facility that processes biomass crops, due to the abundance of feedstock within a small radius of the facility. The most effective transportation method is by rail car. Feedstock availability was considered a more important driver for commercial success than the availability of a butanol market. The average cost of producing switchgrass biomass was calculated to be $65/ton assuming a biomass yield of 8 tons per hectare (the upper end of the yield in the commercial trials in WP2). Lower yields drive up costs, but improved genotypes will conversely reduce costs. Based on farmer surveys, conducting university extension activities was determined to positively influence farmers’ willingness to consider switchgrass. Other factors included experience with pasture land and forest land, and the availability of policies that provide a safety net to the farmers in case of instability in the biofuels market. This instability can be mitigated in part by ensuring adequate biomass supplies through diversification. The project supported the training of 20 graduate students and resulted in 57 peer-reviewed journal articles (with eight additional in review or in progress), eight book chapters and five patents.

09 BIOMASS FUELS↗
DOE OSTI2022

Advance modification of polyacrylonitrile nanofibers for enhanced removal of hexavalent chromium from water

Hexavalent chromium [Cr(VI)] is a known carcinogenic and mutagenic heavy metal. Its level in drinking water is regulated worldwide to protect public health. This work presents a novel chemical method to modify the polyacrylonitrile (PAN) nanofibers for efficient Cr(VI) removal from water. The PAN nanofibers with an average diameter of 165 nm are produced using the electrospinning technique. Through a 2-step chemical modification process, the amidine polyacrylonitrile (APAN) nanofibers are synthesized by the conversion of nitrile groups [—C≡N] in PAN nanofibers into amidines [—C(N=NH)(NH 2 )]. The attenuated total reflectance Fourier transform (ATR-FTIR) spectroscopy revealed the successful conversion of nitrile groups into amidoximes, resulting in amidoximated polyacrylonitrile nanofibers, and subsequent conversion into amidine functional groups, forming the APAN nanofibers. Greater concentration of hydroxylamine hydrochloride, increased reaction time and temperature yielded higher conversion of nitrile groups into amidoximes to a maximum of 37%. The Cr(VI) uptake by APAN nanofibers was found as a multilayer adsorption process modeled by Freundlich isotherm. The maximum Langmuir Cr(VI) adsorption capacity for APAN nanofibers was found as 225 mg g -1 at pH = 3.0 after 4.0 h exposure duration. The regeneration study revealed the excellent reusability of APAN nanofibers after five adsorption/desorption cycles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Co-deposition of hole-selective contact and absorber for improving the processability of perovskite solar cells

Simplifying the manufacturing processes of renewable energy technologies is crucial to lowering the barriers to commercialization. In this context, to improve the manufacturability of perovskite solar cells (PSCs), here we have developed a one-step solution-coating procedure in which the hole-selective contact and perovskite light absorber spontaneously form, resulting in efficient inverted PSCs. We observed that phosphonic or carboxylic acids, incorporated into perovskite precursor solutions, self-assemble on the indium tin oxide substrate during perovskite film processing. They form a robust self-assembled monolayer as an excellent hole-selective contact while the perovskite crystallizes. Our approach solves wettability issues and simplifies device fabrication, advancing the manufacturability of PSCs. Our PSC devices with positive-intrinsic-negative (p-i-n) geometry show a power conversion efficiency of 24.5% and retain >90% of their initial efficiency after 1,200 h of operating at the maximum power point under continuous illumination. The approach shows good generality as it is compatible with different self-assembled monolayer molecular systems, perovskites, solvents and processing methods.

14 SOLAR ENERGY↗
DOE OSTI2020

Unravelling a long-lived ligand-to-metal cluster charge transfer state in Ce–TCPP metal organic frameworks

Metal organic frameworks (MOFs) have emerged as promising photocatalytic materials for solar energy conversion. However, a fundamental understanding of light harvesting and charge separation (CS) dynamics in MOFs remains underexplored, yet they are key factors that determine the efficiency of photocatalysis. In this work, we report the design and CS dynamics of the Ce–TCPP MOF using ultrafast spectroscopic methods.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗