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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

3D printed optimized electrodes for electrochemical flow reactors

Recent advances in 3D printing have enabled the manufacture of porous electrodes which cannot be machined using traditional methods. With micron-scale precision, the pore structure of an electrode can now be designed for optimal energy efficiency, and a 3D printed electrode is not limited to a single uniform porosity. As these electrodes scale in size, however, the total number of possible pore designs can be intractable; choosing an appropriate pore distribution manually can be a complex task. To address this challenge, we adopt an inverse design approach. Using physics-based models, the electrode structure is optimized to minimize power losses in a flow reactor. The computer-generated structure is then printed and benchmarked against homogeneous porosity electrodes. We show how an optimized electrode decreases the power requirements by 16% compared to the best-case homogeneous porosity. Future work could apply this approach to flow batteries, electrolyzers, and fuel cells to accelerate their design and implementation.

25 ENERGY STORAGE↗
DOE OSTI2025

Topology Optimization of Curved Electrodes with Suggested Simplified Corrugated Designs

The demand for space-efficient energy storage, from grid to device scale, has soared with the rapid electrification of society. To increase energy density while maintaining high rate performance, shaping electrodes has been shown to be an effective strategy. Computational optimization can suggest designs that improve energy storage performance; however, generated designs are often complex, leading to manufacturing challenges. Additionally, most optimization is typically conducted in standard rectangular domains, whereas some applications, such as in the aerospace industry or in consumer electronics, may benefit from optimized electrodes that fit in a nonstandard form factor. Here, in this work, we use topology optimization to design capacitive full-cell electrodes in a curved domain. We propose a simplified corrugated electrode design based on the optimization results and show that the energy stored in the simplified design is only reduced by about 5–27% when compared to that in the fully optimized design, with more deviation occurring when ionic transport in the porous electrode is particularly impeded. Overall, we find that these simplified designs are promising, particularly given the more conventional manufacturing techniques required, and have a 42–369% increase in energy stored compared to monolithic electrodes.

Energy - Storage↗
DOE OSTI2024

Li-ion battery design through microstructural optimization using generative AI

Lithium-ion batteries are used across various applications, necessitating tailored cell designs to enhance performance. Optimizing electrode manufacturing parameters is a key route to achieving this, as these parameters directly influence the microstructure and performance of the cells. However, linking process parameters to performance is complex, and experimental or modeling campaigns are often slow and expensive. This study introduces a fast computational optimization framework for electrode manufacturing parameters. A generative model, trained on a small dataset of microstructural images associated with different manufacturing parameters, efficiently generates representative microstructures for new parameters. This model is integrated into a Bayesian optimization loop that includes microstructure generation, characterization, and simulation, aiming to find optimal manufacturing parameters for a particular application. Significant improvement in the energy density of a 4680 cell is achieved through bespoke cell design, highlighting the importance of cell-scale normalization. The framework’s modularity allows its application to various advanced materials manufacturing scenarios.

batteries↗
DOE OSTI2024

Manufacturing of Fabric Electrodes using a High-Throughput Screening Platform for Redox Flow Batteries

The objective of this project is to establish a new manufacturing methodology with machine learning- based high-throughput screening for the design and development of hierarchical structured, high-performance fabric electrodes for redox flow batteries (RFBs). The end goal of the project is to design and manufacture fabric electrodes for RFB applications that can provide 250 mA/cm2 current density operation for 100-cycles with 80% average energy efficiency. This was accomplished by first examining the structure-performance-property linkages of the electrodes provided by our partner, AvCarb. The electrodes’ microstructure was characterized by determining their pore size distribution, tortuosity, specific surface area, and porosity. The ohmic, charge transfer and mass transfer resistances were then calculated using electrochemical impedance spectroscopy. Carbon cloth electrodes showed the greatest resistance, which was dominated by charge transfer resistance, which we believe is related to the surface functionalization. Full cell cycling was used in order to determine the area specific resistance and energy efficiency of the cells. All of this experimental data and the results of the mathematical model (to increase the amount of inputs with parametric sweeping) were used to develop a machine learning-based model for the design of high-performance fabric electrodes. Using the results from the machine learning tool, optimized electrodes were fabricated by AvCarb. The ohmic, charge transfer and mass transfer resistances for these new electrodes were measured, and both performed better than any of the initial samples which had been provided by AvCarb.

25 ENERGY STORAGE↗
DOE OSTI2025

Enhancing surface activity and durability in triple conducting electrode for protonic ceramic electrochemical cells

With the material system operating at lower temperatures, protonic ceramic electrochemical cells (PCECs) can offer high energy efficiency and reliable performance for both power generation and hydrogen production, making them a promising technology for reversible energy cycling. However, PCEC faces technical challenges, particularly regarding electrode activity and durability under high current density operations. To address these challenges, we introduce a nano-architecture oxygen electrode characterized by high porosity and triple conductivity, designed to enhance catalytic activity and interfacial stability through a self-assembly approach, while maintaining scalability. Electrochemical cells incorporating this advanced electrode demonstrate robust performance, achieving a peak power density of 1.50 W cm −2 at 600 °C in fuel cell mode and a current density of 5.04 A cm −2 at 1.60 V in electrolysis mode, with enhanced stability on transient operations and thermal cycles. The underlying mechanisms are closely related to the improved surface activity and mass transfer due to the dual features of the electrode structure. Additionally, the enhanced interfacial bonding between the oxygen electrode and electrolyte contributes to increased durability and thermomechanical integrity. This study underscores the critical importance of optimizing electrode microstructure to achieve a balance between surface activity and durability.

Protonic Ceramic Electrochemical Cells↗
DOE OSTI2024

Interpenetrated Structures for Enhancing Ion Diffusion Kinetics in Electrochemical Energy Storage Devices

The architectural design of electrodes offers new opportunities for next-generation electrochemical energy storage devices (EESDs) by increasing surface area, thickness, and active materials mass loading while maintaining good ion diffusion through optimized electrode tortuosity. However, conventional thick electrodes increase ion diffusion length and cause larger ion concentration gradients, limiting reaction kinetics. We demonstrate a strategy for building interpenetrated structures that shortens ion diffusion length and reduces ion concentration inhomogeneity. This free-standing device structure also avoids short-circuiting without needing a separator. The feature size and number of interpenetrated units can be adjusted during printing to balance surface area and ion diffusion. Starting with a 3D-printed interpenetrated polymer substrate, we metallize it to make it conductive. This substrate has two individually addressable electrodes, allowing selective electrodeposition of energy storage materials. Using a Zn//MnO 2 battery as a model system, the interpenetrated device outperforms conventional separate electrode configurations, improving volumetric energy density by 221% and exhibiting a higher capacity retention rate of 49% compared to 35% at temperatures from 20 to 0 °C. Our study introduces a new EESD architecture applicable to Li-ion, Na-ion batteries, supercapacitors, etc.

25 ENERGY STORAGE↗
DOE OSTI2025

Plasma assisted NH 3 /H 2 /air ignition in nanosecond discharges with non-equilibrium energy transfer

Ammonia (NH 3 ), with its high energy density and easiness to store and transport as a hydrogen carrier, has become a promising alternative green fuel. However, its adoption in power generation is hindered by challenges such as low burning velocity, slow low-temperature oxidation, high NO x emissions, and ignition difficulty. Here, this work computationally investigates the effects of non-equilibrium energy transfer by nanosecond discharges on NH 3 ignition and flame propagation in an NH 3 /H 2 /air flow at 700 K and 1 atm. The simulation results demonstrate that NH 3 /air mixtures require a large ignition energy due to their large critical ignition radius. It is shown that adding 30 % hydrogen significantly reduces the critical ignition radius and minimum ignition energy. Two-dimensional modeling further shows a non-monotonic dependence of ignition kernel volume on the applied voltage and reduced electric field. The optimum ignition enhancement occurs at 200 Td where the generation of electronically excited species and radicals including N 2 (B), O( 1 D) and OH becomes most efficient. Higher voltages divert electron energy toward ionization, which makes it less effective for NH 3 ignition. The study also identifies an optimal electrode gap size for a given pulse energy. Smaller gap sizes increase deposited energy density, raising temperature and radical concentrations. However, excessive reduction of the gap distance reduces flame propagation speed due to the flame stretch effect in rich mixtures with the effective Lewis number greater than unity. A nonlinear relationship between pulse repetition frequency and ignition kernel volume is observed in a nanosecond pulsed high frequency discharge (NPHFD). An optimal frequency range of 200 kHz to 2 MHz is found when two pulses are used. In addition, an optimal number of pulses exists for each pulse repetition frequency, with higher frequencies requiring more pulses to maximize the overlap region. These findings provide critical insights on developing controlled plasma discharge techniques for efficient NH 3 ignition in reactive flows within internal combustion engines and gas turbines.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Impact of processing humidity on ionomer film structure and performance in hydroxide exchange membrane electrolyzers

Hydroxide exchange membrane electrolyzers (HEMELs) enable hydrogen production using low-cost, earth-abundant materials. Improving electrode fabrication is integral to enhancing device performance, and ionomer-responsible for transporting hydroxide and mechanically supporting the catalyst-is a major component. Here, we use experiments and computation to study the effects of relative humidity (RH) during the drying process of poly(aryl piperidinium) ionomer films on HEMEL electrodes. Broadly, the drying environments determine the physical structure and electrochemical traits of the ionomer network. High RH drying yields a highly porous network with excessive water uptake, structural defects, washout, and 64% reduction in hydroxide conductivity. Extremely low RH drying produces an overly compact pore network that hinders hydroxide mobility. In contrast, moderately low RH drying (9% RH) creates an ionomer film with well-balanced traits: excellent mechanical stability and connectivity needed for catalyst retention and hydroxide transport, which improves HEMEL performance by 40% at 1.8 V compared to suboptimal RHs. This research advances HEMEL manufacturing by providing a simple, scalable, and low-cost approach to optimize electrode ionomer films.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Understanding particle size effect on fast-charging behavior of graphite anode using ultra-thin-layer electrodes

Extreme fast charging (≤ 15 min) of lithium-ion batteries is highly desirable to accelerate mass-market adoption of electric vehicles. However, significant capacity fading, as well as safety issues due to the lithium plating caused by the fast charging rate, limit its implementation. In this study, we investigated the fast-charging capability of graphite materials with various particle sizes. To eliminate the Li + ion concentration gradient effect across the thickness of the electrode, ultra-thin-layer graphite electrodes were developed to investigate the "real" fast-charging capability of graphite at the particle level. Electrochemical assessments as well as microscopic characterizations revealed that smaller particles exhibited superior fast-charging performance, featuring enhanced capacity reversibility, faster charging rate, and less lithium plating under the same fast-charging conditions. It is shown that small-particle graphite (mean radius of 3.3 μm) could withstand a 4C charge (to 80 % state-of-charge) without plating, with minimal plating occurring at 6C. Thicker particles exhibited plating at lower C-rates. Since the experimental data could not directly explain whether intra-particle diffusion limitations or interfacial reaction limitations dominated the plating mechanism, the pseudo-2-dimensional model was used to evaluate the most likely plating mechanism. The model suggested that particle-level diffusion is the dominant mechanism contributing to plating at high rates. Finally, this work provides comprehensive insights into the particle size effects on fast-charging capability, offering a better understanding of fast-charging behavior and valuable guidance for designing optimal electrode architecture for high-rate lithium-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Catalytic Promotion of Transition-Metal-Doped Graphene Cathodes in Li-CO 2 Batteries

The Li-CO 2 battery is a promising energy storage system with impressive theoretical specific energy and discharge capacity. Graphene-based single-atom catalysts (SACs) provide high surface area and long-term electrochemical reactivity and stability, making SACs among the most promising cathode catalysts for these batteries. However, current Li-CO 2 systems have high reaction barriers, slowing the reaction and greatly increasing the overpotential. Improvement of the discharge/charge energetics requires atomic-level innovations in cathode design, such as alterations to the catalyst chemical structure. In this paper, we propose enhancing the SAC by using a Ti metal center, which is found to deliver the highest electrochemical Li + CO 2 activity among 3d transition metal candidates. Furthermore, we propose cathode surface coating with ionic liquids, since these environments promote the formation of reaction intermediates in the electrochemical conversion process. Here, our work provides insights to optimize electrode design for high-performance Li-CO 2 batteries, which can open new avenues to recycle greenhouse gases and achieve enhanced renewable energy storage.

25 ENERGY STORAGE↗
DOE OSTI2026

Atomic-Scale Imaging of Lithium Vacancies in a Battery Cathode by Multislice Electron Ptychography

Atomic-resolution imaging of battery materials is critical for identification of local defects and structural variations, which are tied to battery performance. However, since battery materials are, by design, optimized to allow ion motion in response to an applied electric field, they are also very sensitive to radiation damage by an electron beam. Image resolution is therefore severely constrained by the dose applied. Here, we show that multislice electron ptychography (MEP) can provide sub-ångström lateral resolution images of both light and heavy elements of a Li-ion battery cathode, along with nanometer-scale depth information and greater dose efficiency than conventional electron microscopy methods. Using the depth-sectioning capability of MEP, we have been able to obtain direct visualizations of Li vacancy clusters, atom column by atom column, in Li x Ni 0.33 Mn 0.33 Co 0.33 O 2 (NMC111) cathodes. This capability to track Li distributions will be valuable in understanding, informing, and optimizing electrode material design for ion storage and transfer.

batteries↗
DOE OSTI2024

Electrochemical Oxidation of Seawater for Renewable Energy Generation and Storage in Coastal Areas

In this work, we demonstrated how the Clean Sustainable Electrochemical Treatment process can be used to process seawater while simultaneously generating molecular hydrogen. The specific goal of this project is to (1) demonstrate selective removal of chemical oxygen demand over the oxygen and chlorine evolution reactions, (2) optimize electrode composition to improve electrochemical performance, and (3) demonstrate long-term (>100 h) stability experiments.

08 HYDROGEN↗
DOE OSTI2025

Durable, Ultra-Thin Diaphragms for Liquid Alkaline Water Electrolysis

W. L. Gore & Associates assembled a world class team (De Nora Tech, LLC; New York University; and thyssenkrupp nucera) to develop durable, ultra-low resistance diaphragms that dramatically improve system efficiency, dynamic response, and operational flexibility. To enable the use of ultra-thin diaphragms, an optimized electrode package was chosen as part of an electrode down select study. Ultra-thin diaphragms based on microporous polymer scaffolds imbibed with zirconia nanoparticles were developed and tested. Performance and durability on par with incumbent materials was demonstrated. A transparent electrolyzer to directly observe in-situ diaphragm-bubble interactions was designed and built, and simultaneous optical and electrochemical performance tests were performed. A Pressurized Alkaline Water Electrolysis (PAWE) single cell test station was designed to support advanced R&D in high-pressure electrolysis, particularly for evaluating novel electrode and separator configurations under elevated temperature and pressure operating conditions. Due to early project termination, the original scope could not be fully achieved.

08 HYDROGEN↗
DOE OSTI2025

Electronic Structural Optimization of the Air Electrodes for Reversible Protonic Ceramic Electrochemical Cells via IIIA Cation Doping

Reversible protonic ceramic electrochemical cells (R-PCECs) have emerged as a novel technology for clean and efficient energy generation and storage. Improving the oxygen and proton conduction characteristics and stability of air electrodes at intermediate temperatures is crucial for achieving a high performance. Herein, we optimize the electronic structure of a state-of-the-art PrBa 0.8 Ca 0.2 Co 2 O 5+δ (PBCC) air electrode via doping IIIA cations (Al 3+ , Ga 3+ , and In 3+ ). Also, it is shown that PrBa 0.8 Ca 0.2 Co 1.9 Ga 0.10 O 5+δ (PBCCGa 0.10 ) exhibits improved oxygen reaction activity and hydration capability. Density functional theory calculations confirm that Ga doping provides the most favorable electronic structure. An R-PCEC with PBCCGa 0.10 achieves a peak power density of 2.21 W cm -2 and a current density of −4.64 A cm -2 at 1.3 V at 650 °C. Additionally, the PBCCGa 0.10 electrode performs good operational stability in FC mode (for about 100 h), EC mode (for about 100 h), and reversible cyclic testing (over 200 h) at 600 °C.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Formulation of Conductive Inks for DIW Printed Battery Electrodes

Ink formulations for DIW printing of Li ion battery electrodes were optimized for high conductivity, surface area and printability. Our focus is particularly on optimizing Li-ion battery electrodes for low temperature applications by 3-D printing the cathodes into high surface area shapes. The sluggish kinetics of ion transport at the solid-electrolyte phase boundary can be a major problem in batteries at low temperatures, so optimizing for ion transport can help combat these issues. Two families of DIW ink were investigated; aqueous conductive polymer suspension with graphene nano platelets (GNP) ink, and “oil in water” graphene oxide (GO) micro emulsion ink which carbonizes to an open cell graphene aerogel. By iterative formulation changes, the conductivity of PEDOT:PSS based ink was increased over tenfold, and stiffness of GO emulsion ink was increased to provide better printability without sacrificing porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Stabilizing Nickel‐Rich Cathodes in Aqueous Process through Nanocellulose as Water Barrier

Nickel-rich LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NMC 811) cathode offers high voltage and high specific capacity, making it promising for high energy density batteries. However, large-scale manufacturing of aqueous-processed NMC 811 electrodes remains challenging due to proton exchange causing material decomposition and capacity loss. This work addresses this issue by constructing an in situ nanocellulose protective layer for NMC 811 particles via electrostatic interactions during the slurry preparation. For the first time, the interatomic spacing between inter-chains of nanocellulose is measured through wide-angle X-ray scattering and demonstrate the ability to effectively confine interlayer water using atomistic simulations. Moreover, this nanocellulose coverage simultaneously minimizes Li + surface segregation and mitigates water infiltration. Owing to less material decomposition during the aqueous processing, nanocellulose-protected NMC electrodes exhibit higher initial coulombic efficiency (83% vs 62% at 0.1C) and capacity (133 vs 59 mAh g −1 at 6C) than unprotected electrodes. Additionally, optimized aqueous-processed NMC electrodes offer comparable or even superior electrochemical properties compared to the electrodes fabricated using the conventional toxic organic solvent, N-methyl-2-pyrrolidone. Consequently, the developed approach enables affordable, sustainable aqueous processing for Nickel-rich NMC 811 cathodes with excellent electrochemical performances.

25 ENERGY STORAGE↗