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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

Synergistic Combination of Living Ring-Opening Metathesis Polymerization and Atom Transfer Radical Polymerization to Synthesize Structurally Tailored and Engineered Macromolecular Networks

Structurally tailored and engineered macromolecular (STEM) networks are attractive materials for soft robotics, stretchable electronics, tissue engineering, and 3D printing due to their tunable properties. To date, STEM networks have been synthesized by atom transfer radical polymerization (ATRP) or the combination of reversible addition–fragmentation chain-transfer (RAFT) polymerization and ATRP. RAFT polymerization could have limited selectivity with ATRP inimer sites that can participate in radical-transfer processes. On the other hand, living ring-opening metathesis polymerization (ROMP) can produce a polymeric network with latent ATRP initiator sites in high selectivity. Herein, for the first time, we report the syntheses of STEM zero-generation (STEM-0) networks using a monomer, a cross-linker, and an ATRP/ROMP inimer via living ROMP, followed by their modification using a second monomer via ATRP to synthesize STEM first-generation (STEM-1) networks. The mechanical property and swelling capacity analyses of these networks were carried out. A change in mechanical properties and swelling capacity of these networks was observed due to their structural modification.

Absorption↗
DOE OSTI2024

Bubble-Free Frontal Polymerization of Acrylates via Redox-Initiated Free Radical Polymerization

Thermal frontal polymerization (FP) of acrylate monomers mixed with conventional peroxide initiators leads to significant bubble formation at the polymerizing front, limiting their practical applications. Redox initiators present a promising alternative to peroxide initiators, as they prevent the formation of gaseous byproducts during initiator decomposition and lower the front temperature, thereby enabling bubble-free FP. In this study, we investigate the FP of acrylate monomers of varying functionalities, including methyl methacrylate (MMA), 1,6-hexanediol diacrylate (HDDA), and trimethylolpropane triacrylate (TMPTA), using N,N -dimethylaniline/benzoyl peroxide (DMA/BPO) redox couple at room temperature and compare their front behavior, pot life, and bubble formation with those of same resin systems mixed with a conventional peroxide initiator, Luperox 231. The use of redox couples in FP of acrylates shows promise for rapid, energy-efficient manufacturing of polyacrylates and can enable new applications such as 3D printing and composite manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Ethylene Polymerizations Catalyzed by Fluorinated “Sandwich” Diimine-Nickel and Palladium Complexes

Nickel and palladium complexes bearing “sandwich” diimine ligands with perfluorinated aryl caps have been synthesized, characterized, and explored in ethylene polymerization reactions. The X-ray crystallographic analysis of the precatalysts 16 and 6b show differences from their non-fluorinated analogues 17 and 19, with the perfluorinated aryl caps centered precisely over the nickel and palladium centers which results in higher buried volumes of the metal centers relative to the non-fluorinated analogs. The sandwich diimine palladium complexes 5a and 5b containing perfluorinated aryl caps polymerize ethylene in a controlled fashion with activities that are substantially increased compared with their non-fluorinated analogues. Migratory insertion rates in relevant methyl ethylene complexes agree with activities exhibited in bulk polymerization experiments. DFT studies suggest that facility of ethylene rotation from its preferred orientation perpendicular to the Pd-alkyl bond into a parallel in-plane conformation contributes to the higher polymerization activity for 5b relative to 18a. For these palladium systems polymer molecular weights can be controlled via hydrogen addition (hydrogenolysis) which is unusual for late transition metal-catalyzed olefin polymerizations with no catalyst deactivation occurring. Sandwich diimine nickel complexes 6a and 6b with perfluorinated aryl caps show ethylene polymerization activities that are about half that of classical tetraisopropyl-substituted catalyst 2 but again are more active than the analogous nonfluorinated sandwich complexes. Ethylene polymerizations exhibit living behavior and branched ultra-high molecular weight polyethylenes (UHMWPEs) with very low molecular weight distributions (less than 1.1) are obtained. The activated nickel catalysts are stable in the absence of monomer and show good long-term stability at 25 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Surface-Initiated Atom Transfer Radical Polymerization Using Hydrogel Reactors

Atom transfer radical polymerization (ATRP) is a controlled radical polymerization method that enables the synthesis of tailored polymeric materials with low dispersity, highlighting its immense potential for green fabrication of advanced materials. However, its broader implementation is limited by challenges in product isolation, maintaining catalyst activity, and mitigating atmospheric sensitivity arising from oxygen-sensitive metal catalysts. Here, gelatin hydrogels (GHs) are introduced as a soft “reactor” matrix for interfacial ATRP, operating with minimal metal-catalyst loading while exhibiting possibly an organoreductive behavior. This strategy leverages activator regeneration via electron transfer through a ligand–metal charge-transfer (LMCT) mechanism to reduce oxidized metal catalysts within the GH network. Polymerization is evaluated by growing polymer brushes at an active interface formed between GHs swollen in monomer solution and an initiating surface, and sequential growth experiments confirmed that GH-mediated ATRP preserves living character. Under UV illumination, LMCT is activated, producing polymers both at the desired interface and within the GH bulk. UV–Vis spectroscopy revealed active reduction of Cu(II) to Cu(I) along with concentration-dependent complex formation, indicating dynamic coordination chemistry within the hydrogel. The redox-active arginine- and glutamic acid-rich gelatin backbone coordinates and reduces the metal center, enabling ATRP at ppm-level catalyst concentrations. While polymerization proceeds in GH-Cu(II) reactors, adding external mobile ligands to the GH results in longer polymer brushes. Here, the results reported here are exploratory. More experiments are needed to characterize polymer brush growth in GHs and compare it to conventional surface-initiated polymerization in solution.

Absorption↗
DOE OSTI2025

Active light-controlled frontal ring-opening metathesis polymerization

Frontal ring-opening metathesis polymerization (FROMP) is a promising energy-efficient approach to fabricate polymeric materials. Recent advances have demonstrated FROMP for diverse applications, including additive manufacturing, composites, and foams. However, the characteristic properties of the front are currently controlled primarily by varying the resin composition or the environmental conditions. In this work we present an approach to control FROMP of dicyclopentadiene (DCPD) using photochemical methods. A photobase generator is used to inhibit FROMP of DCPD with UV light while a photosensitizer and co-initiator are used to accelerate FROMP with blue light, enabling orthogonal active photocontrol of front velocity. In addition, photoinhibition-enabled lithographic patterning of frontal polymerizations is demonstrated. Frontal polymerizations are spatially controlled, redirected, and even split into diverging fronts. This work establishes a foundation for advanced control of frontal polymerizations, enabling innovation in traditional and additive manufacturing, as well as emerging processes like morphogenic manufacturing.

Polymer synthesis↗
DOE OSTI2024

Photoinitiated thermoset polymerization through controlled release of metathesis catalysts encapsulated in poly(phthalaldehyde)

Photoinitiated polymerization enables spatiotemporal control of reaction conditions and can thereby generate materials with high complexity while consuming minimal energy. Where ring opening metathesis polymerization (ROMP) is concerned, photo-activated processes are typically enabled by chemical inhibition of ruthenium carbenes via the careful design of complexed ligands such that photoactivation can proceed through an isomerization or ligand dissociation event. In this contribution, we have explored a new approach to photoinitiation of ROMP based on physical inhibition through microencapsulation and controlled release of metathesis catalysts. Micron-sized particles of poly(phthalaldehyde) (PPA), catalyst, and photoacid generator were fabricated by spray drying. The particles were dispersed in dicyclopentadiene monomer, after which polymerization was initiated through temperature or UV exposure, both inducing depolymerization of the PPA particles and in situ catalyst release. The monomer/particle dispersions were found to be stable and reproducibly polymerizable with 3 weeks of storage at room temperature. Furthermore, the dispersions can be used for both photo- and thermal-initiated frontal ROMP, yielding a polymerized thermoset of equivalent properties to conventional bulk- and frontally-polymerized analogues. In conclusion, this work will ultimately enable new manufacturing techniques for ROMP-based materials, due to the modular, easily tunable nature of the underlying initiating system and its unparalleled stability.

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

Tricyclononenes and tricyclononadienes as efficient monomers for controlled ROMP: understanding structure–propagation rate relationships and enabling facile post-polymerization modification

Grubbs 3rd-generation (G3) pre-catalyst-initiated ring-opening metathesis polymerization (ROMP) remains an indispensable tool in the polymer chemist's toolbox. Tricyclononenes (TCN) and tricyclononadienes (TCND) represent under-explored classes of monomers for ROMP that have the potential to both advance fundamental knowledge (e.g., structure-polymerization kinetics relationships) and serve as practical tools for the polymer chemist (e.g., post-polymerization functionalization). In this work, a library of TCN and TCND imides, monoesters, and diesters, along with their exo-norbornene counterparts, were synthesized to compare their behaviors in G3-initiated ROMP. Real-time 1 H NMR was used to study their polymerization kinetics; propagation rates ( k p ) were extracted for each monomer. To understand the relationships between monomer structure and ROMP propagation rates, density functional theory methods were used to calculate a variety of electronic and steric parameters for each monomer. While electronic parameters (e.g., HOMO energy levels) correlated positively with the measured k p values, steric parameters generally gave improved correlations, which indicates that monomer size and shape are better predictors for k p than electronic parameters for this data set. Furthermore, the TCND diester—which contains an electron-deficient cyclobutene that is resistant to ROMP—and its polymer p(TCND) are shown to be highly reactive toward DBU-catalyzed conjugate addition reactions with thiols, providing a protecting- and activating-group free strategy for post-polymerization modification.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Regio- and Stereoselective Lactone Polymerization: Divergent Effect of Catalyst Modification and Monomer Structure

Selective ring-opening polymerization (ROP) of chiral lactones enables access to biodegradable polyesters with precisely controlled microstructures. Here, combined DFT modeling and experimental validation elucidate how fine-tuning of enantiopure SalBinam aluminum catalysts (through introduction of bromine atoms and tert-butyl groups, respectively, in ortho- and para-positions) modulates regio- and stereocontrol in the ROP of methyl glycolide (MeG) and lactide (LA). Computations reveal that regioselectivity in MeG polymerization arises mainly from steric repulsion, with a small contribution from weak stabilizing C-H···Br interactions that favor ring-opening at the glycolic site, consistent with the experimentally enhanced regioselectivity for (R)-MeG. In contrast, the same steric congestion at the ligand’s ortho positions destabilizes the key transition states in rac-LA polymerization, reducing the calculated stereoselectivity. Experiments confirm the predicted loss of stereocontrol, yielding nearly atactic PLA under standard conditions. Extension of the computational framework to rac-MeG polymerization promoted by racemic catalyst identified a low-barrier, stepwise polymer chain exchange pathway that rationalizes the experimentally observed syndiotacticity of poly(lactic-co-glycolic acid).

DFT calculations↗
DOE OSTI2026

Active Light-Controlled Frontal Ring-Opening Metathesis Polymerization

Frontal ring-opening metathesis polymerization (FROMP) is a self-propagating, energy-efficient polymerization method used to fabricate polymeric materials. This dataset describes a photochemical approach for controlling the FROMP of dicyclopentadiene (DCPD). A photobase generator is used to inhibit polymerization under 365 nm light, while a photosensitizer combined with a co-initiator enables acceleration of the reaction under 470 nm light. Together, these components provide orthogonal, light-meditated control over front velocity.

Rodriguez, Victoria C.↗
DOE OSTI2026

Gold Catalyzed Polymerization Reactions of Unsaturated Substrates: Towards New Functional, Recyclable, and Upcycled Aromatic Polymers (Final Report)

The overarching goal of this project lied in the translation of gold (Au) catalyzed small molecule synthetic transformations to the field of polymer science, the generation of new macromolecular structures, and the application of the materials and methodologies produced toward sustainable polymer development and chemical upcycling. Specifically, this project aimed to polymerize monomers based on unsaturated precursors and access novel polymeric materials through the extension of Au catalyzed intermolecular processes. The specific objectives of this project comprised: (1) the extension of Au-catalyzed intermolecular reactions to bifunctional monomers and the polycondensation of diverse nucleophiles; (2) to gain fundamental mechanistic insight into Au-catalyzed polymerizations; (3) the application of these reactions to the synthesis of new classes of aromatic polymers that can be readily and/or selectively deconstructed; and (4) to apply these chemistries to post-polymerization modification (PPM) of commercially relevant polyaromatic substrates, including post-industrial plastics and post-consumer waste.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multimaterial 3D Printing in Activating Bath Enables In Situ Polymerization of Thermosets with Intricate Geometries and Diverse Elastic Behaviors

Polydicyclopentadiene, p(DCPD), is a high‐performance thermoset valued for its exceptional toughness, strength, and stiffness. When copolymerized with 1,5‐cyclooctadiene (COD), its mechanical properties can be tuned from glassy to rubbery at room temperature. While frontal polymerization enables a rapid and energy‐efficient route to 3D print DCPD‐based materials, challenges such as ink shelf life and gravitational distortion, especially in direct ink writing of soft COD‐rich formulations, must be considered. Here, a complementary chemical strategy is presented, embedded 3D printing, that enables localized in situ polymerization of printed DCPD/COD inks within a reactive support matrix. The matrix provides both physical support and a reservoir of chemical activator, which diffuses into the ink, activates a latent bis(N‐heterocyclic carbene) Ru precatalyst, and initiates ring‐opening metathesis polymerization. Curing begins at the ink–matrix interface and propagates inward via diffusion, stabilizing the interface and preventing capillary‐driven deformation regardless of the matrix yield stress. This approach eliminates the need for cold storage, external curing, or photoinitiation, significantly expanding the processing window. Using this method, diverse thermosetting and elastomeric architectures are fabricated with features as small as 5 µm and aspect ratios of 100, including interlinked chains, shallow spherical shells exhibiting snap‐through buckling, and hair‐like fin arrays inaccessible through traditional techniques.

chemical activation↗
DOE OSTI2025

Growth-induced Donnan exclusion influences swelling kinetics in highly charged dynamic polymerization hydrogels

Polymeric gels crosslinked by DNA sequences can exploit DNA strand-displacement reactions to promote swelling through dynamic polymerization. The degree of swelling and the rate of swelling must be directly tunable to achieve the promise of programmable soft matter. Though the kinetics of the strand-displacement reaction provide insertion rates up to 10 4 /Molar/second as measured in bulk solution, DNA hydrogel swelling can take upwards of 30 h to complete. Computational modeling of the reaction-induced swelling of these gels with our recently-developed reactive electrochemomechanical theory (Zimmerman et al., 2024) suggests that their extraordinarily slow swelling is partly due to a scaling mismatch between the addition of charge and the addition of fluid volume, leading to a large transient increase in the fixed charge density. The significant increase in the gel’s fixed charge density, due to the binding of negatively charged DNA, sharply restricts the concentration of mobile hairpins through the phenomenon of Donnan charge exclusion, an effect commonly exploited in nanofiltration applications using polymeric membranes. The scaling problem is overcome when the mean additional swelling provided to the hydrogel by addition of a crosslink is above a critical value, thus the swelling outpaces the charge accumulation, leading the fixed charge density to drop and significantly accelerating the swelling process. This study shows that Donnan exclusion can explain the kinetics of DNA hydrogel swelling, and studies ways to modulate the reaction speed by either modifying the salt concentration or increasing or decreasing the number of base pairs in each DNA sequence.

42 ENGINEERING↗
DOE OSTI2025

Chemical Activation of Frontal Ring-Opening Metathesis Polymerization

In this study, we present an innovative approach to frontal ring-opening metathesis polymerization (FROMP) through chemical activation. By locally concentrating Grubbs-type initiators, we accelerate exothermic polymerization at the activation site. Sufficient thermal energy initiates a polymerization front that travels through the remainder of the sample even with reduced initiator concentrations in the bulk resin. Initiation location and timing are controlled by adjusting the initiator reactivity, the properties of the transport solvent, and the air–resin interface. Our technique enables multipoint front activation, either through synchronized injection or by timing the relative reactivity of various initiators. This accessible method of chemical activation enables on-demand production of polymer and composite materials using only the thermal energy generated by the reaction, removing the need for external power sources and enabling deployment in remote or infrastructure-limited environments.

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

Catalytic closed-loop recycling of polyethylene-like materials produced by acceptorless dehydrogenative polymerization of bio-derived diols

Petroleum-derived polyolefins exhibit diverse properties and are the most important and largest volume class of plastics. However, polyolefins are difficult to efficiently recycle or break down and are now a persistent global contaminant. Broadly replacing polyolefins with bio-derived and degradable polyethylene-like materials is an important yet challenging endeavour towards sustainable plastics. Here, in this study, we report a solution for circular bio-based polyethylene-like materials synthesized by acceptorless dehydrogenative polymerization from linear and branched diols and their catalytic closed-loop recycling. The polymerization and depolymerization processes utilize earth-abundant manganese complexes as catalysts. These materials exhibit a wide range of mechanical properties, encompassing thermoplastics to plastomers to elastomers. The branched diols, produced through a thiol-ene click reaction, can be polymerized to plastics with significantly enhanced tensile properties, toughness and adhesive properties. These materials could be depolymerized back to monomers through hydrogenation and were separatable with a monomer recovery of up to 99%, unaffected by the presence of dyes and additives. Overall, this system establishes a route to more sustainable plastics.

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

Curvature effects in the reaction-diffusion system governing frontal polymerization

Frontal polymerization is a fast and energy-efficient curing process of thermoset polymers involving the self-sustained propagation of a sharp front that transforms a liquid monomer or gel into a polymer. The temperature, speed, and geometry of the polymerization front are closely intertwined quantities that can affect the curing process and the mechanical properties of the polymer. This work investigates the effect of the front curvature on the front propagation speed based on a reaction-diffusion model. The proposed analytical relations between front speed and curvature are verified by finite element simulations and validated through experiments. The models show that a concave front has a higher front temperature and speed than its convex counterpart. When the curvature of a convex front reaches a critical value, the reaction can no longer be sustained, and the front is quenched. The relation between the speed of a steadily propagating front and its geometry is derived, showing good agreement with experimental observations. This study also provides analytical estimates of the thickness of the polymerization front and insight into the relationship between the front curvature and the kinetics of the exothermic reaction.

42 ENGINEERING↗
DOE OSTI2026

Influence of linkage chemistry and side-chain polarity on Ion 2 transport in click-functionalized polymerized ionic liquids.

Post-polymerization functionalization offers precise molecular weight control and enables the high-throughput investigation of structure−property relationships in polymer research. However, post-polymerization functionalization strategies often introduce additional linkage chemistry, and its role in the physical properties of polymerized ionic liquids (PILs) has yet to be explored. In this work, a series of PILs were synthesized using Cu(I)-catalyzed azide−alkyne cycloaddition (CuAAC), with comparison made to N-alkylation substitution chemistry. The triazole ring introduced by CuAAC chemistry was found to induce extensive ion aggregation and deteriorate ion transport. The impact of linkage chemistry on ion transport can be alleviated by incorporating polar ethylene glycol spacers in the side chain, achieving an ionic conductivity of 2.1 × 10−4 S/cm at 30 °C. Furthermore, the effect of polar spacer placement was explored, revealing that overall side-chain polarity, rather than polarity in the vicinity of the ionic group, governs ion aggregation and ion transport in PILs.

Shan, Naisong↗
DOE OSTI2024

Heterogeneous Organochromium Catalysts for Stereoselective Isoprene Polymerization

In this study, heterogeneous organochromium catalysts have been developed via surface lithiation of traditional surface organometallic complexes to mediate stereoselective isoprene polymerization. Chemisorption of the molecular complex Cr(CH 2 SiMe 3 ) 4 on high surface area anatase titania nanoparticles as well as on a silica support led to the bipodal complexes Cr/TiO 2 and Cr/SiO 2 , respectively. Subsequent reductive lithium intercalation with n-butyllithium led to the formation of lower valent Cr 2+ species Cr/LTO and Cr/Li/SiO 2 . Alternatively, Cr(CH 2 SiMe 3 ) 4 was allowed to react with nBuLi-reduced anatase titania (LTO) to provide Cr/LTO Inv . Cr/LTO and Cr/Li/SiO 2 both polymerize isoprene with very high activities (154 and 174 kg molCr –1 h –1 , respectively) to provide polyisoprene with cis-1,4 selectivity up to 82% in toluene at 50 °C. On the other hand, Cr/SiO 2 provides polyisoprene with excellent trans-1,4 selectivity up to 98% (16 kg molCr –1 h –1 ), and Cr/TiO 2 was catalytically inactive. Cr/LTO Inv is less active and selective, and X-ray absorption spectroscopy (XAS) measurements of the precatalyst revealed the presence of a mixture of metallic Cr 0 , Cr 4+ , and only minor Cr 2+ species. Thus, surface lithiation can promote the formation of lower valent metal centers which enable stereocontrol in isoprene polymerizations and may be extended as a general protocol to other catalytic systems.

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

A Mechanism-Based Reaction–Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis

Frontal ring-opening metathesis polymerization (FROMP) involves a self-perpetuating exothermic reaction, which enables the rapid and energy-efficient manufacturing of thermoset polymers and composites. Current state-of-the-art reaction–diffusion FROMP models rely on a phenomenological description of the olefin metathesis kinetics, limiting their ability to model the governing thermo-chemical FROMP processes. Furthermore, the existing models are unable to predict the variations in FROMP kinetics with changes in the resin composition and as a result are of limited utility toward accelerated discovery of new resin formulations. In this work, we formulate a chemically meaningful model grounded in the established mechanism of ring-opening metathesis polymerization (ROMP). Our study aims to validate the hypothesis that the ROMP mechanism, applicable to monomer-initiator solutions below 100 °C, remains valid under the nonideal conditions encountered in FROMP, including ambient to >200 °C temperatures, sharp temperature gradients, and neat monomer environments. Through extensive simulations, we demonstrate that our mechanism-based model accurately predicts the FROMP behavior across various resin compositions, including polymerization front velocities and thermal characteristics (e.g., T max ). Additionally, we introduce a semi-inverse workflow that predicts FROMP behavior from a single experimental data point. Notably, the physiochemical parameters utilized in our model can be obtained through DFT calculations and minimal experiments, highlighting the model’s potential for rapid screening of new FROMP chemistries in pursuit of thermoset polymers with superior thermo-chemo-mechanical properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗