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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

Electronic signatures of Lorentzian dynamics and charge fluctuations in lithiated graphite structures

Lithium graphite intercalation compounds (Li-GICs) are essential materials for modern day portable electronics and obtaining insights into their atomic structure and thermodynamics is of fundamental interest. Here we explore the electronic and atomic states of Li-GICs at varying degrees of Lithium loading (i.e., “staging”) by means of ab-initio molecular dynamics simulations and simulated X-ray adsorption spectroscopy (XAS). We analyze the atomic correlation functions and shows that the enhancements of the Li-ion entropy with increased staging result from Lorentzian lithium-ion dynamics and charge fluctuations, which activate low-energy phonon modes. The associated electronic signatures are modulations of the unoccupied π*/σ* orbital energy levels and unambiguous fingerprints in Carbon K-edge XAS spectra. Thus, we extend the canonical view of XAS, establishing that these “static” measurements in fact encode the signature of the thermodynamic response and relaxation dynamics of the system. This causal link between atomic structure, spectroscopy, thermodynamics, and information theory can be generally exploited to better understand stability in solid-state electrochemical systems.

25 ENERGY STORAGE↗

Graphite Oxidation Rate Study on ET-10 and ETU-10 Grades - Task 4: QA Support and Testing for Structural Graphite Oxidation

INL performed targeted oxidation tests to measure oxidation rates for samples of ET-10 and ETU-10 graphite under CRADA No. 21CRA22 Mod. 3, Annex A, “Tritium Testing to Support Kairos Power Advanced Reactor Demonstration” (04/02/2024). All testing was conducted within INL’s Carbon Characterization Laboratory (CCL) using test standard ASTM D7542-21 "Standard Test Method for Air Oxidation of Carbon and Graphite in the Kinetic Regime" [ASTM International, 2021]. Kairos Power provided all test specimens through its graphite vendor Ibiden, Inc. to INL and ASTM specimen specified dimensions. Information within this report only provides the Arrhenius oxidation rate plots as a function of temperature for each graphite grade tested. The raw mass loss per time data will be provided on the Nuclear Data Management and Analysis System (NDMAS) portal located on the INL information system.

36 MATERIALS SCIENCE↗

Enabling high rate capability, low internal resistance, and excellent cyclability for vanadium redox flow batteries utilizing ultrafast laser-structured graphite felt

The electrochemical performance of vanadium redox flow batteries (VRFBs) was enhanced via laser-patterned graphite felt (GF) electrodes. The laser-structured GF electrodes engineered via preparing a series of well-ordered microscopic channel structures with an average width of 200 μm, creating a three-dimensional carbon framework. The ultrafast laser patterning increased the porosity by 10%, as compared to pristine electrode. The analysis of the overpotential distribution using electrochemical impedance spectroscopy revealed that the electrode polarization involving charge transfer and diffusion resistance is strongly alleviated with the aid of carbon micro-perforation. The advanced design of laser-structured GF electrode also exhibits high rate capability, low internal resistance, and excellent cyclability. The improved performance was attributed to the synergistic effect involving (i) high electrochemically active surface area for rapid electrochemical reactions (i.e., V(II)/V(III) and V(IV)/V(V) redox couples) and (ii) excellent transport properties for facile electron/ion/species transport. The micro-scale channels created with the laser-ablation technique act as capillary structures and enabled homogeneous and rapid wetting of GF electrodes as formulated with the classical Washburn equation. The VRFB equipped with the laser-structured GF electrodes delivered a high discharge capacity with exceptional capacity retention upon extended cycling (>84.9%). In conclusion, accordingly, the design of laser-structured electrode paves the pathway towards finely tuning the electrode internal microstructure for improved cyclability, durability, and capacity retention in various electrochemical energy storage/conversion devices (e.g. all-vanadium redox flow batteries).

25 ENERGY STORAGE↗

Moisture loss from graphite structures for the Hubble Space Telescope

The construction and telescope assembly of the NASA's Hubble Space Telescope (HST) is described with particular reference to the features of its construction material. Due to the hygroscopic nature of the graphite-fiber reinforced epoxy, used for much of the structure of the HST, the telescope, when in orbit, suffers losses of water, absorbed during on-ground procedures, accompanied by shrinkage of the epoxy matrix, and needs periodic realignment. Using a combination of analytic, laboratory measured, and in-space measured data, an operational plan for adjusting the alignment of the HST is presented. The refocusing plan must take into account the preceding ground environment, as well as the prelaunch, lift-off, and predeployment environments of the HST-bearing Space Shuttle.

Facey, T. A.↗

Investigating the effect of screen-printed structured graphite electrodes with low tortuosity for high-capacity and fast-charging lithium-ion batteries

A flexible screen-printed graphite electrode was fabricated as an anode for developing fast-charging lithium-ion batteries with low tortuosity. A homogenous anode ink was prepared by mixing graphite as the active material, carbon black (C45) as the conductive additive, and polyvinylidene fluoride (PVDF) as the binder in N-Methyl-2-pyrrolidone (NMP) solvent. The ink was deposited on a flexible copper foil via a stainless-steel screen consisting of an array of pores, that act as secondary pore networks (SPNs), using the screen-printing process. Lithium-ion battery half-cells were assembled using the printed graphite anode, lithium metal foil as the counter electrode, and 1.2 M lithium hexafluorophosphate (LiPF 6 ) in ethyl carbonate: ethyl methyl carbonate (EC: EMC = 3:7) as the electrolyte. The effect of SPNs on the cell performance was investigated by performing formation, rate and cycling tests on the assembled cells, at different C-rates. It was observed that the cells consisting of SPNs with a pore size of 100 μm and edge-to-edge distance of 100 μm between the pores exhibited significantly higher specific capacities of 168 and 129 mAh/g when compared to reference cells without SPNs, which had capacities of 120 and 85 mAh/g, at high C-rates of 4 C and 6 C, respectively. The cells with SPNs also demonstrated excellent cycling performance with ~ 95% capacity retention after 100 cycles at 2 C.

Fast charging lithium-ion battery↗

Measuring Moisture Levels in Graphite Epoxy Composite Sandwich Structures

Graphite epoxy composite (GEC) materials are used in the construction of rocket fairings, nose cones, interstage adapters, and heat shields due to their high strength and light weight. However, they absorb moisture depending on the environmental conditions they are exposed to prior to launch. Too much moisture absorption can become a problem when temperature and pressure changes experienced during launch cause the water to vaporize. The rapid state change of the water can result in structural failure of the material. In addition, heat and moisture combine to weaken GEC structures. Diffusion models that predict the total accumulated moisture content based on the environmental conditions are one accepted method of determining if the material strength has been reduced to an unacceptable level. However, there currently doesn t exist any field measurement technique to estimate the actual moisture content of a composite structure. A multi-layer diffusion model was constructed with Mathematica to predict moisture absorption and desorption from the GEC sandwich structure. This model is used in conjunction with relative humidity/temperature sensors both on the inside and outside of the material to determine the moisture levels in the structure. Because the core materials have much higher diffusivity than the face sheets, a single relative humidity measurement will accurately reflect the moisture levels in the core. When combined with an external relative humidity measurement, the model can be used to determine the moisture levels in the face sheets. Since diffusion is temperaturedependent, the temperature measurements are used to determine the diffusivity of the face sheets for the model computations.

Nurge, Mark↗

Nano-engineering the material structure of preferentially oriented nano-graphitic carbon for making high-performance electrochemical micro-sensors

Direct synthesis of thin-film carbon nanomaterials on oxide-coated silicon substrates provides a viable pathway for building a dense array of miniaturized (micron-scale) electrochemical sensors with high performance. However, material synthesis generally involves many parameters, making material engineering based on trial and error highly inefficient. Here, we report a two-pronged strategy for producing engineered thin-film carbon nanomaterials that have a nano-graphitic structure. First, we introduce a variant of the metal-induced graphitization technique that generates micron-scale islands of nano-graphitic carbon materials directly on oxide-coated silicon substrates. A novel feature of our material synthesis is that, through substrate engineering, the orientation of graphitic planes within the film aligns preferentially with the silicon substrate. This feature allows us to use the Raman spectroscopy for quantifying structural properties of the sensor surface, where the electrochemical processes occur. Second, we find phenomenological models for predicting the amplitudes of the redox current and the sensor capacitance from the material structure, quantified by Raman. Our results indicate that the key to achieving high-performance micro-sensors from nano-graphitic carbon is to increase both the density of point defects and the size of the graphitic crystallites. Our study offers a viable strategy for building planar electrochemical micro-sensors with high-performance.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Fabrication of cooled, graphite-lined structures

Improved method of fabricating cooled graphite-lined thrust chamber has been developed. Layer of nickel is electrodeposited onto outer surface of machined and contoured graphite liner. Coolant passages are machined into nickel layer, filled with wax, outer shell electroformed over this, and wax removed. Tests in flox/methane rocket engine were completely successful.

Duscha, R. A.↗

In-service inspection methods for graphite-epoxy structures on commercial transport aircraft

In-service inspection methods for graphite-epoxy composite structures on commercial transport aircraft are determined. Graphite/epoxy structures, service incurred defects, current inspection practices and concerns of the airline and manufacturers, and other related information were determind by survey. Based on this information, applicable inspection nondestructive inspection methods are evaluated and inspection techniques determined. Technology is developed primarily in eddy current inspection.

Phelps, M. L.↗

Development of IR Contrast Data Analysis Application for Characterizing Delaminations in Graphite-Epoxy Structures

Objective: Develop infrared (IR) flash thermography application based on use of a calibration standard for inspecting graphite-epoxy laminated/honeycomb structures. Background: Graphite/Epoxy composites (laminated and honeycomb) are widely used on NASA programs. Composite materials are susceptible for impact damage that is not readily detected by visual inspection. IR inspection can provide required sensitivity to detect surface damage in composites during manufacturing and during service. IR contrast analysis can provide characterization of depth, size and gap thickness of impact damage. Benefits/Payoffs: The research provides an empirical method of calibrating the flash thermography response in nondestructive evaluation. A physical calibration standard with artificial flaws such as flat bottom holes with desired diameter and depth values in a desired material is used in calibration. The research devises several probability of detection (POD) analysis approaches to enable cost effective POD study to meet program requirements.

Havican, Marie↗

Low void content autoclave molded titanium alloy and polyimide graphite composite structures.

This paper discusses a resin developed for use in autoclave molding of polyimide graphite composite stiffened, titanium alloy structures. Both primary and secondary bonded structures were evaluated that were produced by autoclave processing. Details of composite processing, adhesive formulary, and bonding processes are provided in this paper, together with mechanical property data for structures. These data include -65 F, room temperature, and 600 F shear strengths; strength retention after aging; and stress rupture properties at 600 F under various stress levels for up to 1000 hours duration. Typically, shear strengths in excess of 16 ksi at room temperature with over 60% strength retention at 600 F were obtained with titanium alloy substrates.

Vaughan, R. W.↗

Failure characteristics of graphite-epoxy structural components loaded in compression

Failure characteristics of compressively loaded graphite-epoxy components are described. Experimental results for both strength-critical laminates and structural components with postbuckling strength are presented. Effects of low speed impact damage and circular holes on compressive strength are discussed. Delamination and shear crippling failure mechanisms that limit the performance of strength-critical laminates are described. Transverse shear and skin-stiffener separation failure mechanisms that limit the performance of components with postbuckling strength are also described. The influence of matrix properties on compressive strength improvements for impact damaged laminates is discussed. Experimental data and results from a failure analysis for strength-critical laminates with cutouts are discussed and compared with impact damage results. Typical postbuckling test results are compared with analytical predictions.

Starnes, J. H., Jr.↗

Failure characteristics of graphite-epoxy structural components loaded in compression

Failure characteristics of compressively loaded graphite-epoxy components are described. Experimental results for both strength-critical laminates and structural components with postbuckling strength are presented. Effects of low speed impact damage and circular holes on compressive strength are discussed. Delamination and shear crippling failure mechanisms that limit the performance of strength-critical laminates are described. Transverse shear and skin-stiffener separation failure mechanisms that limit the performance of components with postbuckling strength are also described. The influence of matrix properties on compressive strength improvements for impact damaged laminates is discussed. Experimental data and results from a failure analysis for strength-critical laminates with cutouts are discussed and compared with impact damage results. Typical postbuckling test results are compared with analytical predictions. Previously announced in STAR as N83-12174

Starnes, J. H., Jr.↗

ReaxFF Simulations of Laser-Induced Graphene (LIG) Formation for Multifunctional Polymer Nanocomposites

Irradiation of polymer films by a CO 2 infrared laser under ambient conditions converts the polymer into porous graphene or laser-induced graphene (LIG). In this work, we simulate the formation of LIG from five different commercially available polymers using reactive molecular dynamics. We determined that the molecular structure of the parent polymer has a significant effect on the final graphitic structure. CO is liberated during the initial part of the LIG formation process when the polymer is converted into an amorphous structure, while H 2 is evolved steadily as the amorphous structure is converted to an ordered graphitic structure. The LIG structure has out-of-plane undulations and bends due to a significant number of 5- and 7-member carbon rings present throughout the structure. We find that the simulated molecular structure compares well with recent experimental observations from the literature. We also demonstrate that the yield of LIG is higher in inert conditions, compared to environments with oxygen. Polybenzimidazole-derived LIG has the highest surface area and yield among the five polymers examined. These findings provide knowledge of LIG formation mechanisms that can be leveraged for bulk LIG applications such as sensors, electrocatalysts, microfluidics, and targeted heating for welding polymers.

36 MATERIALS SCIENCE↗