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DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2020

Highly Ordered Carbon Coating Prepared with Polyvinylidene Chloride Precursor for High‐Performance Silicon Anodes in Lithium‐Ion Batteries

Abstract A highly ordered carbon structure based on polyvinylidene chloride precursor has been developed to host silicon nanoparticles. The stoichiometric ratio of sacrificial H and Cl elements facilitated full utilization of the carbon content of the precursor that produced robust carbon coatings on silicon nanoparticles with excellent mechanic properties and electrochemical stabilities. The optimal sintering temperature and carbon content have been investigated. When evaluated as the anode of a lithium‐ion battery (LIB), the Si : C 1 : 2 composite sintered at 800 °C (SiC12‐800) provided excellent capacity retention of 85 % at 0.1 C after 50 cycles with an enhanced CE, which reached 99 % only after 10 cycles. The SiC12‐800 electrode maintained a specific capacity of 709.2 mAh/g after 300 cycles at 0.3 C, and delivered a high rate performance of 737.9 mAh/g and 485.6 mAh/g at 5 C and 10 C, respectively. The results indicate that polymer precursors with stoichiometric ratio of sacrificial elements have high potential for generating highly robust carbon coatings for silicon anodes in high energy density LIBs.

Zhou, Shuo↗

DOE OSTI2020

Erosion and cathodic arc plasma of Nb–Al cathodes: composite versus intermetallic

Many properties of cathodic arcs from single-element cathodes show a correlation to the cohesive energy of the cathode material. For example, the burning voltage, the erosion rate, or, to a lesser extent, plasma properties like electron temperatures or average ion energy and charge states. For multi-element cathodes, various phases with different cohesive energies can initially be present in the cathode, or form due to arc exposure, complicating the evaluation of such correlations. To test the influence of morphology and phase composition of multi-element cathodes on cathodic arc properties, a Nb–Al cathode model system was used that includes: pure Nb and Al cathodes; intermetallic Nb 3 Al, Nb 2 Al and NbAl 3 cathodes; and three composite Nb–Al cathodes with atomic ratios corresponding to the stoichiometric ratios of the intermetallic phases. Pulsed cathodic arc plasmas from these cathodes were examined using a mass-per-charge and energy-per-charge analyzer, showing that charge-state-resolved ion energy distributions of plasmas from the intermetallic and corresponding composite cathodes are nearly identical. An examination of converted layers of eroded cathodes using x-ray diffraction and scanning electron microscopy indicates the formation of a surface layer with similar phase composition for intermetallic and their corresponding composite cathode types. The average arc voltages do not follow the trend of cohesive energies of Nb, Al and intermetallic Nb–Al phases, which have been calculated using density functional theory. Possible reasons for this effect are discussed based on the current knowledge of multi-element arc cathodes and their arc plasma available in literature.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Synergistic interactions between anammox and dissimilatory nitrate reducing bacteria sustains reactor performance across variable nitrogen loading ratios

Anaerobic ammonium oxidizing (anammox) bacteria are utilized for high efficiency nitrogen removal from nitrogen-laden sidestreams in wastewater treatment plants. The anammox bacteria form a variety of competitive and mutualistic interactions with heterotrophic bacteria that often employ denitrification or dissimilatory nitrate reduction to ammonium (DNRA) for energy generation. These interactions can be heavily influenced by the influent ratio of ammonium to nitrite, NH 4 + :NO 2 - , where deviations from the widely acknowledged stoichiometric ratio (1:1.32) have been demonstrated to have deleterious effects on anammox efficiency. Thus, it is important to understand how variable NH 4 + :NO 2 - ratios impact the microbial ecology of anammox reactors. We observed the response of the microbial community in a lab scale anammox membrane bioreactor (MBR) to changes in the influent NH 4 + :NO 2 - ratio using both 16S rRNA gene and shotgun metagenomic sequencing. Ammonium removal efficiency decreased from 99.77 ± 0.04% when the ratio was 1:1.32 (prior to day 89) to 90.85 ± 0.29% when the ratio was decreased to 1:1.1 (day 89–202) and 90.14 ± 0.09% when the ratio was changed to 1:1.13 (day 169–200). Over this same timespan, the overall nitrogen removal efficiency (NRE) remained relatively unchanged (85.26 ± 0.01% from day 0–89, compared to 85.49 ± 0.01% from day 89–169, and 83.04 ± 0.01% from day 169–200). When the ratio was slightly increased to 1:1.17–1:1.2 (day 202–253), the ammonium removal efficiency increased to 97.28 ± 0.45% and the NRE increased to 88.21 ± 0.01%. Analysis of 16S rRNA gene sequences demonstrated increased relative abundance of taxa belonging to Bacteroidetes, Chloroflexi, and Ignavibacteriae over the course of the experiment. The relative abundance of Planctomycetes, the phylum to which anammox bacteria belong, decreased from 77.19% at the beginning of the experiment to 12.24% by the end of the experiment. Analysis of metagenome assembled genomes (MAGs) indicated increased abundance of bacteria with nrfAH genes used for DNRA after the introduction of lower influent NH 4 + :NO 2 - ratios. The high relative abundance of DNRA bacteria coinciding with sustained bioreactor performance indicates a mutualistic relationship between the anammox and DNRA bacteria. Understanding these interactions could support more robust bioreactor operation at variable nitrogen loading ratios.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Phyllosilicate mineral dissolution upon alkaline treatment under aerobic and anaerobic conditions

The dissolution of phyllosilicate minerals exposed to high-pH environments has been studied to determine the influence of alkaline treatments and variable redox conditions on clay dissolution and the potential formation of new phases via incongruent dissolution phenomena. The present study focused on the dissolution of phyllosilicate minerals (illite, muscovite, and montmorillonite) under anaerobic and aerobic conditions using comparative solutions (sodium hydroxide and ammonium hydroxide) at similar ionic strength in the presence and absence of oxygen. Our batch data show that there is a rapid decrease in aluminum dissolution (< 240 hrs) and slow increase in silica over time (up to 1440 hrs). This trend was particularly evident for montmorillonite which shows the greatest dissolution for ammonium hydroxide, likely due to intercalation of the polyatomic cation ammonium into the mineral’s expandable layers. When comparing alkaline treatments, the strong base, sodium hydroxide, dissolved more of the mica minerals, illite and muscovite, likely due to ion-pairing between the silicate tetrahedra [SiO4]n- and Na+ cations in solution. In addition, redox conditions affect the systems similarly with treatment, although the sodium hydroxide treatment results in greater variability in solution redox conditions. For all investigated phyllosilicates, the calculated aqueous aluminum and silicon ratios over time are significantly different from the minerals’ stoichiometric ratios. As a result, we conclude that incongruent dissolution occurred and suggest formation of secondary precipitates. Understanding the potential for clay mineral alterations from interaction with alkaline solutions has implications for in situ remediation, mining operations, and waste interactions with the subsurface. This research shows that incongruent dissolution is likely and will lead to secondary precipitation which may have long term physical and chemical impacts in the subsurface.

mineral dissolution, phyllosilicate, alkaline, amm↗

NASA NTRS1992

Unsteady pressure loads in a generic high speed engine model

Unsteady pressure loads were measured along the top interior wall of a generic high-speed engine (GHSE) model undergoing performance tests in the combustion-Heated Scramjet Test Facility at the Langley Research Center. Flow to the model inlet was simulated at 72000 ft and a flight Mach number of 4. The inlet Mach number was 3.5 with a total temperature and pressure of 1640 R and 92 psia. The unsteady pressure loads were measured with 5 piezoresistive gages, recessed into the wall 4 to 12 gage diameters to reduce incident heat flux to the diaphragms, and distributed from the inlet to the combustor. Contributors to the unsteady pressure loads included boundary layer turbulence, combustion noise, and transients generated by unstart loads. Typical turbulent boundary layer rms pressures in the inlet ranged from 133 dB in the inlet to 181 dB in the combustor over the frequency range from 0 to 5 kHz. Downstream of the inlet exist, combustion noise was shown to dominate boundary layer turbulence noise at increased heat release rates. Noise levels in the isolator section increased by 15 dB when the fuel-air ratio was increased from 0.37 to 0.57 of the stoichiometric ratio. Transient pressure disturbances associated with engine unstarts were measured in the inlet and have an upstream propagation speed of about 7 ft/sec and pressure jumps of at least 3 psia.

Parrott, Tony L.↗

NASA NTRS2020

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS)

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The most challenging of these technical barriers to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL craft, such as specific energy and cycle life, are at least 2 times greater than those of electric automobiles. Furthermore, safety is essential for operation of commercial electric aerovehicles. Preliminary systems level analysis studies have indicated that there are five key properties which must be optimized for successful implementation of battery systems. Those five key criteria are safety, energy density, power, packaging design and scalability. Current state-of-the-art (SOA) lithium-ion batteries meet or exceed the requirements for electric aviation in the areas of power and scalability, yet are insufficient in the key performance criteria of energy, safety and packaging design. The SABERS concept proposes a battery that meets all five key performance criteria through the development of a solid-state architecture cell design utilizing high energy density and power density sulfur-selenium cathode with a lithium metal anode. Data will be presented demonstrating high performing sulfur - selenium cathode that offers a balanced energy to power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This cathode is being developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. Novel processing methods allow developing solid-state electrolyte that is a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. The all solid-state lithium-sulfur-selenium cell design enables the implementation of a bipolar stack configuration, which has the advantages of reducing overall cell weight, reducing the amount of interfaced connections for the cell, and minimizing cooling requirements for the battery. In particular, the solid-state design allows for a serial stacking configuration to enable dense packaging of the cells within the bipolar stack. Lastly, optimization of battery components occurs through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a solid-state battery with operational temperatures from 0 °C to 150 °C which provides the required energy density, discharge rate, and inherent safety to meet strict aerospace performance criteria.

solid state batteries↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety for Electric Aircraft

All electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The most challenging of these technical barriers to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL craft are at least 2 times greater than those of electric automobiles. Furthermore, safety is essential for operation of commercial electric aerovehicles. Preliminary systems level analysis has indicated that there are five key properties which must be optimized for successful implementation of battery systems. Those five key criteria are: safety, energy density, power, packaging design and scalability. Current state-of-the-art (SOA) lithium-ion batteries meet or exceed the requirements for electric aviation in the areas of power and scalability, yet are insufficient in the key performance criteria of energy, safety and packaging design. The SABERS concept proposes a battery that meets all five key performance criteria through development of a solid-state architecture battery utilizing high energy density and power density sulfur-selenium cathode with a lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur-selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, reducing the amount of interfaced connections for the cell, and minimizing the cooling requirements for the cell. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures from 0 °C to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace performance criteria. This presentation will show initial results that demonstrate the SABERS Team has developed a composite carbon-sulfur cathode which exceeds 1100 Wh/kg at a discharge rate of 0.4C, and 804 Wh/kg at a discharge rate of 1C. Additionally, this presentation will show the SABERS Team multiscale computational modeling approach and has produced a novel particle dynamics method called Solid Electrolyte Sphere Approximation Model (SESAM). SESAM is on the 1-10 µm scale and provides electromechanical and grain interactions for predictive design guidelines for the experimental team to follow.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) for Extended Deep Space Applications

Extended duration deep space missions as well as permanent space habitats face numerous technical challenges, key among them is energy generation and energy storage. There are considerable monetary and technical barriers to the generation of power in space. Therefore, it is important to store and be able to access power in an efficient and safe manner over a large number of cycles. Energy storage and in particular, batteries, are vital to the operation of next-generation extraterrestrial shuttles, rovers, habitats and extravehicular activity (EVA) space suits. The performance metrics for extended duration space missions are at least 2 times greater than those set for terrestrial applications such as electric automobiles. Furthermore, safety is essential for operation of space missions particularly involving astronauts such as shuttles, habitats and EVA space suits. Preliminary systems level analysis has indicated that there are five key properties which must be optimized for successful implementation of battery systems. Those five key criteria are: safety, energy density, power, packaging design and scalability. Current state-of-the-art (SOA) lithium-ion batteries can meet or exceed the requirements for certain space applications in the areas of power and scalability, yet are insufficient in the key performance criteria of energy, safety and packaging design. The SABERS concept proposes a battery that meets all five key performance criteria through development of a solid-state architecture battery utilizing high capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements for the cell. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict space mission performance criteria. In particular, the wide operational temperature window is required for the large temperature ranges which are experienced across a broad range of potential space missions. This presentation will show initial results that demonstrate the SABERS team has developed a composite carbon-sulfur cathode which exceeds 1100 Wh/kg at a discharge rate of 0.4C, and 804 Wh/kg at a discharge rate of 1C. Additionally, this presentation will show the SABERS team multiscale computational modeling approach and has produced a novel particle dynamics method called Solid Electrolyte Sphere Approximation Model (SESAM). SESAM is on the 1-10 µm scale and provides electromechanical and grain interactions for predictive design guidelines for the experimental team to follow.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Computational Modeling Development of Solid-state Architecture Batteries for Enhanced Rechargeability and Safety for Electric Aircraft

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) for Electric Aircraft

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This presentation will demonstrate a feasible path for solid-state cells that possess a specific energy of greater than 400 Wh/kg to enable electric aircraft.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Sustainable Electric Aviation

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This presentation will demonstrate a feasible path for solid-state cells that possess a specific energy of greater than 400 Wh/kg to enable electric aircraft.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRS2023

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS): Advanced Battery Technology for Sustainable Aviation

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This presentation will demonstrate a feasible path for solid-state cells that possess a specific energy of greater than 400 Wh/kg to enable electric aircraft. The presentation will also explore novel materials and computational models used to achieve all solid-state cells that operate safely at very high temperatures and specific energies. The cells can withstand damage while operating without an increase in temperature or spontaneous ignition.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Sustainable Electric Aviation

All-electric and hybrid electric aerovehicle concepts face numerous technical barriers prior to their introduction into the consumer marketplace in order to meet sustainable aviation goals. One of the primary barriers to overcome is developing an energy dense storage system capable of meeting the rigorous aerospace safety and performance criteria. Additionally, the electric aviation market requires that the batteries be fabricated in a sustainable manner with materials that are readily available and abundant within the U.S. to ensure there are no supply chain issues during manufacturing. The performance metrics to enable electric aviation are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. The hybrid cathode has been developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte has been used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This poster summarizes recent results from battery component optimization to scale-up production of full SABERS pouch cells.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Next-Generation Sustainable Electric

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system that meets rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for the safe operation of commercial electric aero vehicles. The SABERS concept proposes a battery that meets the critical performance criteria by developing a solid-state architecture battery utilizing a high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed using NASA-patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement for the highly flammable liquid organic electrolytes currently in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed in a serial stacking configuration to enable the dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, the optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150°C, providing the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. The SABERS team employed novel materials development, computational modeling, and design-of-experiments (DOE) optimization studies in their research. This presentation will show the results of these studies and demonstrate a feasible path for solid-state cells with a specific energy greater than 400 Wh/kg to enable electric aircraft.

Computational Modeling↗

DOE OSTI2021

Modulating solvation interactions of deep eutectic solvents formed by ammonium salts and carboxylic acids through varying the molar ratio of hydrogen bond donor and acceptor

Deep eutectic solvents (DESs) have gained increasing popularity in separation science due to the fact that their physico-chemical properties can be easily fine-tuned by varying the type or ratio of hydrogen bond acceptor (HBA) and hydrogen bond donor (HBD). While it is well-known that the molar ratio of HBA/HBD affects the melting point of a eutectic mixture, much less is understood regarding its effect on the magnitude of individual solvation interactions. This is largely due to the fact that established solvatochromic dye methods lack sensitivity when the HBA/HBD ratio is varied slightly in a eutectic mixture. Herein, this study is the first to measure the variation of DES solvation interactions with small changes in the molar ratio of HBA/HBD using inverse gas chromatography (IGC). Solute-solvent interactions of three different DES systems comprised of ammonium salts and organic acids were examined. The probe molecules were studied for 18 eutectic mixtures of varied HBA and HBD composition. We report DES hydrogen bond basicity, hydrogen bond acidity, and dispersive-type interactions exhibited the greatest change when the molar ratio of HBA/HBD was varied in the eutectic mixture. Results from this study demonstrate that the HBA/HBD ratio can be used to modulate the solvation characteristics for this class of DESs in separations and that the stoichiometric ratio of the HBA/HBD is important in ensuring their reproducible preparation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1993

Polyimides with improved compression moldability

The semicrystalline polyimide prepared by reaction of 3,3',4,4' benzophenonetetracarboxylic (BTDA) and 1,3-bis(4-aminophenoxy 4' benzoyl) benzene (1,3-BABB) is modified so that it can be more readily processed to form adhesive bonds, moldings, and composites. The stoichiometric ratio of the two monomers, BTDA and 1,3-BABB is controlled so that the intermediate polyamide acid is of a calculated molecular weight. A polyimide acid with excess anhydride groups is then reacted with the stoichiometrically required amount of monofunctional aromatic or aliphatic amine required for complete endcapping. The stoichiometrically offset, encapped polyimide is processed at lower temperatures and pressures than the unmodified high molecular weight polyimide with the same repeat unit, and exhibits an improved melt stability.

Hergenrother, Paul M.↗

DOE OSTI2020

Synthesis, characterization, and computational modeling of 6,6'-(((2-hydroxyethyl)azanediyl)bis(methylene))bis(2,4-di-tert-butylphenol) modified group 4 metal alkoxides

The coordination behavior of the tridentate alkoxy ligand 6,6'-(((2-hydroxyethyl)azanediyl)bis(methylene)) bis(2,4-di-tert-butylphenol) (termed H 3 -AM-DBP 2 ) with group 4 metal alkoxides ([M(OR) 4 ]) in a 1:1 ratio was previously found to generate [(ONep)Ti(κ 4 (O,O’,O”,N)-AM-DBP2)] and [(OR)Zr(κ 4 (μ-O,O’,O”,N)-AM-DBP 2 )] 2 (M = Zr, Hf). Additional studies revealed that increasing the stoichiometric ratio to 1:2 H3-AM-DBP 2 :[M(OR) 4 ] led to the isolation of [(ONep)Ti(κ 4 (μ-O,O’,O”,N)-AM-DBP2)(μ-ONep)Ti(ONep) 3 ] (1)•tol, [(OBu t)Zr(κ 4 (μ-O,O’,O”,N)-AM-DBP2)(μ-OBu t)Zr(OBu t )3] (2) and [(OBu t)Hf(κ 4 (μ-O,O’,O”,N)-AM-DBP2)(μ-OBu t )Hf(OBu t ) 3 ] (3). The asymmetric dinuclear complexes of 1-3 resemble the chelation of a [M(OR) 4 ] moiety to a “(OR)M(κ 4 (O,O’,O”,N)-AM-DBP 2 )” fragment. The metal complexed by the AM-DBP 2 ligand has a pseudo octahedral geometry while the other metal adopts an intermediate trigonal bipyramidal (TBP-5)/square base pyramidal (SBP-5) geometry for 1 but a distorted SBP-5 for both 2 and 3. The structure and properties of 1-3 were analyzed by computational modeling and fully characterized by standard analytical methods.

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