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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Intense cyclic heating effects on thermo-fracture and thermal shock of solid tungsten and open-cell tungsten foam

Here we investigate here the effects of transient (cyclic) arc-jet plasma and laser heating on fracture behavior of W-foam and solid tungsten. The two key parameters that control the foam thermomechanical response are its density and mean cell size expressed in Pores Per Inch (PPI). Tungsten foam samples were fabricated with Chemical Vapor Deposition (CVD) with variety of PPI and relative density. These were tested under two types of qualitatively different conditions: (1) high-enthalpy arc-jet, and (2) high-power cyclic laser heating. None of the foam samples showed macroscopic through-thickness cracks. However, distributed micro-cracks were observed on ligaments and their triple junctions. Under the same loading conditions, W-foam and solid tungsten showed similar crack network pattern and characteristic length-scale. However, Crack Opening Displacement (COD) was twice as large in solid W as compared to W-foam. Foam samples that have been previously exposed to a low-pressure helium plasma showed significant changes in their surface forming nano-texture fuzz which was removed by subsequent testing in the arc-jet. Extensive fracture and re-crystallization were observed in the thin solid W disk that was fully-constrained from expansion. Thicker and fully-constrained solid W disks did not display recrystallization, grain growth, and extensive cracking. However, thicker disks that were free to expand showed some recrystallization and extensive through-thickness cracks due to less effective cooling and thus higher temperatures. Laser beam testing showed no visible damage formation at 0.19 GW/m 2 and 0.38 GW/m 2 for both low-density (23%) and high-density (43%) foams at low pulses (100-1000). Micro-cracks were observed after 10,000 pulses at 0.19 GW/m 2 in both foams, and in low-density foam after 100,000 at 0.38 GW/m 2 . The nature of thermomechanical damage in W-foam exposed to extreme power (GW/m 2 ) short-duration laser pulses was found to be qualitatively similar to that of high power (MW/m 2 ) long-duration arc-jet.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Upstream surface roughness and terrain are strong drivers of contrast in tornado potential between North and South America

Central North America is the global hotspot for tornadoes, fueled by elevated terrain of the Rockies to the west and a source of warm, moist air from equatorward oceans. This conventional wisdom argues that central South America, with the Andes to the west and Amazon basin to the north, should have a “tornado alley” at least as active as central North America. Central South America has frequent severe thunderstorms yet relatively few tornadoes. Here, we show that conventional wisdom is missing an important ingredient specific to tornadoes: a smooth, flat ocean-like upstream surface. Using global climate model experiments, we show that central South American tornado potential substantially increases if its equatorward land surface is smoothed and flattened to be ocean-like. Similarly, we show that central North American tornado potential substantially decreases if its equatorward ocean surface is roughened to values comparable to forested land. A rough upstream surface suppresses the formation of tornadic environments principally by weakening the poleward low-level winds, characterized by a weakened low-level jet east of the mountain range. Results are shown to be robust for any midlatitude landmass using idealized experiments with a simplified continent and mountain range. Our findings indicate that large-scale upstream surface roughness is likely a first-order driver of the strong contrast in tornado potential between North and South America.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Effect of nozzle translation on a bounded vortex flow

A bounded vortex flow is generated by a nozzle that combines azimuthally tilted downward jets in a circular array and a central suction port. When the nozzle is directed toward a bottom surface (called the impingement surface), the flow develops a strong intake vortex spanning from the impingement surface to the suction port, which acts to generate strong shear stress on the impingement surface. This strong shear stress can aid in removing particles attached to the impingement surface or in enhancement of heat or mass transfer, where in typical applications, the nozzle would be translated along the impingement surface. This paper reports on a computational study of the effect of nozzle translation on the bounded vortex flow field. The nozzle translation induces a bending of the bounded vortex in the downstream flow direction, which becomes larger with increase in the nozzle translation speed. We identify an interesting oscillatory phenomenon by which the bounded vortex can resist the bending induced by the translational flow and rotate about a mean position downstream of the suction port. At sufficiently high translation speeds, the oscillatory process can no longer resist the downwash effect from nozzle translation and the vortex eventually detaches from the impingement surface, limiting the effectiveness of this flow device.

42 ENGINEERING↗
DOE OSTI2023

Single-Phase Jet Impingement Cooling for a Power-Dense Silicon Carbide Power Module

The adoption of silicon carbide (SiC) devices in the electric vehicle (EV) industry is increasing due to their superior performance over silicon devices. SiC devices enable further miniaturization of EV inverters, increasing their power density, which results in thermal management challenges. Here in this paper, the limits of single-phase jet impingement cooling are explored for an automotive SiC power module. We propose embedding pin fins in the direct-bonded-copper (DBC) substrate of the power module package using laser powder bed fusion additive manufacturing. The thermalhydraulic performance of the DBC-embedded pin fins is compared against folded fins that are directly soldered to the DBC substrate. A heat conduction analysis was conducted on a SiC package to determine the target heat transfer coefficient (HTC) for the heat sink. A water-ethylene glycol (WEG) jet impingement on the proposed concepts was studied using unit-cell models to achieve the target HTC. The studied designs put emphasis on the reliability and manufacturability requirements of the automotive industry. The thermal performance of DBC-embedded pin fins outperformed the DBC-soldered folded fins. The performance of the DBC-embedded pin fins is benchmarked against WEG-based cooling systems of commercial EVs. With the proposed cooling solution, we have shown a pathway of reducing the specific thermal resistance by 75% compared to BMW i3 thermal management system without any penalty on pressure drop or parasitic power.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

JET EROSION OF PARTICLE BEDS: PROJECTING CRITICAL SUSPENSION VELOCITIES FROM EFFECTIVE CLEARING / CLEANING RADII

Here we explore the relationship between effective cleaning/clearing radii, ECR, and critical suspension velocities, Ucs. Although one set of physics controls both the radial extent of erosion (i.e., the ECR) and the velocity needed to erode from the center of jet impingement to any given location (i.e., Ucs, typically defined from nozzle center to the vessel center), the relationship between these two remains unexplored quantitatively. Here we advance the model of Kuhn, et al., (PNNL-22816, 2013) as described by Pease, et al. (FEDSM2017-69444, 2017) to evaluate the relationship between the effective clearing/cleaning radius and the nozzle velocity on flat surfaces including flat bottomed vessels. Two governing dimensionless groups are identified. We present both a closed form analytical but transcendental solution and a non-iterative approximation modeled after the Serghides approximation of Colebrook’s nonlinear equation for both ECR versus nozzle velocity and Ucs. Comparison of the model to data from flume testing on a flat surface finds reasonable agreement.

jet, erosion, critical suspension velocity, effect↗
DOE OSTI2024

How Might the May 2015 Flood in the U.S. Southern Great Plains Induced by Clustered MCSs Unfold in the Future?

Abstract The historic 22–26 May 2015 flood event in Texas and Oklahoma was caused by anomalous clustered mesoscale convective systems (MCSs) that produced record‐breaking rainfall and $3 billion of damage in the region. A month‐long regional convection‐permitting simulation is conducted to reconstruct multiple clustered MCSs that lead to this flood event. We further use the pseudo global warming approach to examine how a similar event may unfold in a warmer climate and the driving physical factors for the changes. Tracking of MCSs in observations and simulations shows that the historical simulation reproduces the salient characteristics of the observed MCSs. In a warmer climate under a high‐emission (SSP5‐8.5) scenario, the Southern Great Plains is projected to experience a near surface warming of 4–6 K, accompanied by enhanced moisture transport by the strengthened Great Plains low‐level jet. A warmer and moister lower troposphere leads to 36%–59% larger convective available potential energy, supporting wider and more intense convective updrafts and rainfall production. Consistently, MCSs have wider convective areas and stronger rainfall intensities, producing 50% larger rain volumes during the mature stage. Extreme (99.5%) MCS rainfall frequency and amount will increase by threefold. However, MCS stratiform rain area decreases as a result of elevated stratiform cloud bases that lead to stronger sublimation and evaporation of precipitation in response to warming, resulting in reduced weak‐to‐moderate surface precipitation. Results suggest that global warming greatly increases precipitation intensity of clustered MCS events under strong synoptic influence, with much higher potential to produce serious floods without additional climate adaptation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

AOI [1]: Passive Wireless Sensor Systems Fabricated by Direct-Writing for Temperature and Health Monitoring of Energy Systems in Harsh-Environments (Final Report)

Researchers at West Virginia University (WVU) propose to demonstrate a wireless, high-temperature sensor system for monitoring the temperature and health of energy-system components. The active sensor and electronics for wireless communication will be composed entirely of an electroceramic materials (conductive ceramics) which are capable of withstanding the harsh-environments required for fossil energy-based technologies. This work will focus primarily on the fabrication and testing of temperature (thermocouples and thermistors) and health (strain/stress and crack propagation sensors) that function at extreme temperatures (up to 700-1700ºC). The electronics will accompany the high-temperature sensor, which will include a passive wireless communication circuit that allows the transmission of the data based on the LCR resonance principle to a near-by reader antenna. This passive transmission of data will reduce the need for interconnect wires near the active, and possibly rotating, energy-system component. The research will include process development to permit the 2D/3D direct-writing of the entire sensor and communication circuit onto the energy-system component. The direct-writing will be facilitated by using silicon-based polymer-derived precursors to form the high-temperature, stable electroceramic compositions. In addition, methods for direct-writing the circuit onto a fugitive carrier substrate will be completed, which will permit a “peel-and-stick”-like transfer of the sensor circuit to the energy-system component. This feature will allow the economical and precise placement of the sensor circuit onto components of various shapes and locations, without altering the geometry and active features of the manufactured component, or the removal (or decommissioning) of the component for installation. The proposed work will be directed at the following areas: 1) Investigation of phase formation, sintering/grain growth, and electrical properties of polymer-derived electroceramic composites; 2) Definition of processes to direct-write through ink-jet and robo-casting the polymer-derived electroceramic composites onto oxide and polymer surfaces; 3) Development of methods to form monolithic "peel-and-stick" preforms that will efficiently transfer the sensor circuit to ceramic surfaces after thermal treatment; 4) Design of passive wireless LCR circuits and receiver (reader) antennas for communication and testing at high temperatures; 5) Investigation of the passive wireless sensor system developed (and method of transferring sensor system) for temperature and stress/strain measurements on a SOFC repeat unit and a singular gas turbine blade prototype as example applications.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO 2 , N 2 , or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO 2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO 2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N 2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO 2 , N 2 , and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m 2 , respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Causes of and Solutions to Wind Speed Bias in NREL's 2020 Offshore Wind Resource Assessment for the California Pacific Outer Continental Shelf

This report provides the results of a detailed analysis into the causes of high wind speed bias in the 20-year wind resource data set for offshore California the National Renewable Energy Laboratory (NREL) released in 2020, herein called CA20. The data set was developed using the state-of-the-art Weather Research and Forecasting (WRF) model. Notably, no floating lidars were available at the time in offshore California to validate offshore hub-height wind speeds. In late 2020, the Pacific Northwest National Laboratory (PNNL) deployed two floating lidars in the California outer continental shelf (OCS), near the Bureau of Ocean Energy Management (BOEM) call areas of Humboldt and Morro Bay. Using these observations through 2021, NREL found considerable bias in modeled hub-height winds at both locations: up to +2 m/s at Humboldt over a 6-month period, and up to +1 m/s at Morro Bay over a one-year period. Upon the discovery of this bias, the Department of Energy (DOE) and BOEM funded NREL and PNNL to investigate the causes of, impacts of, and solutions to the bias in the CA20 data set. This report summarizes the findings of this research. We first investigated whether different WRF model setups could lead to reduced bias. We found that the choice of planetary boundary layer (PBL) scheme - which controls the vertical turbulent mixing of momentum, heat, and moisture in the lowermost part of the atmosphere - greatly affected hub-height wind speeds in the region. Specifically, switching from the Mellor-Yamada-Nakanishi-Niino (MYNN) scheme used in CA20 (and widely used across a range of operational and research weather models) to the less common Yonsei University (YSU) scheme nearly eliminated the bias at both the Humboldt and Morro Bay lidar locations. The large discrepancy between the MYNN- and YSU-modeled hub-height winds pointed towards the role of atmospheric stability. In general, PBL schemes agree well in conditions of high turbulence and mixing, normally referred to as "unstable" conditions. By contrast, PBL schemes start to diverge in "stable" conditions, where turbulence is low and thermal stratification (i.e., higher temperature air sitting on top of colder air) greatly suppresses vertical mixing. Under such conditions, winds aloft can decouple from surface effects and greatly accelerate, causing high wind speeds at hub-height and frequent low-level jets (LLJs). We determined that these stable conditions are in fact dominant in offshore California. The region is characterized by moderate-to-extreme stable stratification with a LLJ on average around 200 meters above sea-level. To our knowledge, no wind energy area globally has as strongly stable stratification as offshore California. Under these extreme conditions, we determined that the MYNN scheme models higher stability than YSU, resulting in less vertical turbulent mixing than YSU, allowing for the acceleration of hub-height winds, more intense LLJs, and higher-amplitude inertial oscillations. Using surface observations, we found that MYNN overestimates near-surface stability, whereas YSU tends to model stability better. We then considered several short-term case studies to assess additional meteorological drivers of the bias at Humboldt. We found that during synoptic scale northerly flows driven by the North Pacific High and inland thermal low, a coastal warm bias in the MYNN case studies contributes to the modeled wind speed bias by altering the boundary layer thermodynamics via a thermal wind mechanism. Given the strong performance of the YSU-based runs in offshore California, NREL has produced and published an updated version of the CA20 data set with YSU as the PBL scheme. This updated data set is now part of NREL's 2023 National Offshore Wind (NOW-23) data set, which covers all the U.S. offshore waters. The development and final validation of the NOW-23 data set in offshore California is documented in this report.

17 WIND ENERGY↗
DOE OSTI2026

Idealized Offshore Low‐Level Jets for Turbine Structural Impact Considerations

Low-level jets (LLJs) describe conditions in which the wind speed reaches a local maximum with respect to altitude near the surface; they have been observed intermittently in the US mid-Atlantic offshore environment. LLJs pose unique operating conditions for future wind turbines operating in the region, such as negative shear and locally strong veer, but they are not typically considered in existing turbine standards. This work builds upon recent research that explains the formation and evolution of the US mid-Atlantic LLJs through a simple analytical governing equation. We generate several LLJ inflow conditions with varying jet characteristics based on this analytical model and create monotonically sheared (MS) analogues with matched veer to assess the impacts of the LLJ on turbine performance and loading. Using aeroelastic simulations with these inflow conditions on the International Energy Agency 15-MW reference turbine, we find that the LLJ leads to a greater range of tower-top pitching and yawing moments, which could contribute to larger accumulated structural fatigue in components compared to MS inflow. These preliminary results demonstrate a path toward a unified set of test cases for low-level wind maxima that can inform the International Electrotechnical Commission standards related to offshore wind turbine design.

17 WIND ENERGY↗
DOE OSTI2023

Characterization of a Low-Temperature Plasma (LTP) Ambient Ionization Source Using Temporally Resolved Monochromatic Imaging Spectrometry

The low-temperature plasma (LTP) probe is a common plasma-based source used for ambient desorption–ionization mass spectrometry (MS). While the LTP probe has been characterized in detail with MS, relatively few studies have used optical spectroscopy. In this paper, two-dimensional (2D) imaging at selected wavelengths is used to visualize important species in the LTP plasma jet. First, 2D steady-state images of the LTP plume for N 2 + (391.2 nm), He I (706.5 nm), and N 2 (337.1 nm) emissions were recorded under selected plasma conditions. Second, time-resolved 2D emission maps of radiative species in the LTP plasma jet were recorded through the use of a 200 ns detection gate and varying gate delays with respect to the LTP trigger pulse. Emission from He I, N 2 + , and N 2 in the plasma jet region was found to show a transient behavior (often referred to as plasma bullets) lasting only a few microseconds. The N 2 + and He I maps were highly correlated in spatial and temporal structure. Further, emission from N 2 showed two maxima in time, one before and one after the maximum emission for N 2 + and He I, due to an initial electronic excitation wave and ion–electron recombination, respectively. Third, the interaction of the LTP probe with a sample substrate and an electrically grounded metallic needle was studied. Emission from a fluorophore on the sample substrate showed an initial photon-induced excitation from plasma-generated photons followed by electronic excitation by other plasma species. The presence of a grounded needle near the plasma jet significantly extended the plasma jet lifetime and also generated a long-lived corona discharge on the needle. The effect of LTP operating parameters on emission spectra was correlated with mass-spectral results including reagent-ion signals. Lastly, five movies provide a side-by-side comparison of the temporal behavior of emitting species and insights into the interactions of the emission clouds with a sample surface as well as an external needle. Temporally and spatially resolved imaging provided insights into important processes in the LTP plasma jet, which will help improve analyte ion sampling in LTP–MS.

Chan, George C. -Y.↗
DOE OSTI2024

Ekman-driven salt transport as a key mechanism for open-ocean polynya formation at Maud Rise

Open-ocean polynyas formed over the Maud Rise, in the Weddell Sea, during the winters of 2016–2017. Such polynyas are rare events in the Southern Ocean and are associated with deep convection, affecting regional carbon and heat budgets. Using an ocean state estimate, we found that during 2017, early sea ice melting occurred in response to enhanced vertical mixing of heat, which was accompanied by mixing of salt. The melting sea ice compensated for the vertically mixed salt, resulting in a net buoyancy gain. An additional salt input was then necessary to destabilize the upper ocean. This came from a hitherto unexplored polynya-formation mechanism: an Ekman transport of salt across a jet girdling the northern flank of the Maud Rise. Such transport was driven by intensified eastward surface stresses during 2015–2018. Our results illustrate how highly localized interactions between wind, ocean flow and topography can trigger polynya formation in the open Southern Ocean.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Cold plate with combined inclined impingement and ribbed channels

Heat transfer devices and methods for making the same that include a first enclosure having at least one inlet port; a second enclosure having a bottom plate and one or more dividing walls to establish channels, at least one internal surface of each channel having rib structures to create turbulence in a fluid flow; and a jet plate connecting the first enclosure and the second enclosure having impinging jets that convey fluid from the first enclosure to the channels, said impinging jets being set at an angular deviation from normal to cause local acceleration of fluid and to increase a local heat transfer rate.

42 ENGINEERING↗
DOE OSTI2024

Near-global summer circulation response to the spring surface temperature anomaly in Tibetan Plateau –– the GEWEX/LS4P first phase experiment

Subseasonal to seasonal (S2S) prediction of droughts and floods is one of the major challenges of weather and climate prediction. Recent studies suggest that the springtime land surface temperature/subsurface temperature (LST/SUBT) over the Tibetan Plateau (TP) can be a new source of S2S predictability. The project “Impact of Initialized Land Surface Temperature and Snowpack on Subseasonal to Seasonal Prediction (LS4P)” was initiated to study the impact of springtime LST/SUBT anomalies over high mountain areas on summertime precipitation predictions. The present work explores the simulated global scale response of the atmospheric circulation to the springtime TP land surface cooling by 16 current state-of-the-art Earth System Models (ESMs) participating in the LS4P Phase I (LS4P-I) experiment. The LS4P-I results show, for the first time, that springtime TP surface anomalies can modulate a persistent quasi-barotropic Tibetan Plateau-Rocky Mountain Circumglobal (TRC) wave train from the TP via the northeast Asia and Bering Strait to the western part of the North America, along with the springtime westerly jet from TP across the whole North Pacific basin. The TRC wave train modulated by the TP thermal anomaly play a critical role on the early summer surface air temperature and precipitation anomalies in the regions along the wave train, especially over the northwest North America and the southern Great Plains. The participant models that fail in capturing the TRC wave train greatly under-predict climate anomalies in reference to observations and the successful models. These results suggest that the TP LST/SUBT anomaly via the TRC wave train is the first order source of the S2S variability in the regions mentioned. Furthermore, the TP surface temperature anomaly can influence the Southern Hemispheric circulation by generating cross-equator wave trains. However, the simulated propagation pathways from the TP into the Southern Hemisphere show large inter-model differences. More dynamical understanding of the TRC wave train as well as its cross-equator propagation into the Southern Hemisphere will be explored in the newly launched LS4P phase II experiment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Toward ultrafast, ultra-stable imaging arrays: Superlattice doping to enhance the performance of backside-illuminated 3D-hybridized silicon photodetectors

In this paper, the authors report the latest results on their development of superlattice-doped, thinned, backside-illuminated (BSI), 3D-integrated photodiode detectors—a step toward their ultimate goal of demonstrating ultrafast, ultrastable CMOS imaging arrays. As with most silicon-based photodetectors, backside-illumination and backside surface passivation are keys to achieve the highest performance capability. The two-dimensional (2D) doping technique developed at the Jet Propulsion Laboratory (JPL) has proved to result in a highly efficient, highly stable detector response when combined with a variety of detectors. Here, JPL's 2D-doping has been combined with Sandia's BSI photodetectors hybridized with custom fanout wafer via copper Direct Bond Interconnect (DBI®), a technology that is rapidly becoming industry standard for BSI CMOS imaging arrays. The prototype detectors were packaged and evaluated with respect to their response to low energy electrons. The authors find that the responsivity of 2D-doped BSI detectors is higher than devices prepared using other surface passivation techniques (i.e., ion implantation). The success of the work described herein verifies that the 2D-doping processes previously developed for Sandia's frontside-illuminated photodetectors are generally applicable to BSI detectors and demonstrates for the first time that JPL's 2D-doping process is compatible with the Cu-DBI® technology.

Jewell, April D.↗
DOE OSTI2022

Method of generation of planar plasma jets

Applications of dielectric barrier discharge (DBD) based atmospheric pressure plasma jets are often limited by the relatively small area of treatment due to their 1D configuration. This system generates 2D plasma jets permitting fast treatment of larger targets. DBD evolution starts with formation of transient anode glow, and continues with development of cathode-directed streamers. The anode glow can propagate as an ionization wave along the dielectric surface through and outside of the discharge gap. Plasma propagation is not limited to 1D geometry such as tubes, and can be organized in a form of a rectangular plasma jet, or other 2D or 3D shapes. Also described are a method for generating 2D plasma jets and use of the 2D plasma jets for cancer therapy.

Dobrynin, Danil V.↗
DOE OSTI2023

Abstract for CRADA between NETL and the University of Massachusetts Lowell (AGMT-1275)

The demand for printed electronics over conventional electronics is growing each year due to their low costs, low material waste during manufacturing, and compatibility with flexible substrates. The development of inks for printed electronics is a challenge because each printing technology requires different viscosities and curing behaviors to create devices with controlled structures at the micron scale, or smaller. Carbon is a great candidate for fabricating printed electronics devices because it is inexpensive and earth abundant, easily functionalized to impart miscibility with solvent systems, and has electrical properties that can be tuned from insulating to conducting. Despite these advantages, carbons are rarely used for printed electronics because there is a scarcity of inks available for non-contact printing technologies. To address these challenges, the National Energy Technology Laboratory (NETL) will collaborate with the University of Massachusetts Lowell (Participant) through its Printed Electronics Research Collaborative (PERC) to develop engineered carbons and ink formulations optimized specifically for printing radio- and microwave-frequency electronic devices using ink jet, aerosol jet, syringe dispensing, and other additive manufacturing techniques. NETL will process coal, petroleum, and other carbon feedstocks to make engineered carbons with the appropriate composition, microstructure, surface functionalization, and particle morphologies needed to stabilize ink suspensions and impart useful electronic properties to printed devices. The University of Massachusetts Lowell will utilize these engineered carbons to determine which solvent systems and ink additives are needed to achieve the appropriate viscosity, stability, and printability to make useful ink formulations. The University of Massachusetts Lowell will then utilize these inks to manufacture printed resistors and conductors using inkjet, aerosol jet, and syringe dispensing printing methods and will characterize device performance using four-point probe resistivity measurements, contact angle measurements to assess wettability, adhesion evaluation to various substrates, and focused ion beam and scanning electron microscopy for surface and density investigations of printed devices.

36 MATERIALS SCIENCE↗