MEMS fabrication of a microelectrode for local electrode atom probe microanalysis
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nonorthogonal MEMS three-dimensional atom probe x-↗
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Results for “electrode fabrication”
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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All-Organic Actuator Fabricated with Single Wall Carbon Nanotube Electrodes
Compliant electrodes to replace conventional metal electrodes have been required for many actuators to relieve the constraint on the electroactive layer. Many conducting polymers have been proposed for the alternative electrodes, but they still have a problem of poor thermal stability. This article reports a novel all-organic actuator with single wall carbon nanotube (SWCNT) films as the alternative electrode. The SWCNT film was obtained by filtering a SWCNT solution through an anodized alumina membrane. The conductivity of the SWCNT film was about 280 S/cm. The performance of the SWCNT film electrode was characterized by measuring the dielectric properties of NASA Langley Research Center - Electroactive Polymer (LaRC-EAP) sandwiched by the SWCNT electrodes over a broad range of temperature (from 25 C to 280 C) and frequency (from 1 KHz to 1 MHz). The all-organic actuator with the SWCNT electrodes showed a larger electric field-induced strain than that with metal electrodes, under identical measurement conditions.
Lowther, Sharon E.↗
Thick Electrode Design for Facile Electron and Ion Transport: Architectures, Advanced Characterization, and Modeling
The demand for lithium ion batteries continues to expand for powering applications such as portable electronics, grid-scale energy storage, and electric vehicles. As the application requirements advance, the innovation of lithium ion batteries toward higher energy density and power output is required. Along with the investigation of new materials, an important strategy for increasing battery energy content is to design electrodes with high areal loading to minimize the fraction of nonactive materials such as current collectors, separators, and packaging components, resulting in significant gains in energy content and the reduction of the system-level cost. However, the adoption of thick high areal loading electrodes has been impeded by sluggish charge transport and mechanical instability. With conventional slurry cast electrodes, battery function significantly deteriorates with increases in electrode thickness due to high cell polarization and the incomplete utilization of active materials. Thus, a consideration of approaches that facilitate an understanding and eventual adoption of high-loading electrodes is warranted to enable the deliberate advancement of next-generation batteries. Herein, this Account considers three aspects critical to the science and technology of thick high-loading electrodes. The first discussion covers recent approaches to the design and fabrication of high-loading electrodes. Ensuring electrical contact throughout the electrode is accomplished through the manipulation of conductive additives or using a conductive scaffold within the electrode. Ion transport can be facilitated through electrode design and fabrication approaches that deliberately control the electrode porosity and tortuosity. Second, advanced characterization methodologies are presented as the ability to determine the origins of transport limitations provide the insight needed to deliberately approach future designs. Spectroscopic and diffraction methods have been used to characterize the 2D and 3D pore structure and composition of the electrodes. Furthermore, operando methods that yield spatially and temporally resolved information regarding the progression of the electrochemical reaction are highlighted. The third aspect considered is the utilization of modeling. Physically based continuum models linked with the results of experimental characterization have been demonstrated and then allow the rapid simulation of a variety of deliberate electrode designs and their impacts on functional electrochemistry. Variables relevant to the designs can be tested by the model under a series of use conditions to identify those of most promise for a specific application. Finally, an outlook on future opportunities for high-loading battery electrode research is provided to inform and entice practitioners in the field to pursue these important directions of inquiry.
25 ENERGY STORAGE↗
Fabrication and testing of silver-hydrogen cells
Silver electrodes containing various additives were fabricated and tested in single electrode cells in order to improve the electrochemical utilization of sintered silver cathodes in Ag-H2 aerospace batteries. A standard stack arrangement was used which featured a NASA-developed organic-inorganic separator. All cells were cycled in a regime designed to remove 75% of the cells nominal capacity based on 3.3 gms/AHr Ag utilization. In cases where performance degradation was observed, the main feature mode appeared to be corrosion of either the expanded silver current collector or the connection between the silver electrode and the electrode tab. Promising silver electrodes from single electrode studies were used in the construction of 35 AHr Ag-H2 cells. Two such cells were constructed and installed in heavy walled pressure vessels for testing. Based on the data obtained from all cells tested during the program, four lightweight 35 AHr cells were fabricated. During acceptance testing these cells yielded an average gravimetric energy density of 30 WHr/1b.
Debicarri, D. J.↗
A case study of high-temperature polyetherimide film capacitor fabrication
Capacitors, as the basic building block of power electronics and electrical systems, are the major constraint of the increasingly integrated power systems that require new capable polymer dielectric films operating at higher temperatures >125 °C. Despite tremendous research efforts on the lab scale, there remains a considerable barrier and knowledge basis for converting polymeric films to functioning capacitors desired in actual applications. Here, the authors tackled the polyetherimide (PEI) film scale up issues and developed various engineering processes for film de-wrinkling, optimal metallization, static elimination, and capacitor fabrication improvement. The authors discovered various fabrication challenges such as the electrostatic charge, metallization scheme, winding tension, and end electrode disconnects. To fabricate a high yield of PEI capacitor bobbins, it is necessary to utilize static eliminators (radioactive ionizers), moderately thick aluminum metallization (15–30 Ω/sq), and winding tension (60–100 g). It is also effective to evaluate capacitance, dielectric loss, equivalent series resistance, and thermal cycling stability of capacitors. This work sheds some light on converting PEI films and other polymeric films to capacitors on a scale up fabrication effort. The practical learning from film handling to capacitor fabrication in this work provided the necessary knowledge for manufacturing high-temperature polar film capacitors.
36 MATERIALS SCIENCE↗
Enhanced electronic sensors
A micro-structured device that can improve sensitivity and signal-to-noise for electronic sensor materials is embedded in electrically resistive materials. The technology includes a three-dimensional embedded electrode structure and fabrication methods for making the device for electronic sensing in bulk resistive materials. Embedded electrode structures address issues in conventional sensors by allowing independent control of sensitive material thickness, area, electric field intensity, and field direction.
Doty, Fred Patrick↗
Acoustophoretic Additive Manufacturing for Scalable 3D Battery Electrodes
This project focused on investigating two acoustic-based processing methods: a nozzle-based printhead and a chamber that map to two different battery electrode architectures: (1) a line-pattern electrode and (2) a grid-pattern electrode. These two parallel manufacturing and electrode geometry explorations were proposed for the project to understand the process space of acoustic-based manufacturing methods to fabricate patterned battery electrodes. This two-path exploration also allowed us to de-risk the overall project and not rely on a single process for creating patterned electrodes. This project consisted of six high-level tasks aimed at transitioning the concept of acoustic focusing for battery electrodes from a technology readiness level (TRL) of 1 to 3 by project conclusion. Overall, we believe we have developed a practical and high-impact processing method that is chemistry agnostic and suitable for large-area fabrication of both 3D LIBs and other functional material systems where structuring on the scale of tens of microns has the potential to break conventional bulk material trade-offs in performance. In the case of batteries for electric vehicles, structuring 3D LIBs with our acoustic process breaks traditional energy and power trade-offs observed with conventional flat battery packs.
25 ENERGY STORAGE↗
Direct Electrolytic Deposition of Mats of Mn(x)O(y) Nanowires
Mats of free-standing manganese oxide (MnxOy) nanowires have been fabricated as experimental electrode materials for rechargeable electrochemical power cells and capacitors. Because they are free-standing, the wires in these mats are electrochemically accessible. The advantage of the mat-of-nanowires configuration, relative to other configurations of electrode materials, arises from the combination of narrowness and high areal number density of the wires. This combination offers both high surface areas for contact with electrolytes and short paths for diffusion of ions into and out of the electrodes, thereby making it possible to charge and discharge at rates higher than would otherwise be possible and, consequently, to achieve greater power densities. The nanowires are fabricated in an electrolytic process in which there is no need for an electrode binder material. Moreover, there is no need to incorporate an electrically conductive additive into the electrode material; the only electrically conductive material that must be added is a thin substrate contact film at the anchored ends of the nanowires. Hence, the mass fraction of active electrode material is close to 100 percent, as compared with about 85 percent in conventional electrodes made from a slurry of active electrode material, binder, and conductive additive pressed onto a metal foil. The locations and sizes of the nanowires are defined by holes in templates in the form of commercially available porous alumina membranes. In experiments to demonstrate the present process, alumina membranes of various pore sizes and degrees of porosity were used. First, a film of Au was sputtered onto one side of each membrane. The membranes were then attached, variously, to carbon tape or a gold substrate by use of silver or carbon paste. Once thus attached, the membranes were immersed in a plating solution comprising 0.01 M MnSO4 + 0.03 M (NH4)2SO4. The pH of the solution was kept constant at 8 by addition of H2SO4 or NH4OH as needed. Mn(x)O(y) nanowires were potentiostatically electrodeposited in the pores in the alumina templates. Depending on the anodic deposition potentials, Mn(x)O(y) was deposited in various oxidation states [divalent (Mn3O4), trivalent (Mn2O3), or tetravalent (MnO2)]. The Mn(x)O(y) wires were made free-standing (see figure) by dissolving the alumina templates, variously, in KOH or NaOH at a concentration of 20 volume percent.
Myung, Nosang↗
Design and additive manufacturing of optimized electrodes for energy storage applications
Supercapacitors exhibit fast charging/discharging ability and have attracted considerable attention within the automotive, aerospace, and telecommunication industries. Porous carbons, prized for their high electrical conductivity and high surface area, have been attractive candidates for supercapacitor electrodes. Moving to thick electrodes is one strategy to further increase energy density due to a higher volume fraction of active material. However, thick electrodes suffer from sluggish charged species transport, which is why thin electrodes are currently favored. In this work, we investigate the use of computational optimization and additive manufacturing to design and fabricate thick porous electrodes with improved performance. Electrode performance was maximized by designing their morphologies via topology optimization and printing by projection micro stereolithography (PμSL) using commercial resin (PR48). The PR48 resin was then pyrolyzed (PR48-P) to create the final conductive electrode. The optimized PR48-P electrodes exhibited 99% improvement in capacitance compared to control electrodes printed with cubic lattice morphologies. To further improve performance, we formulated a resin combining graphene oxide (GO) and trimethylolpropane triacrylate (TMPTA). Electrodes printed with 3 wt% GO in TMPTA exhibited improved capacitance retention after pyrolysis compared to the PR48-P electrodes. Finally, this work demonstrates the benefits of using topology optimization to design electrodes and material development to improve functional properties of 3D printable electrodes.
25 ENERGY STORAGE↗
Can Greener Cyrene Replace NMP for Electrode Preparation of NMC 811 Cathodes?
N-methyl-2-pyrrolidone (NMP) is the normally used solvent for cathode processing in lithium battery field. However, its high toxicity attracted more and more environmental scrutiny and was restricted by many chemical legislations in industry applications. So, it is necessary to find a greener and safer alternative to replace it. Dihydrolevoglucosenone (Cyrene), a newly reported green dipolar aprotic solvent, has very similar solvent properties as NMP, making it a very attractive candidate. The possibility to use Cyrene to replace NMP for NMC 811 cathode fabrication was studied. Although PVDF binder has very poor solubility in Cyrene at room temperature, increasing temperature can significantly change this. High temperature (above 80 °C) electrode processing with Cyrene gives promising performance, which is comparable to the conventional NMP fabricated electrode. A proof of principle was provided: Cyrene can be a good green alternative to replace NMP. So, the positive results reported here may also lead to a search for more Cyrene-like green solvents that have a higher solubility for PVDF, or of PVDF-like binders that are more soluble in Cyrene, to help making the electrode processing much greener.
36 MATERIALS SCIENCE↗
Radiation-Insensitive Inverse Majority Gates
To help satisfy a need for high-density logic circuits insensitive to radiation, it has been proposed to realize inverse majority gates as microscopic vacuum electronic devices. In comparison with solid-state electronic devices ordinarily used in logic circuits, vacuum electronic devices are inherently much less adversely affected by radiation and extreme temperatures. The proposed development would involve state-of-the-art micromachining and recent advances in the fabrication of carbon-nanotube-based field emitters. A representative three-input inverse majority gate would be a monolithic, integrated structure that would include three gate electrodes, six bundles of carbon nanotubes (serving as electron emitters) at suitable positions between the gate electrodes, and an overhanging anode. The bundles of carbon nanotubes would be grown on degenerately doped silicon substrates that would be parts of the monolithic structure. The gate electrodes would be fabricated as parts of the monolithic structure by means of a double-silicon-on-insulator process developed at NASA's Jet Propulsion Laboratory. The tops of the bundles of carbon nanotubes would lie below the plane of the tops of the gate electrodes. The particular choice of shapes, dimensions, and relative positions of the electrodes and bundles of carbon nanotubes would provide for both field emission of electrons from the bundles of carbon nanotubes and control of the electron current to obtain the inverse majority function, which is described in the paper.
Manohara, Harish↗
Electrospun Nanofiber Electrodes for High and Low Humidity PEMFC Operation
MEAs with nanofiber mat electrodes containing Pt/C catalyst and Nafion binder were fabricated and evaluated. The electrodes were prepared by electrospinning a solution of catalyst powder, salt-form Nafion (with Na + , Li + , or Cs + as the sulfonic acid counterion), and a carrier polymer of either polyethylene oxide or poly(acrylic acid). The carrier polymer was extracted prior to MEA testing by a hot water soaking step. The resulting fibers were 15%–17% porous, with a core–shell-like morphology (a coating of primarily Nafion on the fiber surface). MEAs with anode/cathode catalyst loadings of 0.1 mg Pt cm −2 each and a Nafion 211 membrane produced high power at both high and low relative humidity (RH) conditions in H 2 /air fuel cell tests, e.g., a maximum power density of 919 mW cm −2 at 100% RH and 832 mW cm −2 at 40% RH for a test at 80 °C and 200 kPa abs . The presence of nm-size pores within the fibers trapped water via capillary condensation during low RH feed gas testing, thus maintaining a high proton conductivity of the Nafion binder in the anode and cathode while minimizing/eliminating ionic isolation of catalyst particles in low water content, poorly conductive binder.
25 ENERGY STORAGE↗
Lightweight fibrous nickel electrodes for nickel-hydrogen batteries
The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art sintered nickel electrodes. Lightweight fibrous materials or plaques are used as conductive supports for the nickel hydroxide active material. These materials are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes that pass the initial tests are life cycle-tested in a low Earth orbit regime at 80 percent depth of discharge.
Britton, Doris L.↗
Transparent conducting oxides: from all-dielectric plasmonics to a new paradigm in integrated photonics
During the past few years, the optics and photonics communities have renewed their attention toward transparent conducting oxides (TCOs), which for over two decades have been broadly employed for the fabrication of transparent electrodes in photovoltaic and communication technologies. This reinvigorated research curiosity is twofold: on the one hand, TCOs, with their metal-like properties, low optical absorption, and fabrication flexibility, represent an appealing alternative to noble metals for designing ultra-compact plasmonic devices. On the other hand, this class of hybrid compounds has been proved to possess exceptionally high optical nonlinearities when operating on a frequency window centered around their crossover point, the wavelength point at which the real part of the dielectric permittivity switches sign. Because TCOs are wide-bandgap materials with the Fermi level located in the conduction band, they are hybrid in nature, thus presenting both interband and intraband nonlinearities. This is the cause of a very rich nonlinear physics that is yet to be fully understood and explored. In addition to this, TCOs are epsilon-near-zero (ENZ) materials within a broad near-infrared spectral range, including the entire telecom bandwidth. In this operational window a myriad of novel electromagnetic phenomena have been demonstrated experimentally such as supercoupling, wavefront freezing, and photon doping. Furthermore, TCOs stand out among all other ENZ systems due to one fundamental characteristic, which is hardly attainable even by using structured materials. In fact, around their ENZ wavelength and for a quite generous operational range, these materials can be engineered to have an extremely small real index. This peculiarity leads to a slow-light effect that is ultimately responsible for a significant enhancement of the material nonlinear properties and is the cornerstone of the emerging field of near-zero-index photonics. In this regard, the recent history of nonlinear optics in conductive oxides is growing extremely fast due to a great number of experiments reporting unprecedentedly remarkable effects, including unitary index change, bandwidth-large frequency shift, efficient ultra-low-power frequency conversion, and many others. This review is meant to guide the reader through the exciting journey of TCOs, starting as an industrial material for transparent electrodes, then becoming a new alternative for low-loss plasmonics, and recently opening up new frontiers in integrated nonlinear optics. The present review is mainly focused on experimental observations.
42 ENGINEERING↗
Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells
Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low Earth orbit regime at 40 and 80 percent depths-of-discharge.
Britton, Doris L.↗
Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells
Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low earth orbit regime at 40 and 80 percent depths-of-discharge.
Britton, Doris L.↗
Progress in the development of lightweight nickel electrode for aerospace applications
The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) cells and batteries. These electrodes are lighter in weight and have higher specific energy than the heavy sintered state of the art nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber, felt, and nickel plated plastic) are fabricated into nickel electrodes by electrochemically impregnating them with active material. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes that pass the initial tests are life cycle tested at 40 and 80 percent depths of discharge (DOD). Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. Over 7,000 cycles of life cycle testing have been accumulated at 40 percent DOD, using the lightweight fiber electrode in a boiler plate Ni-H2 cell with stable voltage.
Britton, Doris L.↗
Advancing the Performance of Anion Exchange Membrane Electrolysis by Employing a Powder-Based Ionomer during Anode Catalyst Layer Fabrication
The performance of anion exchange membrane water electrolysis (AEMWE) can be significantly improved by utilizing powdered ionomers during the fabrication of the anode catalyst layer (CL) to modify the CL properties. When comparing powdered ionomers to dispersed ionomers across various catalysts including cobalt oxide (Co 3 O 4 ), nickel−iron oxide (NiFe 2 O 4 ), and iridium oxide (IrO 2 ) the anode fabricated with powdered ionomers demonstrates improved performance in polarization curves, enhanced charge transfer kinetics, and reduced ohmic and transport losses, as evidenced by voltage breakdown and electrochemical impedance spectroscopy analyses. Optimal performance is achieved using a Co 3 O 4 catalyst with a 10 wt % powdered ionomer via the catalystcoated substrate method. Microscopy analyses reveal that electrodes formed with powdered ionomers during fabrication exhibit a more uniform catalyst and ionomer distribution, increased porosity with smaller pore areas, improved electronic conduction with less catalyst agglomeration isolated by a nonconductive ionomer, and enhanced interfacial contact with the membrane and transport layer. These findings highlight that ionomers in a powdered form can promote beneficial properties and are a promising approach to improving AEMWE efficiency.
08 HYDROGEN↗