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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Fabrication and characterization of nanoscale magnesium diboride and tetraboride for propulsion and hydrogen storage applications

Abstract: Boron-loaded propellants have the potential to dramatically increase the performance of solid fuel ramjets, ducted rockets, and hybrid rocket engines. However, difficult ignition of boron decreases the combustion efficiency of these propellants. One approach to solving this problem involves the use of magnesium diboride, MgB2, which ignites easier than boron. Magnesium tetraboride, MgB4, potentially offers greater energetic performance as B has a higher energy density than Mg. However, the effect of the higher boron/metal ratio on the ignition and combustion is unclear. Nanoscale MgB2 particles and quasi 2D structures are promising propellant ingredients, but the oxidation and combustion properties of nanoscale MgB4 remain unknown. Nanoscale magnesium borides are also of interest as precursors for the synthesis of magnesium borohydride, Mg(BH4)2, a promising hydrogen storage material, but hydrogenation of MgB4 has not been studied yet. The objectives of the present work included synthesis, purification, and high-energy ball milling of MgB2 and MgB4 powders as well as investigation of their hydrogen uptake, thermal decomposition, oxidation, and combustion. The powders were fabricated by combustion synthesis and by heating in a tube furnace. The latter method was superior in the synthesis of MgB4. Oxide impurities in the synthesized powders were removed by acid leaching. Nanoscale powders were obtained by ball-mill exfoliation. The hydrogen intake of the obtained magnesium borides was examined at 700 bar and 300 ℃ and did not reveal any advantage of MgB4 over MgB2. Their thermal decomposition and oxidation were investigated with thermogravimetric analysis (TGA), while their combustion was studied using laser ignition and high-speed video recording. TGA has confirmed prior observations of multistep decomposition of magnesium borides, where each step involves formation of a boride with a higher B/Mg ratio and evaporation of formed magnesium. The oxidation rates of the borides are much higher than that of boron at temperatures over 1200 °C for MgB2 and over 900 °C for MgB4. The burning rates of non-milled MgB₂ and MgB₄ powders were much higher than for the used submicron boron. Milling the MgB₂ and MgB₄ powders further increased their burning rates. The milled MgB4 burned 7.5 times faster than submicron boron.

Combustion of metals, Solid fuels, Propellants, Hy↗
DOE OSTI2020

Performance of Vehicle Fuel System Elastomers and Plastics with Test Fuels Representing Gasoline Blended with 10% Ethanol (E10) and 16% Isobutanol (iBu16)

The compatibilities of fuel system elastomers and plastics were evaluated for test fuels containing 16 vol.% isobutanol (iBu16) and 10 vol.% ethanol (E10). Elastomers included two fluorocarbons, four acrylonitrile butadiene rubbers (NBRs), and one type of fluorosilicone, neoprene, and epichlorohydrin/ethylene oxide. Plastic materials included four nylon grades, three polyamides, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), polyphenylene sulfide (PPS), high-density polyethylene (HDPE), polybutylene terephthalate (PBT), polyoxymethylene (POM), flexible polyvinylchloride (PVC), polyetherimide (PEI), polyetheretherketone (PEEK), and a phenol formaldehyde reinforced with glass fiber (GFPF). For each polymer material, the volume, mass, and hardness were measured before and after drying. Dynamic mechanical analysis (DMA) measurements were also performed on the dried specimens.For the elastomer materials the measured properties were similar for both fuels. The fluorocarbons and fluorosilicone swelled the least (~20%), while more moderate (20-45%) expansion occurred for the two NBR hose grades and (ECO). HNBR, neoprene, and silicone exhibited high swelling and softening, which likely precludes their use in many fuel systems. For the plastic materials, the observed swell was low; Nylon 11 swelled around 15%, but otherwise, their measured swell was <10%. Many of the plastics also showed sensitivity to alcohol type, as the E10 test fuel often imparted appreciably higher swell than iBu16. In general, the plastic materials showed good compatibility with the iBu16 and E10 test fuels. Here, the sole exception was the PVC material, which was structurally degraded from exposure to either fuel type. Compositional analysis showed high fuel retention in Nylon 12 and PVC. PVC also experienced a significant reduction in plasticizer compounds following exposure, which resulted in embrittlement and an increase in the glass-to-rubber transition temperature.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Forecasting EV Charging Demand on the Distribution System

The U.S. transportation and electricity sectors have historically operated independently, but the growth of electric vehicles (EVs) is driving their convergence. After decades of stagnant demand, utilities must prepare for rising load growth, driven in part by transportation electrification. Utilities must anticipate when and where these new loads will materialize to effectively manage EV growth and maintain grid reliability. This presentation outlines NREL's approach to developing high-resolution EV load datasets for distribution planning, with insights from the Multi-State Transportation Electrification Impact Study on EV and load forecasting, infrastructure requirements, and managed charging strategies.

25 ENERGY STORAGE↗
DOE OSTI2024

Field Emission Current Transfer for Homopolar Machines

With the increasing electrification of transportation, the need for high power density electric machines is higher than ever. The required specific power for the more demanding applications, such as airplane propulsion, is over 20 kW/kg for multi-megawatt range power levels. Fully superconducting synchronous machines could reach the required performance, but significant challenges remain to be addressed such as AC losses management and rotating cryogenics implementation. Homopolar machines constitute the simplest electro-mechanical conversion systems possible, however the difficulty of establishing reliable and efficient low voltage, high DC current transfer from a stationary to a rotating system has prevented homopolar machines from competing with AC electrical machines. While sliding contacts or liquid metal contacts are feasible, they lead to high losses, high maintenance requirements and the use of environmentally unfriendly materials. We investigated field emission current transfer as an alternative to sliding contacts. We have demonstrated field emission current transfer in vacuum between a copper electrode and carbon nanotubes and diamond pyramids to evaluate the feasibility of contact-free current transfer for homopolar machines. The initial field emission testing was successfully demonstrated with current densities in the 10 mA/cm 2 range. The initial experiments validated the concept and supported the development of a roadmap for the development of contactless current transfer for homopolar machines, helped understand the limitations of the current test system and identify the key parameters that will lead to better performance.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2021

PPPL Laboratory Directed Research and Development (Project Final Reports, FY2018 - FY2020)

The U.S. Department of Energy’s (DOE) Princeton Plasma Physics Laboratory (PPPL) is a collaborative national center for fusion energy science, basic sciences, and advanced technology. The Laboratory has three major missions: (1) to develop the scientific knowledge and advanced engineering to enable fusion to power the U.S. and the world; (2) to advance the science of nanoscale fabrication for technologies of tomorrow; and (3) to further the development of the scientific understanding of the plasma universe from laboratory to astrophysical scales. PPPL’s Laboratory Directed Research and Development (LDRD) program supports and encourages creativity and innovation and contributes to its long-term viability. New scientific and technical research areas emerge and are nurtured through the program. Furthermore, new capabilities are developed to enable the Laboratory to meet its and DOE’s missions. The program is used to systematically diversify the Laboratory’s programs and mission. In the last few years, the program has started projects in nanomaterial synthesis, microelectronics, advanced x-ray spectroscopy, high-energy-density physics, superconducting magnet technology, machine learning and artificial intelligence, 3D magnetic fields to optimize fusion plasmas, integration of permanent magnets with simple high-field magnets to reduce the cost of producing complex 3D magnetic fields, advanced computational methods for predictive understanding and control of fusion plasma, development of quantum computing algorithms for plasma physics, liquid metal plasma-facing components for fusion reactors, virtual engineering, and plasma-based space propulsion. The program is also the vehicle to recruit and train talented scientists and engineers with the new skills needed to perform the Laboratory’s mission. Many of the new hires through the program go on to become world-class scientists and engineers in their fields. This report provides descriptions and accomplishments of those LDRD projects that were completed during fiscal years 2018 through 2020.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electric-Drive Vehicle Power Electronics Thermal Management: Current Status, Challenges, and Future Directions

Effective thermal management of traction-drive power electronics is critical to the advancement of electric-drive vehicles and is necessary for increasing power density and improving reliability. Replacing traditional silicon devices with more efficient, higher temperature, higher voltage, and higher frequency wide-bandgap (WBG) devices will enable increased power density but will result in higher device heat fluxes. Compact packaging of high-temperature WBG devices near low-temperature-rated components creates thermal management challenges that need to be addressed for future power-dense systems. This paper summarizes the thermal performance of on-road automotive power electronics thermal management systems and provides thermal performance and pumping-power metrics for select vehicles. Thermal analyses reveal that the package/conduction resistance dominates the total thermal resistance (for existing automotive systems). We model advanced packaging concepts and compare the results with existing packaging designs to quantify their thermal performance enhancements. Double-side-cooled configurations that do not use thermal interface materials are package concepts predicted to provide a low junction-to-fluid thermal resistance (compared to current packages). Dielectric-fluid-cooled concepts enable a redesign of the package to reduce the package resistance, can be implemented in single- and two-phase cooling approaches, and allow for cooling of passive components (e.g., capacitors) and bus bars.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Electric Drive Technology Trends, Challenges, and Opportunities for Future Electric Vehicles

The transition to electric road transport technologies requires electric traction drive systems to offer improved performances and capabilities, such as fuel efficiency (in terms of MPGe, i.e., miles per gallon of gasoline-equivalent), extended range, and fast-charging options. The enhanced electrification and transformed mobility are translating to a demand for higher power and more efficient electric traction drive systems that lead to better fuel economy for a given battery charge. To accelerate the mass-market adoption of electrified transportation, the U.S. Department of Energy (DOE), in collaboration with the automotive industry, has announced the technical targets for light-duty electric vehicles (EVs) for 2025. This article discusses the electric drive technology trends for passenger electric and hybrid EVs with commercially available solutions in terms of materials, electric machine and inverter designs, maximum speed, component cooling, power density, and performance. Additionally, the emerging materials and technologies for power electronics and electric motors are presented, identifying the challenges and opportunities for even more aggressive designs to meet the need for next-generation EVs. Some innovative drive and motor designs with the potential to meet the DOE 2025 targets are also discussed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Impacts of Solvent Washing on the Electrochemical Remediation of Commercial End-of-Life Cathodes

Changes to surface structure and chemistry occurring throughout the functional lifetime of lithium-ion batteries (LIBs) may impact the effectiveness of end-of-life rejuvenation methods. Solvent washing prior to electrochemical relithiation is shown to both increase relithiation efficacy and beneficially alter the interfacial chemistry of heavily degraded industrial cathode material. Four common solvents (acetone, diethyl carbonate, isopropyl alcohol, propylene carbonate) are employed to investigate the role of varying physicochemical solvent properties on the mechanism of capacity recovery. Electrochemical (dQ/dV, EIS), structural (XRD), and chemical (SPME-GC-MS) analysis techniques are employed to comprehensively analyze solvent-cathode interactions. Highly nucleophilic solvents (acetone, DEC) are found to reduce cathode charge-transfer impedance and enable stable impedance growth throughout subsequent cycling. The use of nucleophilic solvents under mechanically aggressive washing conditions may also enable the reintroduction of bulk lattice oxygen, thereby restoring anionic redox capacity. Further, the four solvents are found to selectively remove a subset of surface species from the aged cathode material, including residual electrolyte, additives, and electrolyte-additive reaction products, which are qualitatively analyzed. Surface species removal by each solvent is correlated with the electrochemical performance of the correspondingly washed cathode, highlighting the importance of an optimized washing protocol to effective remediation in the context of direct LIB recycling. For the material under study, the use of a simple acetone washing protocol prior to electrochemical relithiation enables up to 174% capacity recovery relative to unwashed/relithiated black mass.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Combined Dimensional and Topology Optimization of Interior Permanent Magnet Synchronous Machine Rotors Using a Permanent Magnet Function Interpolation Method

This paper presents a magneto-structural combined dimensional and topology optimization technique for interior permanent magnet synchronous machine (IPMSM) rotors. Dimensional changes to the permanent magnet (PM) location or size are accomplished by interpolating or projecting a smoothed Heaviside rectangular function representing the presence of PM material onto the IPMSM rotor design domain mesh. A density based Solid Isotropic with Material Penalization (SIMP) topology optimization approach is then used to vary the presence of electrical steel in mesh elements to form flux barriers around the PM. The proposed method enforces a defined shape for the PM without requiring the mesh in the design domain to be deformed. Three examples are presented to demonstrate the technique: two flat bar IPMSM and one V-shaped IPMSM.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Electric Vehicle Lithium-Ion Battery Life Cycle Management

There is no question that electric vehicles (EVs), which are key for addressing climate change impacts from the transportation sector, are quickly gaining popularity and availability. With limits and other challenges related to the supply of critical battery minerals, maximizing the use of EV batteries and ensuring recovery of battery minerals is imperative. Therefore, proper end-of-life-cycle management (reuse and recycling) of these batteries must be part of the EV ecosystem from the perspective of both the supply chain and environmental footprint. Second use of batteries for energy storage systems extends the initial life of these resources and provides a buffer until economical material recovery facilities are in place. Although there are multiple pathways to recycling and recovery of materials, new recovery technologies are moving toward commercially available hydrometallurgy and promising direct recycling, which analysis has shown has the lowest overall carbon footprint. Strategically locating these plants close to battery collection further reduces transportation and thus recycling and recovering costs. Proper life cycle management could alleviate future lithium-ion battery materials supply chains for EVs. Governments and other stakeholders around the world have started initiatives and proposed regulations to address the challenges associated with life cycle management of EV lithium batteries. Finally, as manufacturers are increasingly faced with the likelihood of such extensive regulatory requirements, attention should be given to new designs, sales, and service models that can reduce life cycle management costs.

25 ENERGY STORAGE↗
DOE OSTI2023

North American Lithium-Ion Battery Supply Chain Database Development - Phase II

Lithium-ion batteries (LIBs) are used in a wide range of applications, including cell phones, laptops, power tools, electric vehicles, and grid storage, and are essential for economic growth and addressing climate change. However, the significant demand for LIBs has led to supply chain issues for the United States, as China dominates the processing of battery materials and battery production. To address this concern, NAATBatt International, a trade association of North American battery companies, supported the National Renewable Energy Laboratory in developing a database of companies that mine, process, manufacture, reuse, and recycle batteries in North America. The purpose of this database was to identify strengths and gaps in the supply chain, so that private-government partnerships could develop strategies to create a competitive LIB supply chain in the US. NREL published the first version of this database in 2021 and the second version in 2022. The database includes companies that have a manufacturing facility in North America and are engaged in materials, cells, packs, end-of-life management, as well as those involved in LIB battery modeling, distribution, service and repair, and R&D. In this presentation, we will discuss our approach to collecting data and categorizing various segments and products. We will also provide a summary of the data and present various maps to illustrate the distribution of companies in the database.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗
DOE OSTI2024

Integrated Traction Drive Thermal Management: Keystone Project 3

The presentation represents a report of accomplishments during FY 2024 and is prepared for 2024 DOE VTO Annual Merit Review. The project goal is identifying pathways enabling high-performance, compact, and reliable integrated electric drives and facilitation of achieving DOE 2025 target of 33 kW/L system power density for an electric traction drive through support of other EDT consortium members in design and development of thermal management systems for their respective integrated drive concepts. Specific objectives are: 1) research and evaluation of motor-integrated power electronics packaging technologies and thermal management approaches; 2) explore novel materials and manufacturing options (3D printing with thermally enhanced polymers or ceramic materials) for key thermal management system components; 3) develop thermal management system and its sub-components to enable integrated electric drive DOE power density targets in collaboration with project partners; 4) support activities of DOE's Electric Drive Technologies (EDT) consortium members, Oak Ridge National Laboratory (ORNL), University of Wisconsin and Georgia Tech research teams in thermal management component design and thermal modeling of their integrated traction drives.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Towards high-efficiency particle detection using superconducting microwire arrays

Here, we present a detailed study of an 8-channel 1×1 mm 2 WSi superconducting microwire single photon detector (SMSPD) array exposed to 120 GeV hadron beam and 120 GeV muon beam at the CERN Super Proton Synchrotron H6 beamline. Following up on our first detailed characterization of the efficiency and response of an SMSPD fabricated on a 3 nm WSi film, we report measurements of enhanced particle detection efficiency using a sensor fabricated from a thicker 4.7 nm-thick WSi film. We also report the first SMSPD detection efficiency measurement made for muons. Measurements are enabled by a silicon tracking telescope providing 10 μm in-situ spatial resolution. The results show a fill factor-normalized detection efficiency of 75% and a time resolution of about 130 ps across pixels. These findings represent a significant advancement toward developing high-efficiency SMSPD charged particle tracking systems with simultaneous precision timing, with potential applications in future accelerator-based experiments such as the FCC-ee and Muon Collider.

Cryogenic detectors↗
DOE OSTI2024

Quantitative Risk Assessment for Hydrogen-Powered Locomotive Refueling

Hydrogen powered locomotives are being explored to reduce emissions in rail applications. The risks of operations like refueling should be understood to ensure safe environments for workers and members of the public. Sensitivity analyses were conducted using HyRAM+ to identify major drivers of risk and compare effects of system parameters on individual risk. The consequences of jet fires from full-bore leaks dominated the risk, compared to explosions or smaller leaks. Pipe size, leak detection capability, and leak frequencies of system components greatly affected risk while overpressure modeling parameters and ambient conditions had little effect. The effects of personal protective equipment (PPE) materials on individual risk were quantified by reducing the individual’s exposure time or absorbed thermal dose. PPE only showed a risk reduction in low-risk cases. This study highlighted target areas for risk mitigation, including leak detection equipment and component maintenance, and indicated that the minimal effects of other parameters on risk may not justify prescriptive requirements for refueling operators.

08 HYDROGEN↗
DOE OSTI2022

All Solid State Batteries Enabled by Multifunctional Electrolyte Materials

Solid Power has teamed with University of California San Diego to develop a high energy, long life, low cost, and safe all-solid-state-battery (ASSB). The battery is enabled by a multifunctional solid state electrolyte (SSE). The project enables scalable production of large format solid state batteries required by the vehicle market and building domestic battery manufacturers as leaders in the global vehicle ASSB production. In the project, the multifunctional SSE materials have been developed and optimized with ionic conductivity ≥ 5 mS/cm and electrochemical stability 0 – 4.5V. SSE separator films have been coated by using a roll-to-roll process with thickness ≤ 40 µm. All-solid-state NMC-Li pouch cells containing the developed SSE have been assembled. A cycle life of > 750 at 100% DOD and 45 °C has been demonstrated in a full pouch cell.

25 ENERGY STORAGE↗
DOE OSTI2024

Advanced Test Reactor Long-Term (20-Year) Operational Strategy

The Department of Energy Office of Nuclear Energy (DOE-NE) and the Naval Nuclear Propulsion Program (NNPP) have identified the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) as a critical need for continued thermal irradiation testing capability to support and advance U.S. commercial and naval nuclear power systems. The ATR is currently the only suitable test reactor operating in the world that can provide these capabilities at volume. ATR must, then, plan to operate for at least the next 20 years. As of the beginning of 2024, ATR has operated for 57 years, with many of the original reactor structures, systems, and components installed and operated for 60 years. Some ATR Complex and reactor support equipment that is currently in use was installed 75 years ago with the startup of the Materials Testing Reactor (MTR).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE)

Raytheon Technologies Research Center (RTRC) is the central research and development (R&D) organization for RTX, and has extensive expertise in the design, modeling and analysis of high-performance electrical machines and thermal management for all its business units. The proposing team consists of researchers from RTRC and John Deere (JD), will be referred as “Team”. Each organization a has long track record of successful R&D of materials, manufacturing, components, and systems for energy efficiency applications. Motor power density and efficiency are limited by fundamental physical trade-offs between electromagnetics, thermal management, and structural design considerations. The team is proposing to utilize novel technologies and multi-physics design methods to develop a Motor with Advanced Concepts for High power density and INtegrated cooling for Efficiency (MACHINE), demonstrating an 8X improvement in power density.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

The role of ferrites in wireless charging systems for electric vehicles

This review examines the critical role of magnetic ceramic ferrites in wireless charging systems (WCS) for electric vehicles (EVs). With the increasing shift towards electrifying motor vehicles, advanced charging systems are needed to optimize EV range and performance. Magnetic materials are vital in WCS, as they act as a coupler that enhances power transfer. However, design limitations in weight and size motivate the need for systems tailored to meet a range of specifications. Additionally, ferrite systems can be tailored by altering composition, microstructure, and processing. Furthermore, this review examines advanced manufacturing techniques for improved ferrite design and identifies future directions for ferrite core research to meet future WCS needs.

33 ADVANCED PROPULSION SYSTEMS↗