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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Recycling lead and transparent conductors from perovskite solar modules

Abstract Perovskite photovoltaics are gaining increasing common ground to partner with or compete with silicon photovoltaics to reduce cost of solar energy. However, a cost-effective waste management for toxic lead (Pb), which might determine the fate of this technology, has not been developed yet. Here, we report an end-of-life material management for perovskite solar modules to recycle toxic lead and valuable transparent conductors to protect the environment and create dramatic economic benefits from recycled materials. Lead is separated from decommissioned modules by weakly acidic cation exchange resin, which could be released as soluble Pb(NO 3 ) 2 followed by precipitation as PbI 2 for reuse, with a recycling efficiency of 99.2%. Thermal delamination disassembles the encapsulated modules with intact transparent conductors and cover glasses. The refabricated devices based on recycled lead iodide and recycled transparent conductors show comparable performance as devices based on fresh raw materials. Cost analysis shows this recycling technology is economically attractive.

14 SOLAR ENERGY↗
DOE OSTI2023

Battery passports for promoting electric vehicle resale and repurposing

Starting in 2026, most batteries sold in the European Union will require a battery passport. This initiative is part of a broader legislative framework, led by the European Commission, to improve sustainable battery materials sourcing practices and enable a circular economy. All batteries having a capacity of greater than 2 kilowatt-hours will be covered under the legislation, effectively encompassing all electric vehicle (EV) batteries and stationary grid storage batteries. At its core, a battery passport defines a minimum, standard set of information that must be reported for every battery made and sold (see Figure 1). Legislative actions have so far focused on labeling standards enabling raw material traceability and recycling, which has received ongoing support from the European Council and Parliament. Furthermore, work remains to finalize the electrochemical performance and durability minimum reporting requirements by 2024, which has been challenging since performance and durability are subject to many different interpretations.

25 ENERGY STORAGE↗
DOE OSTI2020

Solvent-free production of carbon materials with developed pore structure from biomass for high-performance supercapacitors

The study aimed at preparing porous carbon materials, with superhydrophilic characteristics and developed micro/mesoporous structure (CSB-800), from corn stover by a solvent-free method including pre-carbonization, ball milling, and activation. The effect of pre-carbonization, ball milling on the detailed structural composition and properties especially the hydrophilicity and porous structures were studied, and the potential application of CSB-800 as electrode in supercapacitors was also investigated. The results revealed that pre-carbonization increased the accessibility of raw materials as well as the efficiency of the ball milling with KOH, leading to small carbon particles with good dispersion behavior. Ball milling promoted the porosity, surface energy, hydrophilicity, crystallinity, and graphitization of the carbon materials. CSB-800 exhibited a high specific surface area of 2440.6 m 2 /g with developed micro and porous structures. The heteroatom nitrogen formed nitrogen-containing groups of N Q and N X, which provided faradaic pseudocapacitance when CSB-800 was used as an electrode material, and this material presented a specific capacitance of 398 F/g at 0.5 A/g in 1 M H 2 SO 4 electrolyte in a three-electrode system, while the value was 243 F/g in a two-electrode system, and the energy density reached 5.01 Wh/kg at a power density of 100 W/kg.

09 BIOMASS FUELS↗
DOE OSTI2020

Estimating the cost and energy demand of producing lithium manganese oxide for Li-ion batteries

Lithium Manganese Oxide (LMO) is one of the important cathode active materials used in lithium ion batteries of several electric vehicles. In this paper, the production of LMO cathode material for use in lithium-ion batteries is studied. Spreadsheet-based process models have been set up to estimate and analyze the factors affecting the cost of manufacturing, the energy demand, and the environmental impact. Two processes based on the solid-state synthesis method and a sol-gel method have been explored. Results show that the solid-state process is more cost-effective because of its lower cost of raw materials. The production cost for a solid-state process is $7 kg -1 and requires 6 kWh·kg -1 of energy. The pack level cost of electric vehicle battery using LMO as a primary active material is studied as a function of LMO production cost and other parameters. The potential for reducing the cost of automotive batteries to $100 per kWh is explored in terms of LMO price and plant production volume (economy of scale), using Argonne’s BatPaC spreadsheet tool.

25 ENERGY STORAGE↗
NASA NTRS1995

Evidence for Chemical Processing of Precometary Icy Grains In Circumstellar Environments of Pre-Main-Sequence Stars

We report the detection of a broad absorption feature near 2166 cm-1 in the spectrum of the Taurus cloud source Elias 18. This pre-main-sequence source is the second in Taurus, the third in our survey, and the fifth known in the sky to show the broad 2166 cm-1 absorption feature. Of equal importance, this feature is not seen toward several other embedded sources in our survey, nor is it seen toward the source Elias 16, located behind the Taurus cloud. Laboratory experiments with interstellar ice analogs show that such a feature is associated with a complex C=-N containing compound [called X(C=-N)] that results from high-energy processing (ultraviolet irradiation or ion bombardment) of simple ice components into more complex, organic components, We find a nonlinear anticorrelation between the abundance of X(C=-N) and frozen CO in non- polar lattices. We find no correlation between the abundance of X(C=-N) and frozen CO in polar lattices. Because the abundances of frozen CO and H20 are strongly correlated with each other and with visual extinction toward sources embedded in and located behind the Taurus molecular cloud, these ice components usually are associated with intracloud material. Our results indicate that X(C=-N) molecules result from chemical processing of dust grains dominated by nonpolar icy mantles in the local environments of pre-main- sequence stars. Such processing of icy grains in the early solar system may be an important source of organic compounds observed in minor solar system bodies. The delivery of these organic compounds to the surface of the primitive Earth through comet impacts may have provided the raw materials for prebiotic chemistry.

Teglier, Stephen C.↗
NASA NTRS2000

Validated Feasibility Study of Integrally Stiffened Metallic Fuselage Panels for Reducing Manufacturing Costs: Cost Assessment of Manufacturing/Design Concepts

The objective of the Integral Airframe Structures (IAS) program was to demonstrate, for an integrally stiffened structural concept, performance and weight equal to "built-up" structure with lower manufacturing cost. This report presents results of the cost assessment for several design configuration/manufacturing method combinations. The attributes of various cost analysis models were evaluated and COSTRAN selected for this study. A process/design cost evaluation matrix was developed based on material, forming, machining, and assembly of structural sub-elements and assembled structure. A hybrid design, made from high-speed machined extruded frames that are mechanically fastened to high-speed machined plate skin/stringer panels, was identified as the most cost-effective manufacturing solution. Recurring labor and material costs of the hybrid design are up to 61 percent less than the current built-up technology baseline. This would correspond to a total cost reduction of $1.7 million per ship set for a 777-sized airplane. However, there are important outstanding issues with regard to the cost of capacity of high technology machinery, and the ability to cost-effectively provide surface finish acceptable to the commercial aircraft industry. The projected high raw material cost of large extrusions also played an important role in the trade-off between plate and extruded concepts.

Metschan, S.↗
NASA NTRS1971

Satellite Relay Telemetry of Seismic Data in Earthquake Prediction and Control

The Satellite Telemetry Earthquake Monitoring Program was started to evaluate the applicability of satellite relay telemetry in the collection of seismic data from a large number of dense seismograph clusters laid out along the major fault systems of western North America. Prototype clusters utilizing phone-line telemetry were then being installed by the National Center for Earthquake Research in 3 regions along the San Andreas fault in central California; and the experience of installing and operating the clusters and in reducing and analyzing the seismic data from them was to provide the raw materials for evaluation in the satellite relay telemetry project. The principal advantages of the satellite relay system over commercial telephone or microwave systems were: (1) it could be made less prone to massive failure during a major earthquake; (2) it could be extended readily into undeveloped regions; and (3) it could provide flexible, uniform communications over large sections of major global tectonic zones. Fundamental characteristics of a communications system to cope with the large volume of raw data collected by a short-period seismograph network are discussed.

Jackson, W. H.↗
DOE OSTI2021

Continuous Fly-Through High-Temperature Synthesis of Nanocatalysts

Conventional thermal treatment system, such as muffle and tube furnaces, typically feature low ramping and cooling rates, which lead to steep thermal gradients during bulk material synthesis that generate inefficient, non-uniform reaction conditions and result in nanoparticle aggregation. Herein, we demonstrate a continuous fly-through material synthesis approach using a novel high-temperature reactor design based on the emerging thermal-shock technology. By facing two sheets of carbon paper with a small distance apart (1–3 mm), we are able to generate uniform, ultra-high temperatures that can reach up to 3200 K within 50 ms by simply applying a voltage of 15 V. We can control this high-temperature to enable ultrafast chemical reactions by continuously feeding raw materials through the device from one end to the other, allowing the final products to be rapidly collected. As a proof-of-concept demonstration, we synthesized Pt nanocatalysts ~4 nm in size anchored to carbon black via this fly-through high-temperature reactor at ~1400 K. Furthermore, we find these supported Pt nanoparticles feature excellent electrocatalytic activities toward methanol oxidation reaction. Compared to existing heating methods, this continuous fly-through high temperature reactor offers a new and highly efficient platform for the synthesis of nanomaterials at high temperatures.

Qiao, Yun↗
NASA NTRS1995

Evidence for chemical processing of precometary icy grains in circumstellar environments of pre-main-sequence stars

We report the detection of a broad absorption feature near 2166/cm in the spectrum of the Taurus cloud cource Elias 18. This pre-main-sequence source is the second in Taurus, the third in our survey, and the fifth known in the sky to show the broad 2166/cm absorption feature. Of equal importance, this feature is not seen toward several other embedded sources in our survey, nor is it seen toward the source Elias 16, located behind the Taurus cloud. Laboratory experiments with interstellar ice analogs show that such a feature is associated with a complex C triple bonded to N containing compound (called X(C triple bonded to N)) that results from high-energy processing (ultraviolet irradiation or ion bombardment) of simple ice components into more complex, organic components. We find a nonlinear anticorrelation between the abundance of X(C triple bonded to N) and frozen CO components in nonpolar lattices. We find no correlation between the abundance of X(C triple bonded to N) and frozen CO in polar lattices. Because the abundances of frozen CO and H2O are strongly correlated with each other and with visual extinction toward sources embedded in and located behind the Taurus molecular cloud, these ice components usually are associated with intracloud material. Our results indicate that X(C triple bonded to N) molecules result from chemical processing of dust grains dominated by nonpolar icy mantles in the local environments of pre-main-sequence stars. Such processing of icy grains in the early solar system may be an important source of organic compounds observed in minor solar system bodies. The delivery of these organic compounds to the surface of the primitive Earth through comet impacts may have provided the raw materials for prebiotic chemistry.

Tegler, Stephen C.↗
NASA NTRS1977

Cost analysis of advanced turbine blade manufacturing processes

A rigorous analysis was conducted to estimate relative manufacturing costs for high technology gas turbine blades prepared by three candidate materials process systems. The manufacturing costs for the same turbine blade configuration of directionally solidified eutectic alloy, an oxide dispersion strengthened superalloy, and a fiber reinforced superalloy were compared on a relative basis to the costs of the same blade currently in production utilizing the directional solidification process. An analytical process cost model was developed to quantitatively perform the cost comparisons. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.

Barth, C. F.↗
DOE OSTI2022

Remining and Restoring Abandoned US Mining Sites: The Case for Materials Needed for Zero-Carbon Transition

The electricity generation sector is responsible for 25% of the world’s greenhouse gas (GHG) emissions and thus has been the focus of efforts to transition to clean energy and sustainable development in many nations. In the past 20 years, renewable energy sources have been the fastest-growing energy source in the world, comprising almost 29% of the world’s electricity generation in 2020. Renewable energy sources are expected to comprise nearly 95% of the world’s power capacity growth through 2026, with a share of planned capacity expansion of up to 46% in 2026. The rapid development of renewable energy sources and technologies will require an enormous amount of raw materials to replace coal and gas plants and increase in the capacity to handle growing electricity demand because renewable energy sources have a low-power density and intermittent behavior. Accounting for the expected scale of rapidly deploying renewable energy sources that require rare earth elements (REEs), cement, and steel, the mining industry may face a supply problem for the materials critical for clean energy. And, as the exploration and development of new mining sites can be expensive and risky, the mining industry may require economic stimuli to grow supply. The increasing demand for renewable energy resources makes mining a threat to the environment unless proper regulations are established and calls for remining, cleanup, and circular economic development are made. Mining also contributes to environmental injustices related to the exploitation and pollution of lands near communities that are dependent on biodiversity in the area, while not always benefiting from technological advancements provided by the use of renewable energy and technologies. This study explored the opportunity of remining abandoned mining waste to extract metals and minerals essential for the production of renewable energy sources. The authors analyzed materials used in the production of these technologies, materials readily available in the United States, and which materials can be extracted locally in the United States from abandoned mine waste. The authors also studied environmental injustices that populations near mining sites experience and ways to mitigate these injustices, such as providing more control over extraction and cleanup activities, providing more job opportunities in those areas, and offsetting costs associated with cleanup and land restoration projects.

42 ENGINEERING↗
DOE OSTI2024

Finding a needle in a haystack: quantitative HERFD-XRF imaging and HERFD-XANES characterization of trace platinum in gold solidi from the Late Roman and Byzantine Empires

High-Energy Resolution Fluorescence Detection X-Ray Fluorescence (HERFD-XRF) imaging and HERFD X-ray Absorption Near Edge Structure (XANES) spectroscopy are used to quantify and characterize trace platinum (Pt) in gold solidi from the Late Roman and Byzantine Empires. Historically, the elemental analysis of coins has been pivotal in distinguishing authentic artifacts from forgeries, elucidating minting practices, and understanding economic shifts. Notably, a new gold source with high platinum content appeared in the fourth century CE, transforming the Roman economy. Traditional methods struggled to detect platinum due to the overwhelming gold matrix. Here, this study demonstrates the effectiveness of HERFD techniques in resolving this challenge. Three gold solidi, minted between 654 and 659 CE, were analyzed alongside reference gold materials with known Pt concentrations. The HERFD-XRF imaging revealed spatial distributions of platinum, highlighting non-uniformities within the coins. Additionally, HERFD-XANES spectroscopy identified the oxidation states and chemical speciation of platinum. Results demonstrate that platinum in the solidi primarily exists as metallic Pt, with some surface oxidation. The findings align with previous measurements but reveal higher Pt concentrations and significant inhomogeneities. This research confirms the reliability of HERFD methods for quantifying trace elements and provides new insights into the raw material sources and minting techniques of ancient gold coins. The non-destructive nature of this approach allows for extensive analyses, offering valuable data for historical, economic, and archaeological studies. This innovative application of HERFD-XRF imaging and XANES in cultural heritage research underscores the potential for detailed material characterization and conservation, enhancing our understanding of ancient economies and trade patterns.

Van Loon, Lisa L.↗
NASA NTRS1993

Production of Ultrafine, High-purity Ceramic Powders Using the US Bureau of Mines Developed Turbomill

Turbomilling, an innovative grinding technology developed by the U.S. Bureau of Mines in the early 1960's for delaminating filler-grade kaolinitic clays, has been expanded into the areas of particle size reduction, material mixing, and process reaction kinetics. The turbomill, originally called an attrition grinder, has been used for particle size reduction of many minerals, including natural and synthetic mica, pyrophyllite, talc, and marble. In recent years, an all-polymer version of the turbomill has been used to produce ultrafine, high-purity, advanced ceramic powders such as SiC, Si3N4, TiB2, and ZrO2. In addition to particle size reduction, the turbomill has been used to produce intimate mixtures of high surface area powders and whiskers. Raw materials, TiN, AlN, and Al2O3, used to produce a titanium nitride/aluminum oxynitride (TiN/AlON) composite, were mixed in the turbomill, resulting in strength increases over samples prepared by dry ball milling. Using the turbomill as a leach vessel, it was found that 90.4 pct of the copper was extracted from the chalcopyrite during a 4-hour leach test in ferric sulfate versus conventional processing which involves either roasting of the ore for Cu recovery or leaching of the ore for several days.

Hoyer, Jesse L.↗
NASA NTRS1992

Return to the Moon: Lunar robotic science missions

There are two important aspects of the Moon and its materials which must be addressed in preparation for a manned return to the Moon and establishment of a lunar base. These involve its geologic science and resource utilization. Knowledge of the Moon forms the basis for interpretations of the planetary science of the terrestrial planets and their satellites; and there are numerous exciting explorations into the geologic science of the Moon to be conducted using orbiter and lander missions. In addition, the rocks and minerals and soils of the Moon will be the basic raw materials for a lunar outpost; and the In-Situ Resource Utilization (ISRU) of lunar materials must be considered in detail before any manned return to the Moon. Both of these fields -- planetary science and resource assessment -- will necessitate the collection of considerable amounts of new data, only obtainable from lunar-orbit remote sensing and robotic landers. For over fifteen years, there have been a considerable number of workshops, meetings, etc. with their subsequent 'white papers' which have detailed plans for a return to the Moon. The Lunar Observer mission, although grandiose, seems to have been too expensive for the austere budgets of the last several years. However, the tens of thousands of man-hours that have gone into 'brainstorming' and production of plans and reports have provided the precursor material for today's missions. It has been only since last year (1991) that realistic optimism for lunar orbiters and soft landers has come forth. Plans are for 1995 and 1996 'Early Robotic Missions' to the Moon, with the collection of data necessary for answering several of the major problems in lunar science, as well as for resource and site evaluation, in preparation for soft landers and a manned-presence on the Moon.

Taylor, Lawrence A.↗
NASA NTRS2019

Ablators for Human and Robotic Exploration of the Moon, Mars and Beyond

When Apollo was designed to carry astronauts safely back from the Moon, at return speeds exceeding 11 km/s, it required development of a new lightweight ablative material to protect the capsule and crew from the intense heat of entry. Soon after the Apollo program, successful Mars Viking Lander missions employed a different and much lighter ablator in more benign entry conditions. On the other hand, the Pioneer-Venus and Galileo Probe missions that followed required yet another ablative system, to manage the extreme heating at those destinations, which was like flying a ballistic missile nose tip into a thermonuclear explosion. NASA had to invent a new heat-shield concept based on the rocket nozzle and ballistic missile ablative materials. In the mid 1990's, as the Science focus returned to Mars, advances in manufacturing, testing and materials technology led to innovative lightweight ablators that enabled comet and asteroid sample return missions and facilitated large lander missions such as MSL and Mars 2020. NASA's current plans for robotic and human exploration of the Moon, Mars and beyond introduce different constraints and new expectations for ablators. Human missions to Moon and Mars, sample return missions from Mars, and exploration of Uranus and Neptune, the two planets we are yet to explore, will require ablators that can withstand extreme environments, with verifiable robustness, and with raw materials and manufacturing approaches that are sustainable in the longer term. This talk will review the history of ablators as well as current ablative TPS development that addresses the requirements for future missions to Moon, Mars and beyond.

Mars and Beyond↗
DOE OSTI2025

Smart culture medium optimization for recombinant protein production: Experimental, modeling, and AI/ML-driven strategies

Recombinant protein production (RPP) is central to biotechnology, where recombinant proteins are used as either end products or catalysts in the synthesis of chemicals, fuels, and materials. Among the major cost drivers, culture medium plays a pivotal role in determining protein yield and quality. This review presents a comprehensive perspective on the critical stages of “smart” culture medium optimization: planning, screening, modeling, optimization, and validation. In the planning stage, we examine the nutritional and energetic roles of medium components, including carbon, nitrogen, amino acids, salts, and trace metals, and their impacts on culture parameters such as pH, oxidative state, and osmolality. We highlight the variability in trace metal content due to water sources, culture vessels, and raw materials, which can substantially influence RPP. The screening stage covers Design of Experiments (DoE) approaches, assessing their theoretical basis, implementation, and limitations. For modeling, we describe methods that integrate experimental data to develop predictive models for smart medium formulation. Model-based optimization strategies can then be employed to select optimal media compositions for a given application. The validation stage aims to evaluate model predictions and provide feedback for model training and refinement. Finally, we survey mechanistic and artificial intelligence/machine learning (AI/ML)-driven models as integrated, transformational tools for predictive modeling of bioprocess conditions, nutrient availability, cellular metabolism, and protein quality, with the goal of optimizing culture media to enhance protein yields while reducing costs and environmental impact. We conclude by addressing the challenges of translating laboratory-scale medium optimization to industrial-scale settings and exploring future AI/ML-driven approaches that may overcome current bottlenecks and accelerate medium design for RPP. Overall, this review provides a unified framework for advancing smart medium design in RPP.

Artificial Intelligence/Machine Learning (AI/ML)↗
DOE OSTI2022

Schema Elements for Granta Annual Report: FY2022

Granta: Materials Intelligence, also known as Granta:MI or Granta, is a commercial database software by Ansys, Inc. that is utilized by the Nuclear Security Enterprise (NSE) to organize and store relevant materials data. For a complete discussion of the use of Granta:MI at NSE sites, see the FY21 annual report. Granta:MI is used by five NSE sites locally, and all NSE sites have access to an enterprise instance on the Enterprise Secure Network (ESN) as well as an unclassified development instance. It has been recognized by NNSA management that a shared repository for additive manufacturing (AM) data would not only ensure data and knowledge is not lost but would provide a pool of information relating AM inputs (build parameters, raw materials properties, post-processing information) to the as-built properties of AM parts. Such a pool of data would enable optimization of AM build design and help NNSA achieve the goals of shortening fielding times for new components.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Economics of polysilicon processes

Techniques are being developed to provide lower cost polysilicon material for solar cells. Existing technology which normally provides semiconductor industry polysilicon material is undergoing changes and also being used to provide polysilicon material for solar cells. Economics of new and existing technologies are presented for producing polysilicon. The economics are primarily based on the preliminary process design of a plant producing 1,000 metric tons/year of silicon. The polysilicon processes include: Siemen's process (hydrogen reduction of trichlorosilane); Union Carbide process (silane decomposition); and Hemlock Semiconductor process (hydrogen reduction of dichlorosilane). The economics include cost estimates of capital investment and product cost to produce polysilicon via the technology. Sensitivity analysis results are also presented to disclose the effect of major paramentes such as utilities, labor, raw materials and capital investment.

Yaws, C. L.↗