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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Fingerprints of composite fermion Lambda levels in scanning tunneling microscopy

A composite fermion (CF) is a topological quasiparticle that emerges from a nonperturbative attachment of vortices to electrons in strongly correlated two-dimensional materials. Similar to noninteracting fermions that form Landau levels in a magnetic field, CFs can fill analogous “Lambda” levels, giving rise to the fractional quantum Hall (FQH) effect of electrons. Here, we show that Lambda levels can be directly visualized through the characteristic peak structure in the signal obtained via spectroscopy with scanning tunneling microscopy (STM) on a FQH state. Complementary to transport, which probes the low-energy properties of CFs, we show that high-energy features in STM spectra can be interpreted in terms of Lambda levels. We numerically demonstrate that STM spectra can be accurately modeled using Jain's CF theory. Our results show that STM provides a powerful tool for revealing the anatomy of FQH states and identifying physics beyond the noninteracting CF paradigm.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2020

Temperature-Dependence of Corrosion of Ni-Based Superalloys in Hot CO 2 -Rich Gases Containing SO 2 Impurities

Future power plants will require Ni-based superalloys resistant to high-temperature corrosion in CO 2 -rich environments containing impurities. In this work, several commercially available Ni-based alloys (617, 230, 625, 263, 740H) were exposed at 600°C, 650°C, 750°C and 1 atm to 95% CO 2 , 4% H 2 O, 1% O 2 without/with 0.1% SO 2 to simulate compositions expected in a direct-fired supercritical CO 2 power cycle. The results indicate no effect of SO 2 at 750°C, a small negative effect at 650°C, and a large negative effect at 600°C. Alloys exposed at the higher temperatures (650–750°C) formed thin Cr-rich oxide scales, whereas the lowest temperature (600°C) resulted in thicker scales consisting of non-protective oxides and sulfates. Thermodynamic analysis indicates this increased corrosion is associated with a transition in the stable compounds in contact with the gas. Understanding the factors that affect this transition will aid in the selection or design of alloys for future CO 2 -based power systems.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Model-based optimization strategies for direct hydrogenation of carbon dioxide to dimethyl ether

Here, this study discusses model-based optimization strategies for CO 2 hydrogenation to dimethyl ether (DME) over aCuZnZr (CZZ) and ferrite (FER) mixed catalyst system in a packed-bed reactor configuration. A two-dimensional axisymmetric, nonisothermal packed-bed reactor model was developed using COMSOL Multiphysics 6.2 software. The model solves two-dimensional (radial and axial) heat and mass transport equations in the packed-bed and integrates intraparticle diffusion and heat transfer in a 1D approach. This powerful feature differs from a traditional porous media approach and takes into account any heat and mass transfer limitations that may exist. Analysis shows that the heat transfer limitations are negligible, but strong internal mass transfer limitations were observed at 10 ≤ WHSV ≤ 90 h -1 on the FER catalyst and at 240 °C. The optimum catalyst composition (i.e., mixing ratio) varies depending on the operating regime. The FER catalyst weight in the mixture can be as low as 5 wt.%, but the ideal composition de-pends on the internal mass transfer limitation and its relationship with the operating regime (i.e., weight hourly space velocity, temperature). A catalyst composition of 80 wt.% CZZ and 20 wt.% FER was suggested; this composition can provide high CO 2 conversion and DME production rates at a wide range of temperatures and flow rates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

TDCOSMO XXIII. Measurement of the Hubble constant from the doubly lensed quasar HE 1104−1805

Time-delay cosmography leverages strongly lensed quasars to measure the Universe’s current expansion rate, H 0 , independently from other methods. The latest TDCOSMO milestone measurement primarily used quadruply lensed quasars for their mass profile constraints. However, doubly lensed quasars, being more abundant and offering precise time delays, could expand the sample by a factor of 5, significantly advancing towards a 1% precision measurement of H 0 . We present the first TDCOSMO analysis of a doubly imaged source, HE 1104−1805, including the measurement of the four necessary ingredients. First, by combining 17 years of data from the SMARTS, Euler, and WFI telescopes, we measured a time delay of 176.3 +11.4 −10.3 days. Second, using MUSE data, we extracted stellar velocity dispersion measurements in three radial bins with 5% to 13% precision. Third, employing F160W HST imaging for lens modelling and marginalising over various modelling choices, we measured the Fermat potential difference between the images. Fourth, using wide-field imaging, we measured the convergence added by objects not included in the lens modelling. By combining these four ingredients, we measured the time delay distance and the angular diameter distance to the deflector, favouring a power-law mass model over a baryonic and dark matter composite model. The measurement was performed blindly to prevent experimenter bias and resulted in a Hubble constant of H 0 = +5.8 −5.0 × λ int km s −1 Mpc −1 , where λ int is the internal mass sheet degeneracy parameter. This is in agreement with the TDCOSMO-2025 milestone and its precision for λ int = 1 is comparable to that obtained with the best-observed quadruply lensed quasars (4–6%). This work is a stepping stone towards a precise measurement of H 0 using a large sample of doubly lensed quasars, supplementing the current sample. The next TDCOSMO milestone paper will include this system in its hierarchical analysis, constraining λ int and H 0 jointly with multiple lenses.

cosmological parameters↗
DOE OSTI2022

Raman Interferometry between Autoionizing States to Probe Ultrafast Wave-Packet Dynamics with High Spectral Resolution

Photoelectron interferometry with femtosecond and attosecond light pulses is a powerful probe of the fast electron wave-packet dynamics, albeit it has practical limitations on the energy resolution. We show that one can simultaneously obtain both high temporal and spectral resolution by stimulating Raman interferences with one light pulse and monitoring the modification of the electron yield in a separate step. Applying this spectroscopic approach to the autoionizing states of argon, we experimentally resolved its electronic composition and time evolution in exquisite detail. Theoretical calculations show remarkable agreement with the observations and shed light on the light-matter interaction parameters. Using appropriate Raman probing and delayed detection steps, this technique enables highly sensitive probing and control of electron dynamics in complex systems.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗
DOE OSTI2020

Molten Salt Reactor Experiment Benchmark Evaluation

As one of the six advanced reactor concepts selected by the 2002 Generation IV roadmap as a technology meriting future research, Molten Salt Reactors (MSRs) attracted broad attention and multiple private and public entities are working towards its commercialization. Facing stringent regulatory requirements, validations of computational codes used to calculate and prove the safety characteristics of MSRs play a key role. This project developed the world-first, MSR-related reactor physics benchmark based on a series of zero-power experiments conducted at the Molten Salt Reactor Experiment (MSRE). The benchmark was successfully reviewed by the International Reactor Physics Experiment Evaluation Project (IRPhEP) committee and is available in the IRPhEP handbook starting form the 2019 edition. To benchmark experimental data from the MSRE, a three-dimensional high-fidelity model was developed using the Monte Carlo neutron transport code Serpent 2 and ad-hoc methods have been implemented to account for the unique feature of fuel salt motion. The calculated effective multiplication factor, k eff , for the first criticality experiment, when 235 U was progressively added to the fuel salt in order to achieve criticality with stationary salt and isothermal conditions, was 1.02132 (±3 pcm). The total uncertainty for experimental k eff was estimated to be 420 pcm. The calculated k eff is 2.154% larger than the experimental and benchmark model value, which is approximately five times the benchmark model uncertainty. It is to be noted that, for systems containing large volume of graphite (or other carbonaceous materials), Monte Carlo codes tend to overestimate the keff of the benchmark model by 1% to 2%. The bias is possibly due to uncertainties in the impurity content of the graphite blocks, uncertainty in the neutron capture cross section of carbon or uncertainty in the properties of nuclear-grade graphite. The calculated reactivity coefficient of 235 U concentration (0.2228 ± 0.0014, represented as the change of reactivity over the relative change of 235 U mass in loop) matches well with the experimental value (0.223 ± 0.006), strengthening the confidence on the accurate representation of the fuel salt composition in the MSRE benchmark. Additional reactivity effect calculations, including the control rod bank worth, reactivity effects of fuel circulation and isothermal and fuel temperature coefficients show good agreement with the experimental values (within 1σ) as well.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Decomposing sources of value for electricity and negative emissions technologies in net-zero power systems

Deep decarbonization of the US power system would require rapid deployment of variable renewable energy (VRE) resources, which are projected to provide a substantial share of electricity generation at the time of net-zero emissions. However, the exact share of generation met by VRE and the roles of other technologies in supplying key electricity services—energy and firm capacity—remain uncertain. This study employs a detailed model of the US power sector to decompose the provision and value of electricity services, including negative emissions, by technology across a range of deep decarbonization scenarios. Results indicate that while technology deployment and the share of services provided by each technology vary significantly depending on future technological and market conditions, the value composition and future roles of individual technologies remain consistent. These findings offer guidance for research and development priorities and provide insights to inform electricity policy and planning.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Circular Economy for Automotive Shredder Residue

Vehicle production has grown substantially worldwide, and subsequently, End-of-Life (EoL) vehicles entering retirement will grow as well. For example, China, the largest passenger car market worldwide, is expected to have 26.3 million passenger vehicles retiring by 2030. Most vehicles are shredded at EoL to recover metals for the robust metal recycling industry, leaving behind a slew of unwanted materials called automotive shredder residue (ASR) on the order of millions of tonnes every year. Additionally, the average weight of vehicles has gone up to 2600 lbs (1180 Kg) for a small passenger internal combustion engine (ICE) vehicles, 4000 lbs (1814 Kg) for large ICE vehicles, and the electric vehicle (EV) versions are substantially heavier at 1000 lbs (454 Kg) or more compared to combustion engine counterparts. While the increase in weight in EVs is increasing primarily due to the batteries needed to power the car, the materials being substituted into either type of vehicle to reduce weight are polymers and composites.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Designing Nuclear Fuels with a Multi-Principal Element Alloying Approach

Previous research has shown that multi-principal element alloys (MPEAs) using chromium, molybdenum, niobium, tantalum, titanium, vanadium, and zirconium can form stable body-centered-cubic (BCC) structures across a large temperature region (25°C to 1000°C). This is the same crystal structure as γ-uranium (U), which has shown desirable thermal and irradiation behavior in previous alloy fuel research. It is hypothesized then that the MPEA alloying approach can be used to produce a stable BCC uranium-bearing alloy and to retain its stability throughout anticipated operating regimes of power-producing reactors. Candidate elements were assessed using Monte Carlo N-Particle (MCNP) analysis to determine uranium densities necessary to make the alloy an economically viable fuel compared to conventional fuel forms. Following neutronic considerations, materials property databases and empirical predictors were used to determine the compositions with a high potential to form a BCC solid solution alloy. The final four alloys were MoNbTaU 2 , MoNbTiU 2 , NbTaTiU 2 , and NbTaVU 2 , which were cast using arc melting of raw elemental foils and chunks. Characterization of the fabricated alloys included scanning electron microscopy, X-ray diffraction, energy dispersive X-ray spectroscopy, and transmission electron microscopy. The results showed a two-phase system with a U-rich matrix phase surrounding the refractory precipitates. The U phase was found to contain varying concentrations of the alloying elements and was a BCC γ-U phase. These results warrant further research to identify ideal compositions for use as an advanced alloy fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

OpenMC

OpenMC is an open source, community-developed framework for performing Monte Carlo particle transport calculations.It is capable of simulating neutron and photon transport below ~50 MeV and also includes a model for bremsstrahlung production of photons by electrons/positrons. Fixed source, k-eigenvalue, and subcritical multiplication problems can be solved. Problem geometries can be modeled either using constructive solid geometry or a CAD representation. A flexible and efficient tally system enables a wide variety of physical quantities to be tallied and analyzed. OpenMC can run in parallel using a hybrid MPI and OpenMP programming model and has been extensively tested on leadership class supercomputers. A built-in Bateman equation solver enables the modeling of material composition changes due to irradiation. One of the unique features of OpenMC is its rich, extensible Python and C/C++ programming interfaces that enable programming pre- and post-processing, multigroup cross section generation, workflow automation, multiphysics coupling, and the visualization of geometry and tally results. In addition to the core Monte Carlo transport solver and associated APIs, OpenMC includes a Python-based nuclear data interface that enables power users to inspect, modify,and perform various types of nuclear data processing on ENDF, ACE, and OpenMC¿s native HDF5 files

ROMANO, PaulK.↗
DOE OSTI2022

Subcomponent Validation of Composite Joints for Marine Energy Structures

The Marine Energy Advanced Materials project addresses the barriers and uncertainties facing marine renewable energy developers in using composite materials for load-bearing structures. Sponsored by the U.S. Department of Energy's Water Power Technologies Office, the multiyear project comprises of collaborators from the National Renewable Energy Laboratory (NREL), Sandia National Laboratories, Pacific Northwest National Laboratory (PNNL), Montana State University (MSU), Florida Atlantic University (FAU), and industry stakeholders. As part of the Marine Energy Advanced Materials project, marine renewable energy industry surveys and assessments were conducted to identify key materials and knowledge gaps that hinder the adoption of composite materials in marine renewable energy structures. Specific knowledge gaps highlighted for composite materials were environmental effects, fatigue strengths, and bonded and bolted interconnects (composite/composite and composite/metal). It was concluded that many of these gaps could be addressed through subcomponent validation; consequently, a program was developed at NREL with the goals of developing subcomponent validation methods for appropriate marine energy materials, which would improve the understanding of design allowables for full-scale structural components and joints. Ultimately, the aim is to reduce timelines and costs associated with full-scale structural validation efforts while also providing near-net-scale static and fatigue data of composite/metal subcomponents for marine renewable energy systems. To approach these goals, a testing program was developed at NREL to investigate a variety of materials and structural design details at the subcomponent scale to understand (a) the effects of harsh and corrosive marine energy environments and (b) the static and fatigue strengths of the complex geometries. The recent study from this testing program is perhaps the largest that has ever been conducted with respect to specimen scale and geographic diversity of underwater environmental conditions that the specimens were subjected to. A variety of specimen geometries were designed by NREL to highlight key features of multimaterial (composite/composite or metal/composite) interconnects that may be used in marine renewable energy structural designs. The designs used several different composite matrices, adhesives, and marine-grade steels, which were highlighted in the surveys as being the most appropriate for harsh marine environments. Composite panels were then manufactured at MSU, and were subsequently manufactured into test specimens by NREL. The specimens were shipped to FAU and PNNL for conditioning in ocean water tanks at various temperatures for an extended period. The specimens were then returned to NREL for structural validation. This presentation will provide an overview of recent advances within the testing program in terms of specimen design and test methods, and will discuss results and key findings of the subcomponent testing program to date at NREL.

adhesives↗
DOE OSTI2022

Nanoscale Three-Dimensional Imaging of Degradation in Composite Si-Containing Anodes

The use of silicon (Si) in next-generation lithium-ion battery (LIB) anodes has the potential to dramatically improve electrochemical performance over current LIB graphite (Gr) anodes, due to silicon’s higher specific capacity.1 However, widespread implementation of Si-containing anodes is inhibited by issues such as significant Si volume expansion during lithiation and an unstable solid-electrolyte interphase (SEI), resulting in unreliable performance and poor cycle life. Currently, composite anodes with both Si and graphite active materials are used to increase capacity and mitigate some of the limitations associated with Si. In composite electrodes with a heterogeneous distribution of components with varying electrical properties (including Si, Gr, conductive carbon additive, and binder), it is important to understand the local distribution of each component to correlate with electrochemical processes, particularly localized degradation and heterogeneous aging, and to optimize performance. To investigate Si-containing composite anodes in the nanoscale, we use scanning spreading resistance microscopy (SSRM), a form of scanning probe microscopy (SPM) that probes local electronic resistivity. By examining the intrinsic electronic resistivity contrast between the anode components, separate phases can be distinguished and understood within the composite structure.2 This work studies the effect of electrochemical cycling in two different electrolytes on component distribution and aging by comparing the electrical and structural evolution of composite Si-graphite electrodes and SEI before and after charge-discharge cycling. 1. W. J. Zhang. A review of the electrochemical performance of alloy anodes for lithium-ion batteries J. Power Sources 196 13–24 (2011). 2. C. Stetson, Z. Huey, A. Downard, Z. Li, B. To, A. Zakutayev, C.-S. Jiang, M. Al-Jassim, D. Finegan, S.-D. Han and S. DeCaluwe: Three-Dimensional Mapping of Resistivity and Microstructure of Composite Electrodes for Lithium-Ion Batteries. ACS Nano Letters Accepted (2020).

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Integrating HPC simulations and physical experiments to characterize the effects of gamma radiation on seismic protective devices

Seismic protective systems, composed of seismic isolators and dampers, can substantially reduce the effects of earthquake shaking on nuclear power plants and components therein. To enable the use of these devices to protect equipment inside a plant and close to a source of radiation, the U.S. Department of Energy (DOE) funded a project at the Idaho National Laboratory (INL) and the University at Buffalo to characterize the effects of absorbed gamma dose on their mechanical properties. An early task in the project was to determine the exposure time required in the INL Foss Therapy Services (FTS) 60 Co gamma irradiator to achieve a target absorbed dose in the materials used to construct isolators and dampers, including fluids, polymers, composites, and metals. This task required the novel integration of high-performance computing (HPC), Monte Carlo N-Particle (MCNP) simulations, and irradiation experiments using Fricke dosimetry. An MCNP model of the FTS irradiator at INL was developed and validated using Fricke dosimetry. Simulations of three experiments in the irradiator, two with Fricke vials only and one with Fricke vials and a large-size isolator, predicted the Fricke-measured absorbed dose rate to within 15% in all three cases, providing high confidence in the calculation of the gamma dose absorbed in the materials comprising the seismic protective devices. The simulations demonstrated that the effects of photon scattering on absorbed dose rate in the FTS irradiator are negligible for test articles installed close to the cobalt sources and near the rear of the irradiator. The validated MCNP model of the FTS irradiator is being used to support ongoing DOE-funded experiments on seismic protective devices and could be applied to future, non-seismic-related experiments. In conclusion, the novel validation process successfully deployed for the FTS irradiator at INL could be applied to other irradiators, requiring new MCNP models and simulations, and irradiation experiments using dosimeters.

42 - ENGINEERING↗
DOE OSTI2024

Constituent Data Replacement Tool

The purpose of this tool is to estimate key parameters that may be missing in public wastewater composition datasets. The tool can be applied to develop complete treatment and critical mineral extraction profiles for leachate, produced water and other aqueous waste streams. The tool applies machine learning algorithms to replace missing data in a user’s water data set that are adjusted based on user preferences for options including algorithm type, number of features, and classification variables. The tool can use the user’s data alone or combine user data with the NEWTS USGS Produced Water Database for more robust training. This research was funded by the U.S. Department of Energy’s Office Fossil Energy and Carbon Management (FECM) through National Energy Technology Laboratory’s ongoing research under the Water Management for Power System Field Work Proposal, DE-FECM 1022428 and Critical Minerals Field Work Proposal, DE-FECM 1022420.

Aqueous Chemistry↗
DOE OSTI2022

Overview of the LANL Multi-Probe Radiography Project [Slides]

Future radiographic facilities for the U.S. defense program will be required to provide more information as simulation codes improve in both physics’ fidelity and resolution. A possible approach is to use more types of probe beams in addition to, or instead of X-rays, generated by 20-MeV electron accelerators from a small number of directions. High power short-pulse laser systems can generate beams of protons, neutrons and electrons, as well as X-rays. The cost of these systems is falling rapidly. So, it can be imagined that deploying multiple short-pulse lasers along with other, more traditional probes, will become feasible. In this project, we are following three paths to determine if such an approach will succeed for cm-scale objects. The first is an experimental one to determine if the presence of multiple short-pulse probes cause interference with each other, especially while radiographing dynamic objects. The second leg of this project is to determine if having multiple types of probes really does give more information on composition. Finally, an overall assessment of the viability of this approach will be made. Examples from recent experiments at the Omega EP laser will be presented. The initial approach to evaluating radiographs with multiple probes using the Bayesian Inference Engine (BIE) also will be given.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Power and energy capacity tradeoffs in an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) can provide energy storage and produce electrical power from low-grade waste heat instead of electricity. The use of all-aqueous copper-based electrolytes has recently produced higher power densities than those achieved using previous TRAB approaches based on reversible metal deposition and dissolution processes, but further gains are possible in power and energy density. We investigated the limitations of power and energy density and how they are impacted by the electrolyte composition and discharge currents. By increasing the ammonia concentration from 1 to 5 M, the power density of the battery increased from 11.2 to 28.5 mW cm –2 , but the energy density decreased from 0.56 to 0.31 Wh L –1 . Increasing discharge current densities from 4 to 12.5 mA cm –2 increased the average power density during discharge from 2.4 to 5.9 mW cm –2 without appreciable losses in energy density. Increasing the copper concentration from 0.1 to 0.5 M increased both energy density to 2.15 Wh L –1 and energy efficiency to 2.2% but did not substantially impact the power density. Furthermore, these results represent the highest performance metrics achieved for a low-grade waste heat to electricity system.

25 ENERGY STORAGE↗
DOE OSTI2023

Advances in Binder Jet Additive Manufacturing

Binder Jetting is a powerful additive manufacturing technology due to its low cost and wide range of types of materials it can shape. The industry partner ExOne has a range of binder jet products for applications such as casting tools, composite layup tools, single-alloy metal components, and more. As such, research and development is of high interest in the area of specialized binders for each type of material, processing technology that improves reliability and quality, and materials to enhance the performance of the final parts. Thus, this work focuses on developing novel binders for sand tools and metal prints, new capabilities in multi-material printing, and build monitoring and correction. The result of this work includes a novel binder system that makes binder jet sand stronger than concrete while still being water soluble, a casting binder that is environmentally friendly and produces better surface finishes on castings, and a binder for metals that reduces the residual carbon.

36 MATERIALS SCIENCE↗