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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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DOE OSTI2024

Long-Term Performance of Reference Electrodes in Alkaline Radioactive Waste Storage Environments

Accurate measurements of corrosion potential are important for assessing the likelihood of internal localized corrosion and stress corrosion cracking of carbon steel tanks used for storing radioactive wastes. Reference electrodes in underground radioactive waste storage tanks are challenging to deploy, and more difficult to extract and replace frequently due to radiological exposure and disposal constraints. Hence, electrodes that exhibit stable performance over long periods of immersion in these waste environments are desirable. The present study evaluates the stability of reference electrodes used in radioactive waste storage tanks over a much longer period than previously studied. Long-term tests on Ag/AgCl and Hg/HgO reference electrodes were performed in nonradioactive simulants formulated from wastes stored at the Hanford site. Electrode degradation, which was studied by various in situ and ex situ evaluation techniques, was correlated to changes in electrode fill chemistry from waste intrusion via the porous frit junction. An intentional contamination study was performed to better understand and predict contamination effects on electrode potential drift.

Materials Science↗

DOE OSTI2026

Evaluation of Three Types of Electric Field Sensors

On June 3-4, 2025, we evaluated three types of electric-field (E-field) sensors: capacitive electrodes, stainless-steel stakes, and porous pots - at two electromagnetic (EM) stations (PWBVI and PWAOF) on Aqueduct Mesa at the Nevada National Security Site. We compared calibrated time series and derived metrics including power spectral density, root-mean-square (RMS) amplitude, signal-to-noise ratio (SNR), and detectability of power line harmonics and Schumann resonance. The objective was to identify an alternative E field sensor with higher SNR than the existing capacitive electrodes. Our data demonstrates that stainless-steel electrodes perform best, with the highest SNR and the most consistent detection of power-line harmonics and Schumann resonance among the three sensor types; they may be used as a supplement to, or replacement for, the existing capacitive electrodes.

58 GEOSCIENCES↗

DOE OSTI2024

Binder-Coated Carbon Cloth Electrodes for All-Vanadium Redox Flow Batteries

Vanadium redox flow batteries (VRFBs) are a promising solution for integrating intermittent renewable energy sources into the existing power grid. However, enhancing the electrochemical performance of VRFBs is critical for their widespread adoption in grid-scale energy storage. This study investigates the impact of adding a porous binder to a carbon-cloth electrode, with a focus on optimizing thermal activation conditions. The electrochemical performance of the binder-coated electrodes compared to uncoated electrodes is evaluated through electrochemical impedance spectroscopy, polarization curve measurements, and charge-discharge cycling. The surface morphology and structural integrity of the binder-coated electrodes at each activation stage are examined using various material characterization techniques to assess the effects of thermal activation. The results are benchmarked against the experiments using non-coated electrodes to determine the performance improvements offered by the binder coating. Notably, the study reveals that binder-coated electrodes exhibit significantly lower resistance and improved efficiency compared to their uncoated counterparts, with optimal activation conditions enhancing performance metrics crucial for VRFB applications. These findings provide valuable insights for further optimizing electrode design and activation strategies, advancing the development of more efficient VRFB systems for large-scale energy storage.

Caiado, Ashley A.↗

DOE OSTI2025

Modeling Electrodeposition in 3D Porous Architectures for Solid-State Li-Metal Batteries

Li-metal storage in three-dimensional (3D) electrodes is considered a potential dendrite-mitigation strategy. The large surface area and high porosity of these electrodes result in reduced local Li-plating current densities. The porous topology provides a scaffold for Li-deposition and stripping, maintaining both mechanical integrity and Li accessibility. The goal of this study is to understand how characteristics, such as geometry and material properties, affect the current distribution and deposition pattern. To this end, we developed a computational method to track material growth driven by electrodeposition within a complex geometry. This method ensures that the finite-element discretization remains conforming to the moving boundary while preserving an adequate mesh quality, and thus maintains solution accuracy. Using this new computational tool, we analyze the conditions under which porous anode architectures effectively expand the surface area of the charge-transfer interface, and self-regulate current density and dendrite growth.

3D electrode architectures↗

DOE OSTI2023

Pathways Toward Efficient and Durable Anion Exchange Membrane Water Electrolyzers Enabled By Electro‐Active Porous Transport Layers

Abstract Green hydrogen, produced via water electrolysis using renewable electricity, will play a crucial role in decarbonizing industrial and heavy‐duty transportation sectors. Anion exchange membrane water electrolyzers (AEMWEs) can overcome many of the performance and cost limitations of incumbent technologies, however, still suffer from durability challenges due to oxidative instability of anion‐exchange ionomers. Herein, the use of an electro‐active porous transport layer as anode (PTL‐electrode) is demonstrated to enable efficient and durable AEMWEs. The stainless‐steel PTL‐electrodes are shown to have superior performance and durability compared to traditional catalyst layers containing ionomer and nanoparticle catalysts. An AEMWE cell operating at 2 A cm −2 for over 600 h exhibited a degradation rate of just 5 µV h −1 . During operation, the surface composition of the stainless steel transforms into a mixture of iron and nickel oxyhydroxides, contributing to enhanced oxygen‐evolution reaction activity. The combination of experimental work and modeling elucidates how the bulk structure of the PTL‐electrode offers an additional design dimension to further improve electrolyzer performance. Lastly, a surface modification strategy is applied to a PTL‐electrode to achieve an even higher performing AEMWE (2.3 vs 2.0 A cm −2 at 1.8 V). Overall, this work lays out pathways toward more efficient, durable, and affordable AEMWEs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Mechanistic insights into structural parameters maximizing energy storage density in Si mesoporous electrodes for Li-ion batteries

Mesoporous Si electrodes have an interesting set of structural parameters, which, when carefully optimized, can lead to ultrahigh energy density Si electrodes for Li-ion batteries. We present here in this paper details of a systematic research leading to the discovery of an “ideal” structure of mesoporous Si electrode, which results in exceptional cracking/damage resistance, while simultaneously having very high specific (>2000 mAh g-1) and total (>1.5 mAh cm-2) capacities for large number of cycles. The electrodes near the “ideal” value of the characteristic structural parameter (the ratio of Si wall thickness to pore diameter) are free from first-cycle capacity degradation, and are efficient in accommodating the volume changes during lithiation by uniformly filling up the porous space between Si walls. Interestingly, these electrodes are also found to be structurally damage-resistant, surviving through many lithiation-delithiation cycles. Using charge-discharge cycling and electron microscopy we show that ideal structure is the key for achieving ultrahigh energy storage density in Si mesoporous electrodes for Li-ion batteries.

25 ENERGY STORAGE↗

NASA NTRS1992

Testing and analyses of electrochemical cells using frequency response

The feasibility of electrochemical impedance spectroscopy as a method for analyzing battery state of health and state of charge was investigated. Porous silver, zinc, nickel, and cadmium electrodes as well as silver/zinc cells were studied. State of charge could be correlated with impedance data for all but the nickel electrodes. State of health was correlated with impedance data for two silver/zinc cells, one apparently good and the other dead. The experimental data were fit to equivalent circuit models.

Norton, O. A., Jr.↗

NASA NTRS2000

Direct methanol feed fuel cell and system

Improvements to non-acid methanol fuel cells include new formulations for materials. The platinum and ruthenium are more exactly mixed together. Different materials are substituted for these materials. The backing material for the fuel cell electrode is specially treated to improve its characteristics. A special sputtered electrode is formed which is extremely porous.

Surampudi, Subbarao↗

NASA NTRS2001

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2004

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2008

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2008

Direct methanol feed fuel cell and system

Surampudi, Subbarao↗

NASA NTRS2009

Direct methanol feed fuel cell and system

Improvements to non acid methanol fuel cells include new formulations for materials. The platinum and ruthenium are more exactly mixed together. Different materials are substituted for these materials. The backing material for the fuel cell electrode is specially treated to improve its characteristics. A special sputtered electrode is formed which is extremely porous. The fuel cell system also comprises a fuel supplying part including a meter which meters an amount of fuel which is used by the fuel cell, and controls the supply of fuel based on said metering.

Surampudi, Subbarao↗

NASA NTRS2015

Graphene-Based Electrode for a Supercapacitor

A supercapacitor electrode mechanism comprising an electrically conductive, porous substrate, having one or more metallic oxides deposited on a first surface and a chemically reduced graphene oxide deposited on a second surface, to thereby provide an electrical double layer associated with the substrate. The substrate may be carbon paper or a similar substance. The layers of the supercapacitor are optionally rolled into an approximately cylindrical structure.

Chen, Bin↗

DOE OSTI2020

N-doped honeycomb-like porous carbon towards high-performance supercapacitor

Biomass-derived porous carbon with developed pore structure is critical to achieving high performance electrode materials. In this work, we report a grape-based honeycomb-like porous carbon (GHPC) prepared by KOH activation and carbonization, followed by N-doping (NGHPC). The obtained NGHPC exhibits a unique honeycomb-like structure with hierarchically interconnected micro/mesopores, and high specific surface area of 1268 m2/g. As a supercapacitor electrode, the NGPHC electrode exhibits a remarkable specific capacitance of 275 F/g at 0.5 A/g in a three-electrode cell. Moreover, the NGHPC//NGHPC symmetric supercapacitor displays a high energy density of 12.6 Wh/kg, and excellent cycling stability of approximately 95.2% capacitance retention after 5000 cycles at 5 A/g. The excellent electrochemical performance of NGHPC is ascribed to its high specific surface area, honeycomb-like structure and high-content of pyrodinic-N (36.29%). It is believed that grape-based carbon materials show great potential as advanced electrode materials for supercapacitors.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

A Highly Effective Polysulfide-Trapping Approach for the Development of High Energy Density, Scalable Lithium-Sulfur Batteries

Lithium-sulfur (Li-S) batteries are identified as one of the most promising next-generation battery technologies owing to their high theoretical specific energy, sustainability, and affordability. However, the commercialization of Li-S batteries has been hindered by severe technical challenges, including the lithium polysulfide (PS) dissolution/shuttling effect, a major cause of fast capacity degradation over cycling. We demonstrated that, for the first time, nanolayer polymer coated high surface area porous carbons (NPCs) were coated directly on sulfur electrodes (NPC-S), which led to a high specific capacity of ∼1,600 mAh g −1 approaching the theoretical specific capacity limit in the NPC-S based Li-S batteries. The NPC-S based Li-S batteries maintained their large initial specific capacity gain compared with the Baseline-S based Li-S batteries (control) over extended cycles. A follow-on study indicated that the NPC-S approach is a necessary and critical step to boost the near-theoretical specific capacity while being stabilized over long cycles with a synergistic strategy. Our experimental and computational results suggest that NPC coated on sulfur electrodes provides not only an effective and strong PS-trapping power but also an increased redox reaction kinetics for sulfur ↔ PS’s conversions during battery charge and discharge, rendering the realization of near-theoretical discharge specific capacity in the NPC-S based Li-S batteries. The findings presented in this study may inspire a new, simple, low-cost, and commercially scalable approach, without adding any appreciable dead weight or volume to the batteries, in the effort to tackle the technical challenges facing SOA Li-S batteries.

25 ENERGY STORAGE↗

NASA NTRS1972

Thin film fuel cell electrodes.

Earlier work shows that fuel cell electrodes prepared by sputtering thin films of platinum on porous vycor substrates avoid diffusion limitations even at high current densities. The presented study shows that the specific activity of sputtered platinum is not unusually high. Performance limitations are found to be controlled by physical processes, even at low loadings. Catalyst activity is strongly influenced by platinum sputtering parameters, which seemingly change the surface area of the catalyst layer. The use of porous nickel as a substrate shows that pore size of the substrate is an important parameter. It is noted that electrode performance increases with increasing loading for catalyst layers up to two microns thick, thus showing the physical properties of the sputtered layer to be different from platinum foil. Electrode performance is also sensitive to changing differential pressure across the electrode. The application of sputtered catalyst layers to fuel cell matrices for the purpose of obtaining thin total cells appears feasible.

Asher, W. J.↗

DOE OSTI2022

Fabrication processes for solid state electrochemical devices

This disclosure provides systems, methods, and apparatus related to electrode structures. In one aspect, a method includes: providing an electrode layer comprising a ceramic, the ceramic being porous; providing a catalyst precursor, the catalyst precursor being a cathode catalyst precursor or an anode catalyst precursor; infiltrating the catalyst precursor in a first side of the electrode layer; after the infiltrating operation, heating the electrode layer to about 750° C. to 950° C., the catalyst precursor forming a catalyst, the catalyst being a cathode catalyst or an anode catalyst; infiltrating the catalyst precursor in the first side of the electrode layer; after the infiltrating operation, heating the electrode layer to about 300° C. to 700° C., the catalyst precursor forming the catalyst, the catalyst being the cathode catalyst or the anode catalyst.

Tucker, Michael C.↗