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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Digital Light Processing (DLP): 3D printing of polymer-based graphene oxide nanocomposites—Efficient antimicrobial material for biomedical devices

Bacterial infections are one of the major causes of surgical implant inefficiency and failure. Herein, we present a Nanocomposite (NC) produced by the addition of Poly(N-vinyl carbazole)-Graphene Oxide dispersion (PVK-GO) as a nanofiller to a commercial photopolymer acrylate resin and 3D printed as coatings via the Digital Light Processing technique. Characterization and bioassay results against Escherichia coli and Staphylococcus aureus confirmed the elevated thermomechanical properties and efficient antibacterial activity of the printed NC-based coatings. In conclusion, the present study demonstrates the fabrication and optimization of a PVK-GO-based NC and its potential utilization as a 3D-printable material for biomedical applications.

2D materials↗
DOE OSTI2023

Report Outlining Computed Tomography Strategy and Microscopy Approach to Qualifying AM 316 Materials

This report is part of work package CR-22OR0406012, Automated, High-Throughput Materials Characterization Techniques , under the Advanced Materials and Manufacturing Technologies program (AMMT). The project’s primary objective is to leverage our AI-based rapid and high-throughput automated characterization framework to qualify additively manufactured 316 materials comprehensively, focusing on optimizing the additive manufacturing process and evaluating the performance of 3D-printed stainless steel components. This report outlines our strategy for leveraging the automated characterization process for qualifying 316H materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High-Throughput Automated Exploration of Phase Growth Behaviors in Quasi-2D Formamidinium Metal Halide Perovskites

Quasi-2D metal halide perovskites (MHPs) are an emerging material platform for sustainable functional optoelectronics, but the uncontrollable, broad phase distribution remains a critical challenge for applications. Nevertheless, the basic principles for controlling phases in quasi-2D MHPs remain poorly understood, due to the rapid crystallization kinetics during the conventional thin-film fabrication process. In this work, a high-throughput automated synthesis-characterization-analysis workflow is implemented to accelerate material exploration in formamidinium (FA)-based quasi-2D MHP compositional space, revealing the early-stage phase growth behaviors fundamentally determining the phase distributions. Upon comprehensive exploration with varying synthesis conditions including 2D:3D composition ratios, antisolvent injection rates, and temperatures in an automated synthesis-characterization platform, it is observed that the prominent n = 2 2D phase restricts the growth kinetics of 3D-like phases—α-FAPbI 3 MHPs with spacer-coordinated surface—across the MHP compositions. Thermal annealing is a critical step for proper phase growth, although it can lead to the emergence of unwanted local PbI 2 crystallites. Additionally, fundamental insights into the precursor chemistry associated with spacer-solvent interaction determining the quasi-2D MHP morphologies and microstructures are demonstrated. The high-throughput study provides comprehensive insights into the fundamental principles in quasi-2D MHP phase control, enabling new control of the functionalities in complex materials systems for sustainable device applications.

2D perovskites↗
DOE OSTI2021

Structural, Thermal, and Mechanical Characterization of a Thermally Conductive Polymer Composite for Heat Exchanger Applications

Polymer composites are being considered for numerous thermal applications because of their inherent benefits, such as light weight, corrosion resistance, and reduced cost. In this work, the microstructural, thermal, and mechanical properties of a 3D printed polymer composite with high thermal conductivity are examined using multiple characterization techniques. Infrared spectroscopy and X-ray diffraction reveal that the composite contains a polyphenylene sulfide matrix with graphitic fillers, which is responsible for the high thermal conductivity. Furthermore, differential scanning calorimetry determines that the glass transition and melting point of the composite are 87.6 °C and 285.6 °C, respectively. Thermogravimetric analysis reveals that the composite is thermally stable up to ~400 °C. Creep tests are performed at different isotherms to evaluate the long-term performance of the composite. The creep result indicates that the composite can maintain mechanical integrity when used below its glass transition temperature. Nanoindentation tests reveal that modulus and hardness of the composite is not significantly influenced by heating or creep conditions. These findings indicate that the composite is potentially suitable for heat exchanger applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Bipolar Membranes with an Electrospun 3D Junction

Freestanding bipolar membranes (BPMs) with an entirely new and transformative morphology were fabricated and characterized. The key disruptive design element was a water-splitting/water-generation junction layer of finite thickness composed of interwoven and interlocking electrospun anion-exchange polymer (AEP) fibers and cation-exchange polymer (CEP) fibers. Methods were developed to sandwich the 3D junction layer between two pre-formed dense AEP and CEP films., with the closure of all interfiber voids, where the processing steps are easily incorporated into a commercial roll-to-roll membrane manufacturing scheme. A series of membranes were made using different polymers and junction layers to identify the optimum morphology and composition for water-splitting and water-generation applications. For water splitting, the 3D junction BPMs worked remarkably well with operating current densities at/above 1.0 A/cm2 (10X greater than commercial BPMs) at a transmembrane voltage drop of only 1.1 V. In water generation mode, the 3D junction BPMs operated at 0.5 A/cm2, a world-record current density. The membranes were found to exhibit outstanding durability and can be manufactured at scale for low cost. The high operating current densities and stable long-term operation are due to the 3D junction layer design, where there is a high interfacial area for water splitting or water generation reactions and where the interlocking fibers prevent delamination of the outer films. These new BPMs are ideal candidate materials for both existing water-splitting electrodialysis separations and new electrochemical processes, such as large-scale direct air capture of CO 2 , reactors for CO 2 reduction, self-hydrating fuel cells, and redox flow batteries.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2017

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

Prater, Tracie↗
DOE OSTI2021

3D-printed B 4 C collimation for neutron pressure cells

A design for an incident-beam collimator for the Paris–Edinburgh pressure cell is described here. This design can be fabricated from reaction-bonded B 4 C but also through fast turnaround, inexpensive 3D-printing. 3D-printing thereby also offers the opportunity of composite collimators whereby the tip closest to the sample can exhibit even better neutronic characteristics. Here, we characterize four such collimators: one from reaction-bonded B 4 C, one 3D-printed and fully infiltrated with cyanoacrylate, a glue, one with a glue-free tip, and one with a tip made from enriched 10 B 4 C. The collimators are evaluated on the Spallation Neutrons and Pressure Diffractometer of the Spallation Neutron Source and the Wide-Angle Neutron Diffractometer at the High Flux Isotope Reactor, both at Oak Ridge National Laboratory. This work clearly shows that 3D-printed collimators perform well and also that composite collimators improve performance even further. Beyond use in the Paris–Edinburgh cell, these findings also open new avenues for collimator designs as clearly more complex shapes are possible through 3D printing. An example of such is shown here with a collimator made for single-crystal samples measured inside a diamond anvil cell. These developments are expected to be highly advantageous for future experimentation in high pressure and other extreme environments and even for the design and deployment of new neutron scattering instruments.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Development of ceria-supported metal-oxide (MO x /CeO 2 ) catalysts via a one-pot chemical vapor deposition (OP-CVD) technique: Structure and reverse water gas shift reaction study

Current synthesis techniques for metal oxide (MO x )-supported catalysts have certain limitations of undesired target loading, ineffective dispersion of active species over the surface, uncontrolled particle size of active species, and complicated synthesis steps. Here, we developed a one-pot chemical vapor deposition (OP-CVD) methodology; by using which a solid metal precursor forms a vapor in a controlled condition and gets supported over the surrounding matrix. The theoretical stability followed by experimental validation using TGA is crucial for selecting the metal precursors. Three simple steps viz. premixing, dispersion, and rapid fixation by calcination are involved in the catalyst development via the OP-CVD approach. This study solely focused on the synthesis of 3d transition MO x over ceria support. The physicochemical characterizations of the prepared catalysts were performed by XRD, ICP-OES, SEM-EDX, CO pulse chemisorption, XANES, and EXAFS analyses to understand the crystal structure of involved species, target metal loading, dispersion, and particle size and prove the feasibility and viability of OP-CVD. The prepared catalysts were further tested for reverse water gas shift (RWGS) reaction to link their structural information with activity. The RWGS reaction data showed that the CO activity and CO selectivity were metal - and metal precursor-dependent. Higher CO activity of > 0.1 mol/h g-cat was observed for Cu and Co-based catalysts, with CO selectivity of ~100 %. This study provides an opportunity to produce efficient supported catalysts in a convenient way, providing effective catalytic activity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A holistic approach to the optimization of neutron beam transport at the LANSCE facility

An advanced neutron beam collimation system has been developed as part of an effort to optimize neutron beam transport at the Weapons Neutron Research (WNR) Facility, located within the Los Alamos Neutron Science Center (LANSCE). The goal of this work was to develop and demonstrate techniques to tailor neutron delivery in order to provide maximum available flux on sample with a specific beam profile, while simultaneously reducing unwanted background. A holistic approach was taken, upgrading the facility spallation target, facility metrology infrastructure, and flight path shutter insert to support the implementation of this advanced collimation system. Here, modern instruments and software were employed to conduct facility surveys, characterization of as-built geometry of critical components, 3D ray tracing and neutron transport calculations. Beam images and flux measurements were acquired after installation to evaluate the performance of the collimation system and to demonstrate consistent agreement with MCNP simulations which showed an 87% increase of flux on sample while providing suppression of background neutron impingement on the sample frame by 10 3 .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Substrate Partitioning into Protein Macromolecular Frameworks for Enhanced Catalytic Turnover

Spatial partitioning of chemical processes is an important attribute of many biological systems, the effect of which is reflected in the high efficiency of enzymes found within otherwise chaotic cellular environments. Barriers, often provided through the formation of compartments or phase segregation, gate the access of macromolecules and small molecules within the cell and provide an added level of metabolic control. Taking inspiration from nature, we have designed virus-like particles (VLPs) as nanoreactor compartments that sequester enzyme catalysts and have used these as building blocks to construct 3D protein macromolecular framework (PMF) materials, which are structurally characterized using small-angle X-ray scattering (SAXS). Additionally, the highly charged PMFs form a separate phase in suspension, and by tuning the ionic strength, we show positively charged molecules preferentially partition into the PMF, while negatively charged molecules are excluded. This molecular partitioning was exploited to tune the catalytic activity of enzymes enclosed within the individual particles in the PMF, the results of which showed that positively charged substrates had turnover rates that were 8500× faster than their negatively charged counterparts. Moreover, the catalytic PMF led to cooperative behavior resulting in charge dependent trends opposite to those observed with individual P22 nanoreactor particles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Gaussian-preserved, non-volatile shape morphing in three-dimensional microstructures for dual-functional electronic devices

Motile plant structures such as Mimosa pudica leaves, Impatiens glandulifera seedpods, and Dionaea muscipula leaves exhibit fast nastic movements in a few seconds or less. This motion is stimuli-independent mechanical movement following theorema egregium rules. Artificial analogs of tropistic motion in plants are exemplified by shape-morphing systems, which are characterized by high functional robustness and resilience for creating 3D structures. However, all shape-morphing systems developed so far rely exclusively on continuous external stimuli and result in slow response. Here, we report a Gaussian-preserved shape-morphing system to realize ultrafast shape morphing and non-volatile reconfiguration. Relying on the Gaussian-preserved rules, the transformation can be triggered by mechanical or thermal stimuli within a microsecond. Moreover, as localized energy minima are encountered during shape morphing, non-volatile configuration is preserved by geometrically enhanced rigidity. Using this system, we demonstrate a suite of electronic devices that are reconfigurable, and therefore, expand functional diversification.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Summary: SEE4GEO

The seismoelectric effects technique (SEE) is a new and innovative approach for geothermal subsurface imaging and monitoring at reservoir scale. The objective of this project is to assess SEE in terms of data acquisition, cost and quality, and to determine its capability in comparison with classical imaging and monitoring techniques, particularly decoupled seismic and electromagnetic methods. This will be achieved by (1) development of a fast, true 3D numerical package, handling SEE imaging and subsurface properties characterization, including resistivity and permeability, (2) laboratory experiments performed in a controlled environment to define optimal deployment design, data quality, and inform field deployment, and (3) field surveys to ultimately test and draw lessons for practical use of SEE technology. There is a relatively extensive body of work in the literature on SEE, and members of this consortium have been involved in theoretical and numerical development of SEE modeling as well as laboratory experiments. Nevertheless, to our knowledge few, if any, documented efforts have been specifically targeting the use of SEE for geothermal subsurface imaging and monitoring. The strength and originality of our proposal rely on an integrated approach leveraging numerical, laboratory and field experiments, to properly document the practical use of SEE. Through this process, SEE in-hand technology for the geothermal industry will be able to progress from a TRL 1 to TRL 3.

58 GEOSCIENCES↗
DOE OSTI2022

Seismoelectric Effects for Geothermal Resources Assessment and Monitoring (SEE4GEO)

The seismoelectric effects technique (SEE) is a new and innovative approach for geothermal subsurface imaging and monitoring at reservoir scale. The objective of this project is to assess SEE in terms of data acquisition, cost and quality, and to determine its capability in comparison with classical imaging and monitoring techniques, particularly decoupled seismic and electromagnetic methods. This will be achieved by (1) development of a fast, true 3D numerical package, handling SEE imaging and subsurface properties characterization, including resistivity and permeability, (2) laboratory experiments performed in a controlled environment to define optimal deployment design, data quality, and inform field deployment, and (3) field surveys to ultimately test and draw lessons for practical use of SEE technology. There is a relatively extensive body of work in the literature on SEE, and members of this consortium have been involved in theoretical and numerical development of SEE modeling as well as laboratory experiments. Nevertheless, to our knowledge few, if any, documented efforts have been specifically targeting the use of SEE for geothermal subsurface imaging and monitoring. The strength and originality of our proposal rely on an integrated approach leveraging numerical, laboratory and field experiments, to properly document the practical use of SEE. Through this process, SEE in-hand technology for the geothermal industry will be able to progress from a TRL 1 to TRL 3.

58 GEOSCIENCES↗
DOE OSTI2020

Perspective: Ferromagnetic Liquids

Mechanical jamming of nanoparticles at liquid–liquid interfaces has evolved into a versatile approach to structure liquids with solid-state properties. Ferromagnetic liquids obtain their physical and magnetic properties, including a remanent magnetization that distinguishes them from ferrofluids, from the jamming of magnetic nanoparticles assembled at the interface between two distinct liquids to minimize surface tension. This perspective provides an overview of recent progress and discusses future directions, challenges and potential applications of jamming magnetic nanoparticles with regard to 3D nano-magnetism. We address the formation and characterization of curved magnetic geometries, and spin frustration between dipole-coupled nanostructures, and advance our understanding of particle jamming at liquid–liquid interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of a forced advection sampling technique (FAST) for quantification of methane emissions from orphaned wells

Abstract. Orphaned wells, meaning unplugged and non-producing wells lacking responsible owners, pose a significant and undersampled environmental challenge due to their vast number and unknown associated emissions. We propose, develop and test an alternative method for estimating emissions from orphaned wells using a forced advection sampling technique (FAST) that can overcome many of the limitations in current methods (cost, accuracy, safety). In contrast to existing ambient Gaussian plume methods, our approach uses a fan-generated flow to force advection between the emission source and a point methane (CH4) sensor. The fan flow field is characterized using a colocated sonic anemometer to measure the 3D wind profile generated by the fan. Using time-series measurements of CH4 concentration and wind, a simple estimate of the CH4 emission rate of the source can be inferred. The method was calibrated using outdoor controlled-release experiments and then tested on four orphaned wells in Lufkin, TX, and Osage County, OK. Our results suggest that the FAST method can provide a low-cost, portable, fast and safe alternative to existing methods with reasonable estimates of orphaned well emissions over a range of leak rates below 40 g h−1 and within certain geometric and atmospheric constraints.

Dubey, Mohit L↗
DOE OSTI2021

Revealing meso-structure dynamics in additive manufacturing of energy storage via operando coherent X-ray scattering

3D printing is an emerging technology for the fabrication of energy storage devices, offering advantages over traditional manufacturing methods. However, optimization and design of such devices requires an understanding of the meso-structure formation during the 3D printing process. This study utilizes operando coherent X-ray scattering, X-ray Photon Correlation Spectroscopy (XPCS), to study the spatiotemporally-resolved far-from-equilibrium dynamics during direct ink writing 3D printing. Here, Lithium Titanate (LTO) based ink is prepared and rheologically tested for its shear-thinning properties. Two-time intensity-intensity functions are calculated to be used in subsequent quantitative analysis, which allows for an overall characterization of the dynamics, description of an initial fast decorrelation and identification of sudden rearrangements of subdomains of the sample. The results show the dynamics to be anisotropic, spatiotemporally heterogenous and marked by distinct rearrangement events, all of which impact the electrochemical performance of energy storage devices. The studied 3D printing ink is used to fabricate electrodes which are then electrochemically tested, showing good performance in cycling and retaining structural integrity. This work furthers the understanding of the far-from-equilibrium material dynamics during 3D printing, giving quantitative characterization of this process, and highlights aspects of structure formation relevant to the electrochemical performance of the resultant energy storage device.

36 MATERIALS SCIENCE↗
DOE OSTI2026

3D Play Fairway Analysis for Examining of Superhot Reservoir Production Scenarios

The DEEPEN (DE-risking Exploration for geothermal Plays in magmatic ENvironments) project was a multi-laboratory, international effort to reduce uncertainty and improve resource characterization in superhot geothermal systems. Building on this foundation, this work advances open-source tools designed to lower the exploration risk and cost of superhot geothermal projects while promoting transparency, reproducibility, and efficiency in exploration workflows. These tools are being tested at two key sites: (1) the Nesjavellir Geothermal Area in Iceland, where the Icelandic Deep Drilling Project (IDDP) will drill its third well, and (2) Newberry Volcano in Oregon, USA, where Mazama Energy will pilot the first superhot enhanced geothermal system (EGS). A major outcome is the creation of a modular, open-source Python framework for play fairway analysis (PFA) in 2D and 3D, called geoPFA. The PFA workflow has been expanded to produce pseudo conceptual models, and will soon be refined to assess reservoir components through integration with the thermo-hydraulic-mechanical-chemical (THMC) simulator TReactMech, to enable iterative coupling between PFA and THMC models, improving characterization of superhot systems. All three of the Icelandic Deep Drilling Project's production scenarios were analyzed via this framework: (1) a superhot deep injection well paired with conventional production wells at Nesjavellir, (2) a superhot deep production well at Nesjavellir, and (3) superhot enhanced geothermal system at Newberry Volcano. This analysis provides useful insights around conceptual modeling of these production scenarios, helping to inform decisions around which scenario is best suited for which types of environments.

15 GEOTHERMAL ENERGY↗