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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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Manufacturing Processes for Permanent Magnets: Part I—Sintering and Casting
Abstract Permanent magnets (PMs) produce magnetic fields and maintain the field even in the presence of an opposing magnetic field. Electrical machines using permanent magnets are more efficient than those without. Currently, all known strong magnets contain rare earth (RE) elements, and they are core components of a wide range of applications including electric vehicles and wind turbines. RE elements such as Nd and Dy have become critical materials due to the growing demand and constrained supply. Improving the manufacturing process is effective in mitigating the RE criticality issue by reducing waste and improving parts consistency. In this article, the state of the industry for PM is reviewed in detail considering both the technical and economic drivers. The importance of RE elements is discussed along with their economic importance to green energy. The conventional sintering and casting manufacturing processes for commercial magnets, including Nd-Fe-B, Sm-Co, Alnico, and ferrite, are described in detail.
Manufacturing Processes for Permanent Magnets: Part II—Bonding and Emerging Methods
Abstract Permanent magnets produce magnetic fields and maintain the field even in the presence of an opposing magnetic field. They are widely used in electric machines, electronics, and medical devices. Part I reviews the conventional manufacturing processes for commercial magnets, including Nd-Fe-B, Sm-Co, alnico, and ferrite in cast and sintered forms. In Part II, bonding, emerging advanced manufacturing processes, as well as magnet recycling methods are briefly reviewed for their current status, challenges, and future directions.
The Addition of Boron to Melt-Spun Fe-6.5%Si Ribbons
Fe-6.5%Si has higher electrical resistivity, lower magnetocrystalline anisotropy, and lower magnetostriction than traditional Fe-3.2%Si silicon steel. The reduced iron losses of Fe-6.5%Si render it a highly favorable candidate for high-speed motors and transformers. However, large-scale production of wide Fe-6.5%Si tape by rapid solidification can be challenging mainly because of its high melting point. In this work, boron is alloyed to Fe-6.5%Si to reduce its melting temperature and interfacial energy to improve the alloy’s processability. Boron additions from 0.01 wt.% to 2.24 wt.% into Fe-6.5%Si and its effect on ribbon thickness, grain size, magnetic, and mechanical properties were studied. Further, minor boron alloying significantly changed the melt pool stability and wetting on the quench wheel and in turn increased the quench rate with minimum impact on the magnetic saturation and ductility. Boron addition of < 0.06 wt.% was also found beneficial to the magnetic property of the alloy by lowering both its hysteresis and eddy current losses.
Effects of Post-sintering Annealing on (NdLa)-(FeCo)-B Magnets
A common limitation of La substitutions into (Nd, La) 2 Fe 14 B magnets is the reduction of the anisotropy field (H a ), which decreases magnet coercivity (H cj ). In this study, adding a small amount of Pr-Cu to a La-containing neo magnet may modify the grain boundary (GB), which can help recover a fraction of the degraded H cj . An optimal GB modification requires a carefully designed post-sinter heat treatment, which is the focus of this work on characterizing the effects of multi-step post-sintering annealing on the evolutions of microstructure and magnetic properties. We find that Nd and Cu concentrations at GBs and triple junctions (TJs) increase when the annealing temperatures are lowered. Annealing temperatures of 580°C and 480°C (near rare-earth-rich eutectic temperatures) enabled the development of a thick and continuous GB phase, which helps to magnetically decouple the grains, and, thus, enhance H cj . For the alloy with 25% Nd replaced by La, and with the addition of 7.5 wt.% of Pr 68 Cu 32 as GB modifier, the optimized multi-step post-sinter annealing improved the H cj from 4.8 kOe to 9 kOe.
Hot-Roll Fabrication of Anisotropic Nanograin Nd-Fe-B Magnet
Nd-Fe-B based magnets have the highest energy product among all permanent magnets, which is required for numerous clean energy technologies. For higher temperature applications (T > 150°C), additions of heavy rare earth elements (HREEs) such as Dy are required to maintain sufficient coercivity during operation. Additions of Dy are expensive. Thus, it is desirable to reduce the need for HREEs by reducing the grain size to the nanoscale, which increases the coercivity and decreases its temperature dependence. Here, we report a novel nanograin Nd-Fe-B magnet fabrication method that is continuous and inexpensive. The process uses mechanically milled Nd-Fe-B melt-spun flakes as feedstock powder that is packed into a metal vessel and then hot rolled to form a fully dense and highly textured strip magnet with tailored thicknesses, down to 800 µm. Finally, using this process, fully dense nanograin bulk magnets can be synthesized in minutes compared to the traditional multi-step processes that are typically low throughput.
A novel battery scheme: Coupling nanostructured phosphorus anodes with lithium sulfide cathodes
Lithium-ion batteries are approaching their theoretical limit and can no longer keep up with the increasing demands of human society. Lithium-sulfur batteries, with a high theoretical specific energy, are promising candidates for next generation energy storage. However, the use of Li metal in Li-S batteries compromises both safety and performance, enabling dendrite formation and causing fast capacity degradation. Previous studies have probed alternative battery systems to replace the metallic Li in Li-S system, such as a Si/Li2S couple, with limited success in performance. Recently, there is a focus on red P as a favorable anode material to host Li. In this work, we establish a novel battery scheme by utilizing a P/C nanocomposite anode and pairing it with a Li 2 S coated carbon nanofiber cathode. We find that red P anode can be compatible in ether-based electrolyte systems and can be successfully coupled to a Li 2 S cathode. Our proof of concept full-cell displays remarkable specific capacity, rate and cycling performances. We expect our work will provide a useful alternative system and valuable insight in the quest for next generation energy storage devices.
Scalable synthesis of nanoporous silicon microparticles for highly cyclable lithium-ion batteries
Nanoporous silicon is a promising anode material for high energy density batteries due to its high cycling stability and high tap density compared to other nanostructured anode materials. However, the high cost of synthesis and low yield of nanoporous silicon limit its practical application. Here, we develop a scalable, low-cost top-down process of controlled oxidation of Mg 2 Si in the air, followed by HCl removal of MgO to generate nanoporous silicon without the use of HF. By controlling the synthesis conditions, the oxygen content, grain size and yield of the porous silicon are simultaneously optimized from commercial standpoints. In situ environmental transmission electron microscopy reveals the reaction mechanism; the Mg 2 Si microparticle reacts with O 2 to form MgO and Si, while preventing SiO 2 formation. Owing to the low oxygen content and microscale secondary structure, the nanoporous silicon delivers a higher initial reversible capacity and initial Coulombic efficiency compared to commercial Si nanoparticles (3,033 mAh/g vs. 2,418 mAh/g, 84.3% vs. 73.1%). Synthesis is highly scalable, and a yield of 90.4% is achieved for the porous Si nanostructure with the capability to make an excess of 10 g per batch. Our synthetic nanoporous silicon is promising for practical applications in next generation lithium-ion batteries.
In-situ synchrotron high energy X-ray diffraction study of spontaneous reorientation of R phase upon
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Spark plasma sintering of tungsten-based WTaVCr refractory high entropy alloys for nuclear fusion applications
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Peptoid-based hierarchically-structured biomimetic nanomaterials: Synthesis, characterization and applications
Peptoids (or poly-N-substituted glycines) is a promising class of bioinspired sequence-defined polymers due to their highly efficient synthesis, high chemical stability, enzyme hydrolysis resistance, and biocompatibility. By tuning the side chain chemistry of peptoids, it allows for a precise control over sequences and achieving a large side-chain diversity. Due to these unique features, in the last several years, many amphiphilic peptoids were designed as highly tunable building blocks for the preparation of biomimetic nanomaterials with well-defined hierarchical structures and desired functionalities. In this paper, we provide an overview of the recent achievements in this area by dividing them into the following three aspects. First, mica- and silica-templated peptoid self-assembly was summarized. Here, the presence of inorganic substrates provides the guarantee of investigating their self-assembly mechanisms and interactions between peptoids and substrates using nanoscale characterization techniques, particularly in situ atomic force spectroscopy (AFM) and AFM-based dynamic force spectroscopy (AFM-DFS). Second, solution-phase self-assembly of peptoids into nanotubes and nanosheets was presented, as well as their self-repair properties. Third, the applications of peptoid based nanomaterials were outlined, including the construction of catalytic nanomaterials as a template and cytosolic delivery as cargoes.
Cosmology with the Laser Interferometer Space Antenna
The Laser Interferometer Space Antenna (LISA) has two scientific objectives of cosmological focus: to probe the expansion rate of the universe, and to understand stochastic gravitational-wave backgrounds and their implications for early universe and particle physics, from the MeV to the Planck scale. However, the range of potential cosmological applications of gravitational-wave observations extends well beyond these two objectives. This publication presents a summary of the state of the art in LISA cosmology, theory and methods, and identifies new opportunities to use gravitational-wave observations by LISA to probe the universe.
Halide perovskite-polymer composite film for bright and stable light-emitting devices
Stability is the primary hindrance for the application of halide perovskite material in light-emitting devices, solar cells, and other devices. In this work, halide perovskite and polymer composite film have been prepared for stable and bright light-emitting devices. Pure-phase Cs4PbBr6 crystals have been synthesized, and their photoluminescence (PL) properties and fluorescence lifetimes have been investigated. The Cs 4 PbBr 6 crystals exhibited high uniformity but underwent rapid photodegradation under light irradiation. To address this issue, we prepared bright light-emitting devices using composite of Cs 4 PbBr 6 crystals and polyethylene oxide (PEO) as the emission layer. The aim was to improve the optical and physical properties of halide perovskites, such as photodegradation and stability. PEO, with its excellent film-forming ability, created a uniform and dense film on the halide perovskite surface, filling microscopic defects and providing a protective barrier. FTIR, morphology, and PL analyses confirmed the protective role of the halide perovskite and polymer composite film. The composite film light-emitting devices demonstrated improved stability and higher PL brightness, with a peak brightness approaching 3 × 10 8 cd/m 2 , which was approximately 75% higher than the pure halide perovskite devices.
Nutrient alterations following biochar application to a Cd-contaminated solution and soil
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Sequential oxidation-depolymerization strategies for lignin conversion to low molecular weight aromatic chemicals
Lignin is the largest source of bio-derived aromatic chemicals, and oxidative conversion of this polymeric material can generate valuable oxygenated aromatic compounds. Oxidative depolymerization of lignosulfonate feedstocks under alkaline conditions is used commercially for vanillin production. Recent studies have led to other oxidation methods that access different aromatic products from lignin in good yields. A particularly effective strategy that accesses some of the highest yields of aromatic monomers to date features a two-step process in which the oxidation of specific alcohol groups in lignin is followed by an oxidative, reductive, or redoxneutral step that cleaves the polymer into aromatic monomers and oligomers. Studies of model compounds have provided crucial mechanistic insights and contributed to the development of effective lignin depolymerization methods. Furthermore, this review provides a general overview of lignin depolymerization methods, followed by a survey of oxidation-depolymerization methods that access oxygenated aromatic monomers in good yields.
Irradiation damage in (Zr0.25Ta0.25Nb0.25Ti0.25)C high-entropy carbide ceramics
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