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DOE OSTI2024

Ink Casting and 3D‐Extrusion Printing of Yb 14 MnSb 11 for High‐Temperature Thermoelectric Material

Abstract Complex shapes are created from Yb 14 MnSb 11 , a high‐temperature thermoelectric Zintl phase, via a two‐step process: i) layer‐by‐layer 3D‐extrusion of ink containing partially‐reacted powders which are ball‐milled from a blend of Yb, MnSb, and Sb powders; ii) heat treatment to synthesize the ternary compound Yb 14 MnSb 11 and densify the extruded powders. A high phase purity for Yb 14 MnSb 11 (83–94%) is achieved in both cast and 3D‐extruded ink specimens via a solid‐state reaction between Yb, MnSb, and Yb 4 Sb 3 during reactive sintering. Pressure‐free sintering at temperatures of 1200–1400 °C densifies the powders to 82% relative density but can also induce the decomposition of the Yb 14 MnSb 11 phase due to Yb sublimation. A process window with optimized sintering temperature and time is identified, achieving both low porosity and high phase purity and reaching a maximum zT = 0.61 at 1000 °C, about half of the maximum zT value for bulk Yb 14 MnSb 11 made via conventional processes (pressure sintering of precursor powders). The present approach – direct ink writing of ball‐milled powders, combined with reactive sintering – is a scalable and affordable method to fabricate thermoelectric legs with intricate 3D shapes, for enhanced performances in high‐temperature thermoelectric applications.

Chen, Ming [Department of Materials Science &amp, ↗

DOE OSTI2025

Observation of Extraordinary Vibration Scatterings Induced by Strong Anharmonicity in Lead‐Free Halide Double Perovskites

Abstract Lead‐free halide double perovskites provide a promising solution for the long‐standing issues of lead‐containing halide perovskites, i.e., the toxicity of Pb and the low stability under ambient conditions and high‐intensity illumination. Their light‐to‐electricity or thermal‐to‐electricity conversion is strongly determined by the dynamics of the corresponding lattice vibrations. Here, the measurement of lattice dynamics is presented in a prototypical lead‐free halide double perovskite(Cs 2 NaInCl 6 ). The quantitative measurements and first‐principles calculations show that the scatterings among lattice vibrations at room temperature are at the timescale of ≈1 ps, which stems from the extraordinarily strong anharmonicity in Cs 2 NaInCl 6 . Further the degree of anharmonicity of each type of atom is quantitatively characterized in the Cs 2 NaInCl 6 single crystal, which stems from the interatomic forces, and demonstrate that this strong anharmonicity is synergistically contributed by the bond hierarchy, the tilting of the NaCl 6 and InCl 6 octahedral units, and the rattling of Cs + ions. Consequently, the crystalline Cs 2 NaInCl 6 possesses an ultralow thermal conductivity of ≈0.43 W mK −1 at room temperature, and a weak temperature dependence ofT −0.41 . These findings uncovered the underlying mechanisms behind the dynamics of lattice vibrations in double perovskites, which can largely benefit the design of optoelectronics and thermoelectrics based on halide double perovskites.

Chemistry↗

DOE OSTI2025

The Effect of Hydrothermal Alteration and Microcracks on Hydraulic Properties and Poroelastic Deformation: A Case Study of the Blue Mountain Geothermal Field

Abstract Geothermal energy plays a vital role in decarbonizing electricity and heat supply. Effective utilization of geothermal resources hinges on identifying or generating permeable reservoir zones and understanding how effective pressure variations affect fluid circulation and reservoir properties by poroelastic deformation. Hydrothermal alteration can modify the petrophysical properties of geothermal reservoir rocks, which may increase or decrease its productivity. Understanding these alteration effects is essential to predict and optimize long‐term sustainable geothermal operations. Here, we investigate the impact of hydrothermal alteration on poroelastic and hydraulic properties of diverse lithologies in a series of deformation tests performed at several confining (0–80 MPa) and pore pressure (10–30 MPa) levels. Experimental results of hydrothermally altered dikes and phyllites obtained from the Blue Mountain geothermal field (Nevada, USA) are compared to thermally cracked La Peyratte granite (France) and correlated with petrophysical properties, mineral composition, and microstructures. Argillic alteration of dikes increases porosity and storage capacity but lowers thermal conductivity and increases pore compressibility. Conversely, silicate precipitation in phyllites increases stiffness and thermal conductivity but also reduces porosity and permeability. Experimentally determined effective pressure coefficients range from 0.1 to 0.9, differ for permeability and volumetric strain and decrease with increasing effective pressure. The presence of compliant microcracks and crack‐like pores significantly increases the stress sensitivity of La Peyratte granite and silicified phyllites. This study demonstrates how thermal and chemical alteration impacts poromechanical and petrophysical characteristics of geothermal targets, which ultimately govern reservoir stability and subsidence, induced seismicity as well as fluid and heat extraction efficiency during geothermal operations.

Schuster, Valerian [Helmholtz Centre Potsdam GFZ G↗

DOE OSTI2025

Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing

Fiber-reinforced polymer composites are lightweight structural materials widely used in the transportation and energy industries. Current approaches for the manufacture of composites require expensive tooling and long, energy-intensive processing, resulting in a high cost of manufacturing, limited design complexity, and low fabrication rates. Here, we report rapid, scalable, and energy-efficient additive manufacturing of fiber-reinforced thermoset composites, while eliminating the need for tooling or molds. Use of a thermoresponsive thermoset resin as the matrix of composites and localized, remote heating of carbon fiber reinforcements via photothermal conversion enables rapid, in-situ curing of composites without further post-processing. Rapid curing and phase transformation of the matrix thermoset, from a liquid or viscous resin to a rigid polymer, immediately upon deposition by a robotic platform, allows for the high-fidelity, freeform manufacturing of discontinuous and continuous fiber-reinforced composites without using sacrificial support materials. This method is applicable to a variety of industries and will enable rapid and scalable manufacture of composite parts and tooling as well as on-demand repair of composite structures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

SnSe 2 thermal conductivity from optothermal Raman and Stokes/anti-Stokes thermometry

The optothermal Raman method is useful in determining the in-plane thermal conductivity of two-dimensional (2D) materials that are either suspended or supported on a substrate. We compare this method with the Stokes/anti-Stokes scattering thermometry method, which can play a role in both calibration of Raman peak positions as well as extraction of the local phonon temperature. This work demonstrates that the Stokes/anti-Stokes intensity ratio plays an important role in determining the in-plane thermal conductivity of 2D tin diselenide (SnSe 2 ) dry-transferred onto a polished copper (Cu) substrate. The statistically-averaged thermal conductivity of the 108 ± 24 nm-thick SnSe 2 yielded 5.4 ± 3.5 Wm −1 K −1 for the optothermal Raman method, and 2.40 ± 0.81 Wm −1 K −1 for the Stokes/anti-Stokes thermometry method, indicating that the Stokes/anti-Stokes thermometry method to calculate the thermal conductivity of a material can simultaneously increase both precision and accuracy. The uncertainty value was also lowered by a factor of 1.9 from the traditional optothermal Raman method to the Stokes/anti-Stokes thermometry method. The low in-plane thermal conductivity of 2D SnSe 2 , 1.3–2.9 times lower than bulk, is useful for applications in thermal and electrical energy conversion and thermoelectric devices.

2D materials↗

DOE OSTI2026

Localized Heterogeneous Nucleation for Vapor‐Assisted Sequential Deposition of Metal Halide Perovskites

Vapor-assisted hybrid two-step deposition, which combines thermally evaporated inorganic layers with solution-processed organic halides to form halide perovskites, has emerged as a scalable and industry-compatible route for textured tandem photovoltaics. However, this process is often hindered by reaction-limited phase formation, particularly when compact, non-porous, and highly crystalline inorganic layers formed by thermal evaporation restrict subsequent conversion, resulting in incomplete reaction and pronounced depth-dependent heterogeneity. In this study, we introduce a strategy to regulate the inorganic precursor layer by incorporating localized heterogeneous nucleation sites. Sparsely distributed hydrophilic metal oxide species serve as effective nucleation centers during vapor deposition, enabling effective control over film morphology and crystal orientation from the early stages of growth. This tailored inorganic framework facilitates the subsequent incorporation of organic halides, alleviating reaction limitations and suppressing residual unreacted precursors. Consequently, the perovskite films exhibit improved stoichiometric uniformity and enhanced optoelectronic quality, enabling wide-bandgap perovskite solar cells with markedly improved performance and operational stability. This work provides important mechanistic insight into crystal growth engineering of vapor-deposited perovskite thin films.

nucleation↗

DOE OSTI2024

Large Area Near‐Field Thermophotovoltaics for Low Temperature Applications

Abstract Thermophotovoltaics, devices that convert thermal infrared photons to electricity, offer a key pathway for a variety of critical renewable energy technologies including thermal energy storage, waste heat recovery, and direct solar‐thermal power generation. However, conventional far‐field devices struggle to generate reasonable powers at lower temperatures. Near‐field thermophotovoltaics provide a pathway to substantially higher powers by leveraging photon tunneling effects. Here a large area near‐field thermophotovoltaic device is presented, created with an epitaxial co‐fabrication approach, that consists of a self‐supported 0.28 cm 2 emitter‐cell pair with a 150 nm gap. The device generates 1.22 mW at 460 °C, a 25‐fold increase over the same cell measured in a far‐field configuration. Furthermore, the near‐field device demonstrates short circuit current densities greater than the far‐field photocurrent limit at all the temperatures tested, confirming the role of photon tunneling effects in the performance enhancement. Modeling suggests several practical directions for cell improvements and further increases in power density. These results highlight the promise of near‐field thermophotovoltaics, especially for low temperature applications.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Biomass Demineralization: A Critical Need for Future Biorefineries

Biomass contains up to 14 essential elements that serve as nutrients for plant growth and development, including photosynthesis and enzyme functionalities. These elements in different chemical forms (e.g., minerals) constitute the inorganic fraction of biomass and can cause operational issues in thermal and biochemical biomass conversion technologies. In biomass gasification and pyrolysis processes, for instance, inorganics can cause fouling, tar formation, and corrosion. In catalytic and biochemical processes, inorganics can poison catalysts, alter biochemical pathways, and modify product yields and selectivity. This review provides an overview of the inorganic content in biomass feedstocks, the critical role inorganics play in plant biochemistry, the effect that inorganics have in various thermochemical and biochemical biomass conversion technologies, and different approaches to remove them from biomass. We provide recommendations for future research, focusing on developing technologies to effectively remove inorganics from biomass, using the inorganics to improve soil quality and for alternative applications, and designing biorefineries to convert demineralized biomass obtained from diverse sources.

09 - BIOMASS FUELS↗

DOE OSTI2025

Thermal energy transport in laser-driven high x-ray conversion efficiency metallic silver nanowire foams

Here, we report on record brightness from Ag x-ray emission obtained using a novel laser-produced plasma source. The reported K-shell conversion efficiency of nearly 1% with a radiant energy of ≈ 0.6 kJ/sr from Ag ions is the highest presently recorded and is about twofold greater than more conventional metal-lined cavity targets. He-like Ag ions are the dominant radiators at ≈ 22.7 keV, which contrast the x-ray sources from other pulse power facilities that produce K-shell x-rays from Auger processes in near-neutral ions driven by the nonthermal hot electrons produced in the Z-pinch implosion. The reported x-ray emission was produced from a 4-mm-diameter, 4-mm-long underdense silver nanowire target at 10⁢ mg/⁢cm 3 . The National Ignition Facility laser beams deposited ≈ 1000 kJ of 3ω light into the target with a ≈ 400 TW, 2.5 ns square pulse. Finally, we show via comparisons of data with radiation-hydrodynamics simulations that flux-limited classical thermal energy transport models are inadequate in correctly modeling the behavior of these non-local thermodynamic equilibrium plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Non-thermal atmospheric pressure plasma–liquid synthesis of organic acids in aqueous solution from carbon monoxide

This work aims at understanding the conversion of CO to organic acids, namely oxalic acid and formic acid, using non-thermal atmospheric pressure plasma over aqueous solutions. CO exhibited significantly higher conversion to organic acids (more than 15×) compared to CO 2 under the same reaction conditions. The result bolsters a proposed two-step process for CO 2 fixation, whereby CO 2 is first converted to CO, and then CO is converted to organic acids. The organic acids produced from CO are intermediates in the water–gas shift (WGS) reaction of CO in the presence of an aqueous solution to dissolved CO 2 and hydrogen gas. Based on a simple thermodynamic analysis, the organic acid yield was increased by lowering the plasma–liquid reaction temperature using an ice bath to cool the reaction flask. The composition of the organic acids could be varied by changing the pH of the solution. Oxalate was formed in higher concentrations with increasing solution pH above the pK a of the radical species (CO 2 )˙ − . Below the pK a value, formate was the exclusive organic acid formed. The production of formate has a rather weak pH dependence but is enhanced slightly at a basic pH above 10. Furthermore, at basic pH, the effect of electrolyte concentration comes into play. Higher electrolyte concentrations, leading to shorter electrolyte Debye lengths, resulted in lowered organic acid yields. The highest yields of organic acids obtained in our system were 122 mg L −1 for oxalate and 77 mg L −1 for formate at an optimum 1 mM NaOH concentration in the starting solution. This work is a successful pioneering example of CO to organic acids conversion using non-thermal plasmas, which opens the pathway for a promising two-step conversion process of CO 2 to organic acids.

Sudagar, Alcina Johnson [Washington University in ↗

DOE OSTI2025

Thermally Evaporated Naphthalene Diimides as Electron Transport Layers for Perovskite Solar Cells

Thermally evaporated organic electron transport layers (ETLs) have the potential to enable high-performance and scalable perovskite solar cells (PSCs). Among these, naphthalene diimide (NDI)-based ETLs are a promising family of materials that exhibit the optoelectronic properties, ambient stability and versatility required of high-performance ETLs. Here, we synthesized five NDI derivatives with varying functional groups and identified the two most promising candidates for evaluating the impact of molecular structure on processability via thermal evaporation. While phosphonic acid functionalization was shown to introduce thermal instability, leading to chemical changes during evaporation, NDI-bis N-phenyl-bromide (NDI-(PhBr) 2 ) emerged as a promising ETL candidate. NDI-(PhBr) 2 demonstrated excellent compatibility with the thermal evaporation process and enabled PSCs with power conversion efficiencies (PCEs) of 15.6%, surpassing all previously reported PSCs containing thermally evaporated NDI ETLs. Furthermore, NDI-(PhBr) 2 exhibited excellent operational stability, retaining 75% of the initial PCE after 150 h of operation under continuous illumination at 65 °C. These results highlight the potential of NDI-based ETLs for advancing the scalability and performance of PSCs.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Impact of U-10Mo HALEU fuel element tolerances on the Massachusetts Institute of Technology reactor safety and operational performance – Thermal hydraulics

The U.S. is coordinating efforts for the conversion of six U.S. High Performance Research Reactors (USHPRR) including one critical facility from highly enriched uranium (HEU) to low-enriched uranium (LEU). In order to continue the mission of these reactors, including the Massachusetts of Institute of Technology Reactor (MITR), and achieve similar performance, high-assay low-enriched uranium (HALEU) with a high-density metallic alloy of uranium with 10 wt% molybdenum (U-10Mo) is being evaluated. The impact of the fabrication specification and tolerances was assessed following the preliminary design of the MITR LEU fuel elements using the U-10Mo monolithic alloy. This research focuses on the analysis of fabrication specification impact on thermal hydraulics (TH) characteristic of the MITR LEU core as a function of the variation of the relevant fuel specification parameters (e.g., coolant channel gap thickness, fuel plate thickness, etc.). The analyses are performed based on an all-fresh LEU fuel conversion plan identified in a preliminary safety analysis report submitted to the Nuclear Regulatory Commission. The reactor power margin to the onset of nucleate boiling (ONB) is assessed under the limiting safety system settings (LSSS), where a scram occurs, to ensure there is sufficient margin to the reactor safety limit, which is defined by the onset of flow instability that occurs after the ONB. The best estimate plus uncertainty approach is employed to analyze this TH characteristic, which yields realistic results while maintaining adequate conservatism, utilizing a statistical uncertainty propagation method with the STAT7 code. The TH characteristic is analyzed as a function of the variability of the specification parameters resulting from the fabrication process. The main findings of this study show that the MITR core can meet the TH safety and operational requirements at the all-LEU initial core startup (cycle 1), selected transition cycles (most reactive cycle and most limiting cycle: cycle 3 and 5, respectively) and equilibrium (cycle 14) cores under all limiting fabrication parameter combinations considered. In addition, the analyses show that the dependency of the core power margin to ONB on those specification parameters that have the most direct impact on TH performance is non-linear but monotonically decreasing within the specification tolerances. The third order polynomial fit curves are reported in detail for selected limiting cases and can serve as a powerful tool for future MITR fuel management in cases such as when HALEU supply is established that may allow additional cycle length or other operational benefits.

Conversion↗

DOE OSTI2025

A layered Prussian blue analogue as fast-charging negative electrode material for lithium-ion batteries

The simultaneous achievement of fast-charging and high specific capacity remains a critical challenge for lithium-ion battery negative electrodes. Here we report a layered manganese-based Prussian blue analogue, synthesized through vacancy control and subsequent thermal transformation. As a conversion-type negative electrode, this material exhibits high-rate performance, delivering a specific capacity of 510 mAh g −1 at a specific current of 8 A g −1 , and operates at a moderate average voltage of approximately 1.2 V vs. Li/Li + , which mitigates lithium plating risks. This high-rate capability stems from the analogue’s specific linkage configurations, which facilitate a high content of active transition metal and strong Li+ adsorption at nitrogen sites. The high transition metal content enables a high reversible capacity, while strong Li + adsorption promotes an efficient initial crystalline-to-amorphous transformation. This process induces dynamically reversible component migration during subsequent cycling, thereby enhancing conversion reaction kinetics. Our findings provide insights into the application of Prussian blue analogues as fast-charging negative electrode materials. The development of fast-charging and high-capacity negative electrodes is critical for advanced lithium-ion batteries. Here, authors use a vacancy engineering strategy to develop a layered Prussian blue analogue with competitive rate capability, delivering a specific capacity of 510 mAh g −1 at a specific current of 8 A g −1 .

25 ENERGY STORAGE↗

DOE OSTI2026

Hierarchical microstructure of Yb-filled skutterudites through ultrasonically atomized spherical powders for enhanced thermoelectric performance

Hierarchical microstructures are widely explored as a strategy to reduce lattice thermal conductivity in thermoelectric materials while preserving favorable electronic transport. Here we demonstrate that ultrasonic atomization of precursor powders provides an intrinsic pathway to generate such architectures in n-type Yb0.3Co4Sb12 skutterudites. Materials were synthesized by both conventional sealed-ampoule and ultrasonic atomization routes, each yielding essentially single-phase skutterudite after densification. However, the atomized spherical powders undergo a distinct reaction-driven microstructural evolution during thermal treatment prior to densification. Electron microscopy reveals that the skutterudite phase within the particles induces swelling, cracking, and fragmentation of the droplets before consolidation. Multimodal structural and microstructural characterizations show that densification of these fragmented powders produces a hierarchical microstructure consisting of submicron grains, micrometer-scale faceted crystallites, and powder-derived domains separated by oxide-decorated boundaries. Comprehensive thermoelectric transport measurements evidence that this multiscale architecture lowers the lattice thermal conductivity while maintaining favorable electronic transport, leading to an average ~10% enhancement in the thermoelectric figure of merit. Complementary 121Sb Mössbauer spectroscopy further indicates lattice softening in the atomized material. These results demonstrate that ultrasonic atomization provides an effective route to engineer hierarchical microstructures in skutterudite thermoelectrics and offers a promising strategy for tailoring thermal transport in energy-conversion materials.

Bouteiller, Hugo [ORNL] (ORCID:0009000421322962)↗

DOE OSTI2026

In-situ observation of calcium chloride hexahydrate phase separation via neutron imaging

Inorganic salt hydrate offers a low-cost thermal energy storage solution with high energy density, but phase separation during thermal cycling poses a significant challenge, leading to irreversible performance degradation. In this research, neutron radiography was used to investigate phase separation in calcium chloride hexahydrate (CaCl₂·6H₂O, CCH) during thermal cycling to track its gradual accumulation into calcium chloride tetrahydrate (CaCl₂·4H₂O, CC4). Through in-situ visualization, phase separation and CC4 sedimentation were observed to occur during the cooling phase between 301.40 K and 304.80 K. CC4 accumulated linearly to 7.99 wt% after 10 thermal cycles. Crystallization and multi-cycle conversion models were developed to validate neutron imaging results of CC4 formation. The predicted CC4 content after 10 thermal cycles closely aligned with experimental observations. Neutron imaging offers a novel approach to investigate salt hydrate phase change materials (PCMs). It enables in-situ visualization of sub-hydrate (CC4) formation from original hydrate (CCH) in metastable phase change range (between 301.40 ± 0.66 K and 304.80 ± 0.60 K). Thereby, it provides a new insight of understanding the basis of phase separation mechanism and paves the way for future research of improving PCM thermal cycling performance.

Li, Yucen [The University of Tennessee, Knoxville]↗

DOE OSTI2025

Modulating Poly(oligocyclobutane) Properties Through Backbone Modifications

Poly(1,n′-divinyl)oligocyclobutane (pDVOCB) has emerged as a class of poly(cycloolefin) that is amenable to chemical recycling and demonstrates promising thermomechanical properties. However, their high melting temperatures coupled with insolubility makes melt processing challenging due to thermo-oxidation of internal alkenes. To address these issues, we describe a series of polymers incorporating modifications to the pDVOCB backbone and analyze the effects on material stability and processability. Intentional migration of the internal 1,2-disubstituted alkenes to an exocyclic trisubstituted position yields isomerized pDVOCB (IpDVOCB) which exhibits a depression of thermal transitions by up to 50 °C. Conversely, elimination of stereoirregularity between enchained DVOCB oligomers through alkene saturation yields hydrogenated pDVOCB (HpDVOCB), resulting in elevated thermal transitions by up to 30 °C. Furthermore, these shifts are attributed to changes in crystal defect density which is strongly influenced by chain stereoregularity. Understanding these behaviors guides future polymer design and expands the control and use of this new class of recyclable poly(cycloolefin)s.

Differential scanning calorimetry↗

DOE OSTI2025

Development of BPM Electronics for PIP-II at Fermilab

This paper presents the uTCA4.0-based BPM electronics for PIP-II, featuring four 250 MSPS ADCs and a Xilinx UltraScale+ MPSoC FPGA with 10 GbE uplink. Design elements include signal conditioning, clock, and thermal management. The FPGA performs signal processing, time tagging, digital down-conversion, and phase drift compensation. Position and phase resolution, and thermal stability is validated through dedicated testing.

Liu, Shengli [Fermilab] (ORCID:0009000128436936)↗

DOE OSTI2025

Development of BPM electronics for PIP-II at Fermilab

Liu, Shengli [Fermilab] (ORCID:0009000128436936)↗