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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 OSTI2023

Hierarchical thermal-conductive polymer nanocomposites for thermal management

Managing heat in electrical conductors is a major challenge to meet the demands for sustainable energy use and electrical reliability, most notably power electronics and energy-critical electrical machines. Achieving such disparate functionalities, such as high temperature thermal and electrical reliability, require rational design and manufacturing of thermal conductor material and its hierarchical structures. Here we present hierarchical thermal-conductive nanocomposites, consisting of nanostructured ceramic conformal coating and aligned ultrahigh molecular weight polyethylene fiber, to tailor heat dissipation in electric conductors. The hybrid aligned thermal interface exhibits a highly desirable temperature dependent anisotropic high thermal conductivity with 0.98W m –1 K –1 and dielectric strength with 3.4. In addition, electrically insulating thermal interfaces demonstrate high-performing and reliable electrical systems under the dynamic load conditions. The surface temperature of heterogeneous ceramic-polymer encapsulated conductor is 17.8 °C lower than that of polymer-encapsulated conductor at the same electrical load. Consequently, the findings shown here hold great promises for directing heat extraction in electrical machine systems, advancing thermal management for emerging electronic applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

DuPont Nomex 410 Datasheet

Nomex 410 is a type of electrical insulation paper that can be found in a large variety of electrical applications. It exhibits a combination of good thermal stability, mechanical toughness, abrasion resistance, dielectric strength, broad chemical compatibility, and flame resistance. Nomex 410 is a high-density variety of a broader class of Nomex insulation papers, which makes it suitable for applications where high mechanical resilience is more important than impregnability or saturability.

Pingree, Richard↗

DOE OSTI2021

Flow-regulated growth of nanotubes

A method for growing nanotubes via flow-regulated microfluidic electrochemical anodization, includes providing a microfluidic device having a fluid inlet; a fluid outlet; and a fluidic microchannel connecting the fluid inlet and outlet, wherein the microchannel includes a Pt cathode and a Ti anode separated by an electrical insulator; providing an electrolyte fluid flow through the microchannel; and providing an electrical current across the anode and cathode sufficient to cause electrochemical anodization growth of TiO2 nanotubes in the microchannel on a surface of the anode.

Wan, Jiandi↗

DOE OSTI2022

Evidence for a spinon Kondo effect in cobalt atoms on single-layer 1T-TaSe 2

Quantum spin liquids are highly entangled, disordered magnetic states that are expected to arise in frustrated Mott insulators and to exhibit exotic fractional excitations such as spinons and chargons. Despite being electrical insulators, some quantum spin liquids are predicted to exhibit gapless itinerant spinons that yield metallic behaviour in the charge-neutral spin channel. For this study, we deposited isolated magnetic atoms onto single-layer 1T-TaSe 2 , a candidate gapless spin liquid, to probe how itinerant spinons couple to impurity spin centres. Using scanning tunnelling spectroscopy, we observe the emergence of new, impurity-induced resonance peaks at the 1T-TaSe 2 Hubbard band edges when cobalt adatoms are positioned to have maximal spatial overlap with the local charge distribution. These resonance peaks disappear when the spatial overlap is reduced or when the magnetic impurities are replaced with nonmagnetic impurities. Theoretical simulations of a modified Anderson impurity model show that the observed peaks are consistent with a Kondo resonance induced by spinons combined with spin-charge binding effects that arise due to fluctuations of an emergent gauge field.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Thermal conductivity of multilayer polymer-nanocomposite thin films

The development of electrical insulators that are thermally conducting is critical for thermal management applications in many advanced electronics and electrical devices. Here, we synthesized polymer nanocomposite (PNC) films composed of polymers [polyethylenimine, poly(vinylamine), poly(acrylic acid), and poly(ethylene oxide)] and dielectric fillers (montmorillonite clay and hexagonal boron nitride) by layer-by-layer technique. The cross-plane thermal conductivity (k⊥) of the film was measured by the 3ω method. The effect of various factors such as film growth, filler type, filler volume fraction, polymer chemical structures, and temperature on the thermal conductivity is reported. The k⊥ of PNCs with thickness from 37 nm to 1.34 μm was found to be in the range of 0.11 to 0.21 ± 0.02 W m−1 K−1. The k⊥ values were found to be lower than the constituent polymer matrix. The experimental result is compared with existing theoretical models of nanocomposite systems to get insight into heat transfer behavior in such layered films composed of dielectrics and polymers.

Physics↗

DOE OSTI2024

Advanced Packaging Designs

The primary deliverable for this project will be to construct a power electronics package utilizing an organic, electrically insulating substrate material and demonstrate superior thermal performance and greater reliability under thermal cycling, thermal aging, vibration, power cycling, and electrical high-potential evaluation over traditional packages.

ENGINEERING↗

DOE OSTI2025

Recent trends in all-organic polymer dielectrics for high-temperature electrostatic energy storage capacitors

Electrostatic energy storage (EES) capacitors are critical for renewable energy and high-power systems, driving the search for dielectric materials that combine superior electrical insulation, mechanical flexibility, low density, cost-effectiveness, and processability. Polymer-based dielectrics have emerged as leading candidates, particularly for high electric field applications. However, conventional polymers often fail to meet the demands of high-temperature environments due to increased electrical conductivity and reduced discharged energy density at elevated temperatures, resulting in energy loss and reduced performance. High glass transition temperature (T g) polymers show promise but require further optimization to enhance their energy storage capabilities under thermal and electrical stress. This review provides a comprehensive update on recent advancements in high-T g polymer-based dielectrics for EES capacitors, focusing on both intrinsic polymers and all-organic composites. It outlines key design principles, critical performance parameters, and innovative strategies—such as nanofiller doping, layered architectures, physical blending, and chemical crosslinking—to improve electrical, thermal, and mechanical properties. The review also highlights emerging trends, including the integration of machine learning algorithms to explore novel polymer structures and expand the chemical design space. By bridging the gap between academic research and industrial application, this review aims to accelerate the development of next-generation dielectric materials capable of balancing multiple performance metrics for high-temperature EES capacitors.

Xie, Zongliang↗

DOE OSTI2021

Design and Optimization of a 200-kW Medium-Frequency Transformer for Medium-Voltage SiC PV Inverters

This paper presents a design and optimization methodology for a 200-kW medium-frequency transformer (MFT) based on low-loss magnetic core (FINEMET FT-3TL). The proposed optimal design methodology consists of predesign, preliminary design, and optimal design. In the preliminary design, the parallel-concentric winding structure is selected to increase the current carrying capability and reduce the leakage inductance. Based on the parallel-concentric winding concept, a novel cooing and insulation structure with 3-D printed bobbins are proposed. The optimal designed MFT prototype achieves a power density higher than 19.23 kW/L. The electrical insulation system is tested at 12 kV ac peak voltage. In addition, the partial discharge (PD) test is conducted at 7.5 kV ac peak voltage to ensure the PD-free design. The high-frequency bipolar pulsewidth modulation voltage insulation (PD) test is the first time applied in MFT design and test process. Finally, the transformer is applied in a dual-active-bridge (DAB) converter with 200 kW rated power. The peak efficiency of the DAB converter is 99.53%, and the efficiency at 200 kW is 98.85%. The peak efficiency of MFT is 99.844%, and the efficiency at 200 kW is 99.842%.

42 ENGINEERING↗

DOE OSTI2023

Integrated electro-hydraulic machine

An integrated electromechanical and hydraulic system is disclosed which includes an electric machine, the electric machine includes a casing, a stator adapted to remain stationary within the casing, one or more electrically insulated windings coupled to the stator, a rotor separated from the stator and the one or more windings by a radial diamagnetic gap, electrical power couplings, and a first mechanical power couplings, and a hydraulic machine also disposed in the housing, the hydraulic machine having hydro-mechanical couplings as well as a second mechanical power couplings, wherein the second mechanical power couplings are coupled to the first mechanical power couplings.

Vacca, Andrea↗

DOE OSTI2022

Metal-like Charge Transport in PEDOT(OH) Films by Post-processing Side Chain Removal from a Soluble Precursor Polymer

Herein, a route to produce highly electrically conductive doped hydroxymethyl functionalized poly(3,4-ethylenedioxythiophene) (PEDOT) films, termed PEDOT(OH) with metal-like charge transport properties using a fully solution processable precursor polymer is reported. Further, this is achieved via an ester-functionalized PEDOT derivative [PEDOT(EHE)] that is soluble in a range of solvents with excellent film-forming ability. PEDOT(EHE) demonstrates moderate electrical conductivities of 20–60 S cm -1 and hopping-like (i.e., thermally activated) transport when doped with ferric tosylate (FeTos 3 ). Upon basic hydrolysis of PEDOT(EHE) films, the electrically insulative side chains are cleaved and washed from the polymer film, leaving a densified film of PEDOT(OH). These films, when optimally doped, reach electrical conductivities of ≈1200 S cm -1 and demonstrate metal-like (i.e., thermally deactivated and band-like) transport properties and high stability at comparable doping levels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

From an antiferromagnetic insulator to a strongly correlated metal in square-lattice MCl 2 (pyrazine) 2 coordination solids

Electronic synergy between metal ions and organic linkers is a key to engineering molecule-based materials with a high electrical conductivity and, ultimately, metallicity. To enhance conductivity in metal-organic solids, chemists aim to bring the electrochemical potentials of the constituent metal ions and bridging organic ligands closer in a quest to obtain metal- d and ligand- π admixed frontier bands. Herein, we demonstrate the critical role of the metal ion in tuning the electronic ground state of such materials. While VCl 2 (pyrazine) 2 is an electrical insulator, TiCl 2 (pyrazine) 2 displays the highest room-temperature electronic conductivity (5.3 S cm –1 ) for any metal-organic solid involving octahedrally coordinated metal ions. Notably, TiCl 2 (pyrazine) 2 exhibits Pauli paramagnetism consistent with the specific heat, supporting the existence of a Fermi liquid state (i.e., a correlated metal). This result widens perspectives for designing molecule-based systems with strong metal-ligand covalency and electronic correlations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Direct in situ measurements of electrical properties of solid–electrolyte interphase on lithium metal anodes

The solid–electrolyte interphase (SEI) critically governs the performance of rechargeable batteries. An ideal SEI is expected to be electrically insulative to prevent persistently parasitic reactions between the electrode and the electrolyte and ionically conductive to facilitate Faradaic reactions of the electrode. However, the true nature of the electrical properties of the SEI remains hitherto unclear due to the lack of a direct characterization method. Here we use in situ bias transmission electron microscopy to directly measure the electrical properties of SEIs formed on copper and lithium substrates. We reveal that SEIs show a voltage-dependent differential conductance. A higher rate of differential conductance induces a thicker SEI with an intricate topographic feature, leading to an inferior Coulombic efficiency and cycling stability in Li||Cu and Li||LiNi 0.8 Mn 0.1 Co 0.1 O 2 cells. Further, our work provides insight into the targeted design of the SEI with desired characteristics towards better battery performance.

25 ENERGY STORAGE↗

DOE OSTI2020

Advanced Power Electronics Designs - Reliability and Prognostics (Keystone Project 1)

The primary deliverable for this project will be to construct a power electronics package utilizing an organic electrically insulating substrate material with a direct chip-to-chip interconnect technology and demonstrate superior thermal performance and greater reliability under thermal cycling, thermal aging, vibration, power cycling, and electrical high-potential evaluation over traditional packages.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Advanced Power Electronics Designs - Reliability and Prognostics (Keystone Project 1)

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Advanced Power Electronics Designs - Reliability and Prognostics (Keystone Project 1)

ADVANCED PROPULSION SYSTEMS,ENGINEERING↗

DOE OSTI2023

Electrical Interrogation of Thickness‐Dependent Multiferroic Phase Transitions in the 2D Antiferromagnetic Semiconductor NiI 2

Abstract 2D magnetic materials hold promise for quantum and spintronic applications. 2D antiferromagnetic materials are of particular interest due to their relative insensitivity to external magnetic fields and higher switching speeds compared to 2D ferromagnets. However, their lack of macroscopic magnetization impedes detection and control of antiferromagnetic order, thus motivating magneto‐electrical measurements for these purposes. Additionally, many 2D magnetic materials are ambient‐reactive and electrically insulating or highly resistive below their magnetic ordering temperatures, which imposes severe constraints on electronic device fabrication and characterization. Herein, these issues are overcome via a fabrication protocol that achieves electrically conductive devices from the ambient‐reactive 2D antiferromagnetic semiconductor NiI 2 . The resulting gate‐tunable transistors show band‐like electronic transport below the antiferromagnetic and multiferroic transition temperatures of NiI 2 , revealing a Hall mobility of 15 cm 2 V −1 s −1 at 1.7 K. These devices also allow direct electrical probing of the thickness‐dependent multiferroic phase transition temperature of NiI 2 from 59 K (bulk) to 28 K (monolayer).

2D magnets↗

DOE OSTI2025

Numerical investigation of two-dimensional buoyancy-driven eddies in liquid metal magnetohydrodynamic flows in breeding blankets *

Abstract Lead–lithium flows are key features in the design of tokamak breeding blanket concepts such as the dual-coolant lead–lithium (DCLL). Since they flow under magnetic fields, they are affected by magnetohydrodynamic (MHD) effects. The neutron flux originating in the tokamak plasma heats the breeding blanket channels in a non-uniform manner, inducing buoyancy forces in the liquid metal. Buoyancy may become a source of quasi-two-dimensional (Q2D) turbulence, and the appearance of eddies may affect the transport of heat and tritium across the blanket. Blankets characterized by high-speed liquid metal flows (such as DCLL) will need ceramic insulating walls to reduce the MHD-related pressure drop in the channels. In our simulations, we have used the Q2D model proposed by Sommeria and Moreau (SM82) which is especially suitable for modeling electrically insulating channel flows. On top of that, we have modelled buoyancy forces in the momentum equation using the Oberbeck–Boussinesq approximation. In this work, we include a validation of the implemented Q2D model in buoyancy-driven cases and identify a thermohydraulic configuration that promotes the generation of eddies and the accumulation of tritium. We also show the results provided by our post-processing tool based on the bi-dimensional fast Fourier transform for eddy detection and characterization. We complete our investigation by performing an initial assessment of how eddies can accumulate tritium in the breeding blanket. We conclude by discussing the relevance of preventing accumulation of tritium within the blanket and suggest a possible solution.

Suarez, Daniel (ORCID:0000000251740100)↗

DOE OSTI2022

Characterization of Candidate Insulation Resins for Training Reduction in High Energy Physics Magnets

Superconducting magnets are critical components in particle accelerators and are used to generate and sustain the large magnetic fields needed for High Energy Physics programs. One significant issue with current epoxy insulated Nb$_{3}$Sn magnets is the long training process required before stable magnet performance can be realized. It is believed that training can be significantly reduced by addressing magnet quenching through improvements in the epoxy electrical insulation. In this work, two approaches for insulation modification have been undertaken: (1) addition of thermally conductive fillers to help with quench management and (2) development of insulation resins with high strain capability at cryogenic temperatures. This paper will discuss the characterization of these insulation systems to verify their performance prior to evaluation in subscale Nb$_{3}$Sn canted cosine theta accelerator dipole magnets.

43 PARTICLE ACCELERATORS↗