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DOE OSTI2024

Robust Solar Receivers Using MAX Phase Materials

This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Room-Temperature Pseudo-Solid-State Iron Fluoride Conversion Battery with High Ionic Conductivity

Li-metal batteries (LMBs) employing conversion cathode materials (e.g., FeF 3 ) are a promising way to prepare inexpensive, environmentally friendly batteries with high energy density. Pseudo-solid-state ionogel separators harness the energy density and safety advantages of solid-state LMBs, while alleviating key drawbacks (e.g., poor ionic conductivity and high interfacial resistance). In this work, a pseudo-solid-state conversion battery (Li-FeF 3 ) is presented that achieves stable, high rate (1.0 mA cm –2 ) cycling at room temperature. The batteries described herein contain gel-infiltrated FeF 3 cathodes prepared by exchanging the ionic liquid in a polymer ionogel with a localized high-concentration electrolyte (LHCE). The LHCE gel merges the benefits of a flexible separator (e.g., adaptation to conversion-related volume changes) with the excellent chemical stability and high ionic conductivity (~2 mS cm –1 at 25 °C) of an LHCE. The latter property is in contrast to previous solid-state iron fluoride batteries, where poor ionic conductivities necessitated elevated temperatures to realize practical power levels. Importantly, the stable, room-temperature Li-FeF 3 cycling performance obtained with the LHCE gel at high current densities paves the way for exploring a range of architectures including flexible, three-dimensional, and custom shape batteries.

25 ENERGY STORAGE↗

DOE OSTI2023

Development of Binder Jet Compatible Silicon Carbide Mixtures for Increased Sintered Density

Binder jet additive manufacturing can process a variety of ceramic powder feedstocks to manufacture near net shape green parts that are subsequently sintered to achieve densification. In particular, silicon carbide (SiC) is a promising ceramic material for heat exchangers in energy storage applications and binder jet is a well-suited process for manufacturing these heat exchangers due to the often geometrically complex designs. However, the need for good powder flowability in binder jet printing often limits the feedstock powder to be larger particles rather than that of ultra fine submicron powders used in conventional ceramic processing, which are more readily densified during sintering. The present work explores the use of various powder mixtures and sintering settings to identify strategies for achieving high density sintered parts in binder jet compatible systems without the use of infiltration. Liquid-phase sintering additives and bimodal powder mixtures are explored alongside different sintering temperatures, rates, atmospheres, and hold times. Two mixtures were found to be good candidates for further exploration: 1) 90 wt% 0.6 µm SiC + 6.25 wt% Al 2 O 3 + 3.75 wt% Y 2 O 3 mixture achieved the highest sintered relative density of 91.2%; and 2) a bimodal mixture comprised of 45 wt% 10 µm SiC + 45 wt% 0.6 µm SiC + 6.25 wt% Al 2 O 3 + 3.75 wt% Y 2 O 3 had the best powder flowability of the powders measured and a 75.1% sintered relative density.

25 ENERGY STORAGE↗

DOE OSTI2023

Vadose Zone Soil Flushing for Chromium Remediation: A Laboratory Investigation to Support Field‐scale Application

Cr(VI) flushing from the vadose zone to the groundwater (with subsequent Cr(VI) removal in groundwater by pump-and-treat system) is a promising remedial technique that has recently been used at field scale. This laboratory study was conducted to provide the technical basis to design a field soil flushing strategy. The objectives were to (1) quantify the relationship between sediment Cr(VI) and Cr(III) mass and release rates and subsequent Cr(VI) leaching; (2) investigate different methodologies to maximize Cr(VI) leaching, and (3) investigate methods to minimize leaching of remaining residual Cr. Characterization of Cr-contaminated sediments (Hanford Site, WA) exhibited Cr(VI) showed that leach rates that were correlated to different Cr surface phases. Sediments with low leachable Cr(VI) (<2 μg/g) leached Cr rapidly, so slow infiltration of water in a single pulse was sufficient to leach most Cr. In contrast, sediments with high Cr (2 to 200 μg/g) released some Cr(VI) quickly but 10 to 50% Cr(VI) slowly (tens to hundreds of hours). Efficient unsaturated leaching of these sediments required a different infiltration strategy that includes: multiple slow leach pulses with time between flushing cycles; the use of a surfactant to increase Cr leaching from low-permeability zones, and the use of a reductant (Na-dithionite or Ca-polysulfide) in the final leach water was highly effective at decreasing residual Cr leaching. This study clearly demonstrated that the methodology of basing laboratory Cr flushing on parameters such as Cr release mass and rates could be used to improve the efficiency of soil flushing at field scale.

Accelerated Cr Flushing↗

DOE OSTI2025

Viewing is understanding: Graphite microstructure effects on infiltrated molten salt distribution revealed by 3D neutron tomography

Molten salt infiltration in the pore network of nuclear graphite may cause unwanted changes to graphite's local structure and mechanical and thermal properties. A detailed and comprehensive understanding of molten salt intrusion (distribution across sample cross section and penetration depth) is needed to assess its effects. Here, in this work, we report on an improved methodology for the use of neutron imaging (computed tomography) to evaluate salt penetration and distribution of a wide range of graphite grades with diverse microstructures. Neutron tomography data were acquired on the same graphite sample before and after salt intrusion; the 3D reconstructed volumes were digitally co-registered and subtracted. The difference in neutron attenuation coefficient represents direct visualization of FLiNaK (LiF–NaF–KF) salt distribution in the salt-impregnated graphite samples. This improved methodology was applied to investigate the effect of exposure times (12 h and 336 h) and of graphite microstructure when exposed to FLiNaK at 750 °C and 3 bar (gauge) pressure, starting from flowing argon at near atmospheric pressure. The results show that medium-grained and fine-grained graphites evolve to equilibrium at significantly different rates: fast salt uptake in medium-grained graphites produces salt deposits throughout the volume of graphite specimens, whereas salt infiltration in fine-grained graphites is much slower and limited to exposed surfaces.

FLiNaK infiltration↗

DOE OSTI2024

Designing Particle Morphologies for Materials with Solid Transport Limitations: A Case Study of Lithium and Manganese Rich Cathode Oxides

A lithium and manganese rich nickel-manganese-cobalt oxide (LMR-NMC) cathode is a promising candidate for next-generation batteries due to its high specific capacity, low cost, and low cobalt content. However, the material suffers from poor rate capability due to the diffusion limitations of lithium in the cathode particles. Understanding the material performance requires careful control of the morphology of the cathode particles, taking into account the primary and agglomerated diffusion pathways and the presence of pores, some of which could be closed from electrolyte infiltration. Here, in this study, we use a microstructure-based mathematical model combined with experimental data to understand the role of the complex cathode particle morphology in the rate performance of the material. Scanning electron microscopy images of cathodes made under different synthesis conditions, which results in different agglomerate morphologies, serve as the input into the mathematical model. The model is then compared to rate data to understand the controlling parameters. The presence of intra-agglomerate closed pores results in a large agglomerate diffusion length in comparison to the ideal condition, where the primary particles are agglomerated in an open and dispersed manner such that the entire interfacial area is available for electrochemical reaction. Smaller primary and agglomerate diffusion lengths result in better electrochemical performance. This points us toward designing the morphology of the cathode particles to compensate for the diffusion limitation of LMR-NMC while maximizing the density.

Tewari, Deepti↗

DOE OSTI2023

Optimization of metal-supported solid oxide electrolysis cells with infiltrated catalysts

We report metal-supported solid oxide electrolysis cells (MS-SOECs) are being developed for steam-to-hydrogen electrolysis, especially for utilization of dynamic or intermittent electrical power from renewable sources. Various aspects of the electrocatalyst processing and composition, and metal support structure were explored. Catalyst materials, infiltration temperature and infiltration cycles were optimized for high performance and durability. Numerous catalyst materials were screened for both oxygen and steam electrodes. The oxygen catalyst had moderate impact on both initial cell performance and durability. Reducing Ni content in the steam electrode had little effect on durability, but reduced initial performance. Ex-situ XRD analysis and cell assessment of catalyst infiltration temperature revealed that the optimal range is 750–850 °C. The best cell performance and durability was achieved with LSCF-SDC oxygen electrocatalyst and SDC-Ni (60:40 vol%) steam electrocatalyst infiltrated 11 times at 800 °C and operated at 700 °C. At low steam content, a significant mass transport limitation on the steam side results in limiting current behavior. Thinner and more porous metal supports were implemented, and found to improve steam mass transport at low steam content, relevant for SOECs operating under high H 2 recycle rate or high steam utilization.

08 HYDROGEN↗

NASA NTRSDate not supplied

Neurovascular Responses to Simulated Deep Space Radiation in a Human Organ-on-a-Chip Model

A major health risk for human deep space exploration is central nervous system (CNS) damage by galactic cosmic ray radiation. Simulated galactic cosmic rays or their components, especially the high-linear energy transfer (LET) particles such as 56Fe ions, have been shown to cause CNS damage, neuroinflammation and cognitive dysfunction in rodent models, but their effects on human CNS remain to be investigated. CNS damage from any insult, including ionizing radiation, is partially mediated by the blood-brain barrier (BBB), which regulates interactions between CNS and the rest of the body. The main cellular regulators of BBB permeability are astrocytes, which also modulate neuroinflammation. However, there have been few studies on BBB and astrocyte functions in regulating CNS responses, especially in human tissue analogs. Therefore, we utilized a high-throughput 3D organ-on-a-chip system, seeded with human induced pluripotent stem cell-derived astrocytes and brain endothelial cells, or brain endothelial cells alone, to study human neurovascular responses to simulated deep space radiation. We investigated the permeability and morphology of vascular structures formed by endothelial cells, as well as oxidative stress and secreted cytokines and chemokine levels over 1-7 days after irradiation with 0.25 – 0.5 Gy 5-ion simplified simulated galactic cosmic rays or 0.3 – 0.8 Gy high-LET 600 MeV/n 56Fe particles, and compared the outcomes to low-LET X-ray irradiation. We observed that simulated deep space radiation caused delayed astrocyte activation in a pattern resembling CNS responses to brain injury, caused oxidative stress and the production of inflammatory cytokines, and compromised BBB integrity by damaging tight junctions, thus increasing vascular permeability. Furthermore, our results indicate that astrocytes have a dual role in regulating radiation responses: they exacerbate blood-brain barrier permeability early after irradiation, followed by switching to a more protective scar-like phenotype by reducing oxidative stress and pro-inflammatory cytokine and chemokine secretion. In a follow-up study using the same platform, we investigated the dose-rate effects of ionizing radiation, by exposing our model to chronic, low dose-rate, gamma radiation. Our model was significantly improved by adding additional cell types composing the BBB, modelling immune cell infiltration into the brain, and studying the effect of an antioxidant, to measure more complex outcomes and model more closely the effect of deep space radiation on the human BBB. In summary, our results present a human neurovascular model for space radiation studies and potential future automated payload adaptation, and suggest astrocyte regulatory mechanisms as targets for countermeasures to mitigate human neurovascular impairments during deep space exploration.

Ionizing radiation↗

DOE OSTI2024

SPRUCE Xylem Native Embolism and Leaf Traits of Picea mariana and Larix laricina, 2019

This data set contains measurements of native embolism in branch xylem and associated branch and leaf traits from Picea mariana (Black Spruce) and Larix laricina (Tamarack) from September-October 2019 at the SPRUCE experiment (Hanson et al. 2017). Data are presented in one comma-separated (*.csv) file. Native embolism, a measurement of in-situ embolism in the xylem tissue that blocks water movement, measurements were conducted at the end of the growing season on cut branches using the hydraulic pipette method (see Peters et al. 2023 for full method). In short, branch segments were connected to hydraulic apprentice and flow rates of perfusion liquid were measured using graduated pipettes and stopwatch. After initial conductance measurements, branch segments were flushed using vacuum infiltration and hydraulic conductance was remeasured to calculate the percent loss in conductance due to embolism (PLC). Three branch segments (distal, middle, and proximal) were measured from each branch representing different diameters size classes. This dataset also contains leaf area associated with each measured branch segment, calculate leaf mass per area (LMA), sapwood specific conductivity (Ks), leaf area specific conductivity (Kl) and the sapwood area to leaf area ratio (Huber value). Measurements were made on mature trees from all ten treatment enclosures. One branch from each of five trees per species were used from each enclosure where available. Some plots do not contain five individual Larix laricina, in which case all available trees were sampled. All measurements were conducted in late September/early October 2019, at the end of growing season but before Larix laricina needle senescence. There are 10 experimental plots at SPRUCE: five temperature treatments (+0, +2.25, +4.5, +6.75, +9°C) at ambient CO2, and the same five temperature treatments at elevated CO2 (+500 ppm). These data were collected after the treatments had been running in full for three years, meaning much of the material measured was grown under treatment conditions.

Huber value↗

NASA NTRS1967

Plasma jet electrode has longer operating life

Water-cooled, silver-infiltrated tungsten electrode has twice the operating lifetime of the pure tungsten electrode used in plasma jet generators. This electrode reduces the erosion rate, ensures excellent heat transfer, and reduces thermal stresses.

Gracey, C. M.↗

NASA NTRS2000

Method for Fabricating Composite Structures Using Pultrusion Processing

A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electronbeam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Farley, Gary L.↗

NASA NTRS1993

TiC growth in C fiber/Ti alloy composites during liquid infiltration

A cylindrical model is developed for predicting the reaction zone thickness of carbon fiber-reinforced Ti-matrix composites, and good agreement is obtained between its predicted values and experimental results. The reaction-rate constant for TiC formation is estimated to be 1.5 x 10 exp -9 sq cm/sec. The model is extended to evaluate the relationship between C-coating thicknesses on SiC fibers and processing times.

Warrier, S. G.↗

DOE OSTI2024

Electrical Resistivity Tomography Monitoring of In Situ Soil Flushing at the Hanford 100-K East Area: 100KE Soil Flushing Monitoring

Former operations in the 100-KE Area at the Hanford Site resulted in vadose zone hexavalent chromium that provides a source of groundwater contamination. Previous efforts to remediate vadose zone chromium involved excavation and offsite treatment of contaminated soils. Although much of the chromium was removed, contamination still exists in native soil between the water table and the bottom of the pit, which has since been backfilled. In-situ soil flushing was tested at the 100-KE Area to accelerate the removal of the remaining hexavalent chromium in the vadose zone. Soil flushing works by applying clean flush water at the surface, which mobilizes and transports chromium as it migrates downward to the water table. Once the chromium reaches the water table, it is hydraulically contained, extracted, and treated through pump and treat operations. The efficacy of soil flushing is directly related to the volume of clean water that infiltrates through contaminated soils. Therefore, performance monitoring requires and understanding of flush water migration through the vadose zone. It is challenging to comprehensively assess soil flushing performance via borehole access due to the limited volume of investigation afforded by a given wellbore. As an alternative, 3D time-lapse electrical resistivity tomography (ERT) was tested as a method of monitoring the distribution of flush water over time within the vadose zone. ERT is a method of imaging the bulk electrical conductivity of the subsurface, which is highly dependent on water saturation levels in unconsolidated and unsaturated sediments. Thus, the timing and location of changes in bulk conductivity caused by soil flushing can be used to infer flush water migration pathways. In this report we present results of 3D time-lapse ERT imaging during two separate soil flushing campaigns conducted during the spring and summer months of 2022 and 2023. Results show generally that: 1) Pit backfill materials appear to nominally have larger permeability than native soils. Consequently, the boundary between pit backfill and native soil had a significant impact on flush water migration, causing some flush water to migrate along the pit boundary to the bottom of the pit. 2) Non-uniform flows, likely caused by variations in hydrogeologic properties, developed in the pit backfill materials, resulting in uneven flush water distribution on the southern margin of the soil flushing zone. 3) Redistribution of water at the interface between backfill materials and Hanford formation materials likely facilitated elevated and uniform distribution of flush water within native soils beneath the deeper parts of the pit boundary beneath the center of the flush zone, which presumably overlie soils with elevated chromium contamination. These areas appear to have been infiltrated by higher volumes of flush water than the northern and southern margins of the flush zone. 4) In comparison to 2022, high flush water application rates significantly improved flush water distribution throughout the target flushing zone. 5) Imaging resolution was limited to a depth of approximate 20 meters below the land surface, due primarily to limitations on the lateral extent of the surface ERT array. The ~10 m region of the vadose zone between approximately 130 meters elevation and the water table at approximately 120 meters elevation was unresolved.

100 Area↗

NASA NTRS2024

Interim Measures Work Plan: South Repeater Building: Solid Waste Management Unit 121: Hydraulic Containment and Groundwater Treatment System for Per- and Polyfluoroalkyl Substances: Kennedy Space Center, Florida

This document presents the design details of a granular activated carbon (GAC) hydraulic containment and groundwater treatment system Interim Measures Work Plan for the South Repeater Building site (South Repeater, Solid Waste Management Unit 121), located at John F. Kennedy Space Center (KSC), Florida. The interim measures (IM) treatment area includes the source area and downgradient property boundary, which have been impacted by per- and polyfluoroalkyl substances (PFAS). The objectives of the IM are to treat the source area and mitigate PFAS migration to areas outside of KSC boundaries. This document was prepared by AECOM Technical Services, Inc., for the National Aeronautics and Space Administration under Contract 80KSC019D0010, Task Order 80KSC021F0096. The IM consists of the installation and operation of 19 extraction wells and an associated groundwater treatment system. A total of 13 wells will be installed to a depth of 34 feet below land surface (bls) to target the upper medium-grained sand with shell layer. A total of six wells will be installed to a depth of 56 feet bls to target the lower layer of poorly graded sand with shell fragments. The system will be designed to operate each extraction well simultaneously using submersible pumps at flow rates of 5 or 10 gallons per minute (gpm), excluding one extraction well with a flow rate of 30 gpm. The extracted groundwater will be conveyed to a groundwater treatment system, where it will be treated via GAC prior to disposal via infiltration. To evaluate treatment system performance, baseline groundwater sampling will be conducted prior to treatment system startup. Performance monitoring will be completed quarterly for the first year. A total of eight performance monitoring wells will be installed to a depth of 12 feet bls, and eight performance monitoring wells will be installed to a depth of 30 feet bls. In addition to the installation of 16 performance monitoring wells, 12 existing monitoring wells will be incorporated into the performance monitoring program.

groundwater treatment↗

NASA NTRS1995

Method for Fabricating Composite Structures Including Continuous Press Forming and Pultrusion Processing

A method for fabricating composite structures at a low-cost, moderate-to-high production rate is disclosed. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply, and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform, and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length, and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Farley, Gary L.↗

NASA NTRS1997

Method for Fabricating Composite Structures Using Continuous Press Forming

A method for fabricating composite structures at a low-cost. moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates. resulting in lower cost and high structural performance.

Farley, Gary L.↗

NASA NTRS2000

Method for Fabricating Composite Structures Using Pultrusion Processing

A method for fabricating composite structures at a low-cost, moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Farley, Gary L.↗

DOE OSTI2022

Optimization of metal-supported solid oxide fuel cells with a focus on mass transport

Performance of symmetric-architecture metal-supported solid oxide fuel cells was improved significantly by optimizing the catalyst infiltration process and metal support structure. Optimization of component structure and processing parameters was performed during tape-casting and fabrication of button cells. Mass transport of oxygen in the metal support was identified as a major limitation. To overcome this limitation, pore former loading and thickness of the metal support (130–250 μm) were optimized. The catalyst infiltration process was also improved by studying the impact of firing temperature (400 °C–900 °C) and infiltration cycle numbers (1–15). The maximum power density of the optimized cell was 0.9 W cm –2 at 700°C using hydrogen as a fuel, a three-fold increase over the baseline cell performance. The degradation rate of optimized cells at 550 °C, 600 °C, and 700 °C was 2%, 4.5%, and 5.5% per 100 h, respectively. Here, the phenomena of mass transport, catalyst coarsening, and chromium poisoning on the catalyst were analyzed by electrochemical impedance spectroscopy and scanning electron microscopy.

13 HYDRO ENERGY↗