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Enhanced Performance of Li|LiFePO4 Cells Using CsPF6 as an Electrolyte Additive
The practical application of lithium (Li) metal anode in rechargeable Li batteries is hindered by both the growth of Li dendrites and the low Coulombic efficiency (CE) during repeated charge/discharge cycles. Recently, we have discovered that CsPF6 as an electrolyte additive can significantly suppress Li dendrite growth and lead to highly compacted and well aligned Li nanorod structure during Li deposition on copper substrates. In this paper, the effect of CsPF6 additive on the performance of rechargeable Li metal batteries with lithium iron phosphate (LFP) cathode was further studied. Li|LFP coin cells with CsPF6 additive in electrolytes show well protected Li anode surface, decreased resistance, enhanced rate capability and extended cycling stability. In Li|LFP cells, the electrolyte with CsPF6 additive shows excellent long-term cycling stability (at least 500 cycles) at a charge current density of 0.5 mA cm-2 without internal short circuit. At high charge current densities, the effect of CsPF6 additive becomes less significant. Future work needs to be done to protect Li metal anode, especially at high charge current densities and for long cycle life.
Evaluation of Dissolvable Additively Manufactured Molds and Supports for Electroimpacts Innovative Additive Manufacturing Process
Electroimpact inc. has developed a new additive manufacturing process involving continuous fiber reinforcement along with high-strength thermoplastics. A unique part of this process includes using additive manufacturing to print a base geometry that is then used as a tool for continuous fiber placement. Ideally the tool should be disposable and cost effective. After printing the base tool, continuous fiber is printed on top of the tool using a secondary additive head on the same system to create the final printed part. After continuous fiber printing is completed, the tool is removed and disposed of to leave only the final desired structure. Materials used for the base tool have several requirements that must be met in order to complete this process. First, the material must be rigid and strong enough to support the loads from the secondary printing operation (continuous fiber printing). In addition, the material must be able to adhere to the secondary process material as well be capable of being removed such that the only remaining structure is continuous fiber composite. Using innovative soluble materials allows for parts to be produced through additive with molds that are produced as non-reusable one-off shapes and sizes.
Methods and apparatus for additively manufacturing structures using in situ formed additive manufacturing materials
A method of additively manufacturing a structure comprises nuclear reactor comprises disposing a feed material on a surface of a substrate in a reaction vessel, disposing at least one material formulated and configured to react with the feed material in the reaction vessel, and exposing the feed material and the at least one material to energy from an energy source to react the feed material and the at least one material to form an additive manufacturing material and reaction by-products. The additive manufacturing material is separated from the reaction by-products and exposed to energy from the energy source to form inter-granular bonds between particles of the additive manufacturing material and form a layer of a structure comprising the additive manufacturing material. Related apparatuses and methods are disclosed.
Energy and emissions saving potential of additive manufacturing: the case of lightweight aircraft components
Additive manufacturing (AM) holds great potential for improving materials efficiency, reducing life-cycle impacts, and enabling greater engineering functionality compared to conventional manufacturing (CM), and AM has been increasingly adopted by aircraft component manufacturers for lightweight, cost-effective designs. This study estimates the net changes in life-cycle primary energy and greenhouse gas emissions associated with AM technologies for lightweight metallic aircraft components through the year 2050, to shed light on the environmental benefits of a shift from CM to AM processes in the U.S. aircraft industry. A systems modeling framework is presented, with integrates engineering criteria, life-cycle environmental data, aircraft fleet stock and fuel use models under different AM adoption scenarios. Estimated fleet-wide life-cycle primary energy savings at most reach 70-173 million GJ/year in 2050, with cumulative savings of 1.2–2.8 billion GJ. Associated cumulative GHG emission reductions were estimated at 92.1–215.0 million metric tons. In addition, thousands of tons of aluminum, titanium and nickel alloys could be potentially saved per year in 2050. The results indicate a significant role of AM technologies in helping society meet its long-term energy use and GHG emissions reduction goals, and highlight barriers and opportunities for AM adoption for the aircraft industry.
Dimethylammonium Addition to Halide Perovskite Precursor Increases Vertical and Lateral Heterogeneit
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Heat Transfer Characteristics of Particle and Air Flow Through Additively Manufactured Lattice Frame Material Based on Octet-Shape Topology
Particle-to-supercritical carbon dioxide (sCO 2 ) heat exchanger is a critical component in next-generation concentrating solar power (CSP) plants. The inherently low heat transfer between falling particles and sCO 2 imposes a challenge toward economic justification of levelized cost of electricity produced through solar energy. Introduction of integrated porous media with the walls bounding particle flow has the potential to enhance the overall particle-to-sCO 2 heat exchanger performance. Here, this paper presents an experimental study on heat transfer characterization of additively manufactured lattice frame material based on Octet-shaped unit cell with particles and air as working fluids. The lattice structures were additively manufactured in stainless steel (SS) 316L and SS420 (with 40% bronze infiltration) via Binder jetting process, where the lattice porosities were varied between 0.75 and 0.9. The mean particle diameters were varied from 266 μm to 966 μm. The effective thermal conductivity and averaged heat transfer coefficient were determined through steady-state experiments. It was found that the presence of lattice enhances the effective thermal conductivity by 2–4 times when compared to packed bed of particles alone. Furthermore, for gravity-assisted particle flow through lattice panel, significantly high convective heat transfer coefficients ranging from 200 W/m2K to 400 W/m2K were obtained for the range of particle diameters tested. The superior thermal transport properties of Octet-shape-based lattice frame for particle flow makes it a very promising candidate for particle-to-sCO 2 heat exchanger for CSP application.
Simultaneous Stabilization of LiNi 0.76 Mn 0.14 Co 0.10 O 2 Cathode and Lithium Metal Anode by Lithium Bis(oxalato)borate as Additive
Abstract The long‐term cycling performance, rate capability, and voltage stability of lithium (Li) metal batteries with LiNi 0.76 Mn 0.14 Co 0.10 O 2 (NMC76) cathodes is greatly enhanced by lithium bis(oxalato)borate (LiBOB) additive in the LiPF 6 ‐based electrolyte. With 2 % LiBOB in the electrolyte, a Li∥NMC76 cell is able to achieve a high capacity retention of 96.8 % after 200 cycles at C/3 rate (1 C=200 mA g −1 ), which is the best result reported for a Ni‐rich NMC cathode coupled with Li metal anode. The significantly enhanced electrochemical performance can be ascribed to the stabilization of both the NMC76 cathode/electrolyte and Li‐metal‐anode/electrolyte interfaces. The LiBOB‐containing electrolyte not only facilitates the formation of a more compact solid–electrolyte interphase on the Li metal surface, it also forms a enhanced cathode electrolyte interface layer, which efficiently prevents the corrosion of the cathode interface and mitigates the formation of the disordered rock‐salt phase after cycling. The fundamental findings of this work highlight the importance of recognizing the dual effects of electrolyte additives in simultaneously stabilizing both cathode and anode interfaces, so as to enhance the long‐term cycle life of high‐energy‐density battery systems.
Heat Transfer Coefficients of Additively Manufactured Tubes with Internal Pin Fins for Supercritical Carbon Dioxide Cycle Recuperators
This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO 2 flowing in additively manufactured tubes with internal pin fins at the US DOE’s National Energy Technology Laboratory in Morgantown, WV. The measurement procedures were validated by conducting benchmark tests with smooth stainless-steel tube and comparing the results with published correlations for Nusselt number (Nu) and friction factor. Over Reynolds numbers (ReD) ranging from 5 × 10 4 to 2.5 × 10 5 , measured Nu was within 5% of the Dittus-Boelter correlation and measured friction factors were within 5% of the McAdams correlation for smooth tube flow. The candidate pin fin patterned pipes were additively manufactured (AM) at the Oak Ridge National Laboratory. The pins were circular or elliptical in cross-section and were printed at a 30⁰ angle relative to the inner wall (to meet AM constraints). The pin arrangement was helical to promote enhanced heat transfer due to swirl flow. Pin length to diameter aspect ratio was 1.33, 2, and 8, while the pin diameter to tube diameter ratio was 0.188, 0.125, and 0.063. Tests were performed for ReD varying from 6.9 × 10 4 to 2.2 × 10 5 and at conditions equivalent to the low pressure (LP) outlet (8.69 MPa, 361 K) and the high pressure (HP) inlet (20.7 MPa, 350 K) of the low temperature recuperator (LTR) in an indirect sCO 2 cycle. The Wilson plot technique was utilized to measure the bulk heat transfer coefficients. For the best performing design (tube A, pin length to tube diameter ratio: 1.33, pin diameter to tube diameter ratio: 0.19), the local heat transfer coefficient increased by 136% relative to the Dittus-Boelter correlation at the LTR low pressure outlet and 194% at the LTR high pressure inlet. These correspond to a 282% and a 271% increase in the product of the heat transfer coefficient and surface area (adjusted for fin efficiency) product, respectively. Large pressure drops across the test articles were observed. For Tube Design A, the average friction factor, across the range of ReD considered, was significantly larger than the McAdams correlation at both the LTR LP outlet and the LTR HP inlet. A thermal performance factor was utilized to express the ratio of material required to build a finned heat exchanger relative to a finless heat exchanger with the same heat duty and pumping power. Tube Design A was estimated to decrease the required heat exchanger material by 13%.
Additive Effect on the Electrochemical Performance of Lithium–Sulfur Battery
Lithium difluoro(oxalato) borate (LiDFOB) was investigated as an electrolyte additive for the Li-S battery. This additive was identified to be an efficient electrolyte additive to suppress the polysulfide shuttling effect existing in the conventional Li-S chemistry. To detect the positive impact of the new additive, oligo (ethylene glycol) functionalized silane was employed as the electrolyte solvent due to its high solvation capability with the lithium polysulfides. The electrochemical results and the SEM data of Li-S battery using the new electrolyte confirmed the role of the LiDFOB as a critical component to eliminate the shuttling of the dissolved polysulfides thus enabling a high coulombic efficiency. (C) 2014 Elsevier Ltd. All rights reserved.
Multifunctional Thiol-Containing Additives for Improved Photoluminescence and Photovoltaic Performance of Cs 0.15 FA 0.85 PbI 3 Perovskites
Thiol containing molecules as both interfacial surface ligands and additives are promising modulators for enhancing photoluminescence (PL) properties, stability, and photovoltaic (PV) performance of metal halide perovskites. However, alkanethiols are much more effective for improving photoluminescence (PL) intensity and stability in metal halide perovskite nanocrystals than in their thin film analogues. Herein, we investigate how additional functional groups on a pyrimidine core can alter thiol reactivity and influence the PL, stability, and PV performance of organic metal halide perovskites. Through an investigation of five different pyrimidine derivatives, it is shown that all derivatives containing thiol groups form thiolates in the presence of the perovskite precursors and increase the photoluminescence intensity of the perovskite film. The largest all-around improvement to the PL intensity, stability, and photovoltaic performance of Cs 0.15 FA 0.85 PbI 3 perovskites is realized through the addition of a hydroxyl group combined with a trifluoromethyl group to form 4-hydroxy-6-(trifluoromethyl)pyrimidine-2-thiol. Furthermore, this investigation helps illuminate how combinations of functional groups can be employed to further increase the beneficial effects over monofunctional additives in organic metal halide perovskites.
High-Power Lithium Metal Batteries Enabled by High-Concentration Acetonitrile-Based Electrolytes with Vinylene Carbonate Additive
To enable next-generation high power, high-energy-density lithium (Li) metal batteries (LMBs), an electrolyte possessing both high Li Coulombic efficiency (CE) at high-rate and good anodic stability on cathodes is critical. Acetonitrile (AN) is a well-known organic solvent for high anodic stability and high ionic conductivity, yet its application in LMBs is limited due to its poor compatibility with Li metal anode even at high salt concentration conditions. Here, we developed a highly concentrated AN-based electrolyte with vinylene carbonate (VC) additive to suppress Li+ depletion at high current densities. Addition of VC in the AN-based electrolyte leads to the formation of a polycarbonate-based solid electrolyte interphase which minimizes Li corrosion and leads to very high Li CE of up to 99.1% at a current density of 0.2 mA cm-2. Using such an electrolyte, fast charging of Li||NMC333 cells has been realized at a high current density of 3.6 mA cm-2, and stable cycling of Li||NMC622 cells with a high cathode loading of 4 mAh cm-2 has also been demonstrated.
Room Temperature Phase Transition in Methylammonium Lead Iodide Perovskite Thin Films Induced by Hydrohalic Acid Additives
Abstract Although reactive additives have been employed in perovskite solar cells to enhance film morphology and significantly increase device performance, little is known about the effect of these additives on perovskite structural and optical properties. Here we report a systematic study of how the properties of methylammonium lead iodide perovskite (CH 3 NH 3 PbI 3 ) are influenced by hydrohalic acid additives (HX; X=I, Br, Cl) in the precursor solution. Detailed structural and optical spectroscopic analysis reveals that all three acids affect the optical properties and alter the unit cell lattice parameters. Depending on the identity and concentration of HX, optical bandgaps widen or compress: addition of HBr yields a wider bandgap, whereas HI compresses the gap at high concentrations; HCl, on the other hand, has no significant effect on the bandgap. These changes can be understood by correlating them with the types of defects present in polycrystalline perovskite thin films in combination with the structural strain induced in very small crystallites. The presence of extra halides from HX in the precursor solution enables filling of the lattice vacancies in the perovskite, thereby altering metal–halogen–metal bond connectivity and consequently cell volumes and optical bandgaps. Remarkably, a room temperature tetragonal→cubic phase transition is observed for CH 3 NH 3 PbI 3 films treated with high HX concentrations. Further insights into this anomalous phase transformation are obtained from in situ variable‐temperature X‐ray diffraction in the 25–55 °C (298–328 K) range, revealing a monotonic fall in transition temperature with increasing precursor solution HX concentration.
Effect of hypoeutectic boron additions on the grain size and mechanical properties of Ti-6Al-4V manufactured with powder bed electron beam additive manufacturing
In additive manufacturing, microstructural control is feasible via processing parameter alteration. However, the window for parameter variation for certain materials, such as Ti-6Al-4V, is limited, and alternative methods must be employed to customize microstructures. Grain refinement and homogenization in cast titanium alloys has been demonstrated through the addition of hypoeutectic concentrations of boron. This work explores the influence of 0.00 wt.%, 0.25 wt.%, 0.50 wt.%, and 1.0 wt.% boron additions on the microstructure and bulk mechanical properties of Ti-6Al-4V samples fabricated in an Arcam A2 electron beam melting (EBM) system with commercial processing parameters for Ti-6Al-4V. Analyses of EBM fabricated Ti-6Al-4V + B indicate that the addition of 0.25–1.0 wt.% boron progressively refines the grain structure, and it improves hardness and elastic modulus. Furthermore, despite a reduction in size, the β grain structure remained columnar as a result of directional heat transfer during EBM fabrication.
Effects of pH on cell growth, lipid production and CO2 addition of microalgae Chlorella sorokiniana
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In-Situ Thermal Imaging for Single Layer Build Time Alteration in Large-Scale Polymer Additive Manufacturing
Ideally, objects are constructed as quickly as possible; however, short build times for a layer can present an issue. Short layer build times do not provide enough time for the material to cool sufficiently. As a result, an object cannot support its own weight nor deal with overhanging features. Additionally, the generation of support structures may be impractical either due to geometry or, in the case of large-scale polymer additive manufacturing, due to being difficult to remove. To address these issues, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated the use of a thermal camera mounted to a gantry to collect data on an object under construction. This data provided feedback for an in-situ control system to adjust layer build times. Adjustments were made in the form of additional waiting to allow the material to cool to specific thermal thresholds. This additional cooling time allowed the construction of objects with low layer build times or overhanging features that would have otherwise failed.
Instrumentation for In situ/Operando X-ray Scattering Studies of Polymer Additive Manufacturing Processes
With new opportunities and challenges from additive manufacturing (AM), novel characterization approaches are needed to realize reliable and industry-transferrable material systems and processes. The Complex Scattering Program at the National Synchrotron Light Source II (NSLS-II), a Department of Energy (DOE) Office of Science User Research Facility located at Brookhaven National Laboratory, has capabilities on three beamlines to support in situ and operando soft material additive manufacturing measurements. In this article, we describe some of the additive manufacturing capabilities that have been implemented on these beamlines, including in-line 3D printers for Continuous-flow Direct Writing (CDW), Fused Filament Fabrication (FFF) printing, and an instrument for Electrospray Deposition (ESD). We also describe a development program in autonomous experimentation that will be critical for addressing the complexity involved in optimizing additive manufacturing processes and materials.
Experimental and Numerical Investigation of a Miniature Additively Manufactured Vortex Tube
Ranque–Hilsch vortex tubes are simple devices that can produce a cooling effect using compressed air. A key advantage of vortex tubes is the lack of moving solid parts; however, their efficiencies are relatively low. The present study focuses on the development of a miniature variable-diameter tube using additive manufacturing. A metal-based 3D printing technique was utilized to fabricate this vortex tube monolithically. Computational fluid dynamics simulations employing software STAR-CCM + with a compressible Reynolds-Averaged Navier–Stokes (RANS) approach and the elliptic-blending lag k-epsilon turbulence model have been applied to model thermofluid processes inside the vortex tube, to good agreement with the experiment. In conclusion, a temperature decrease of 13.3 °C and a cooling power of approximately 4 W were experimentally achieved with a pressure ratio of 4 in the air at normal conditions. This result shows promise for the goal of utilizing additive manufacturing to design and build complex-geometry vortex tubes intended for use with cryogenic fluids.