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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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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

High Throughput Solvent-free Manufacturing of Battery Electrodes

The project goal is to develop and demonstrate an advanced solvent-free lithium-ion battery electrode process through proposed Advanced Dry Electrode Process (ADEP) equipment, which is expected to exhibit a better binder fibrillization and high throughput and suitable for high performance electrode manufacturing, and commonize the anode and cathode dry processing equipment, supply chain and operation for lithium-ion battery OEMs for replacing the solvent-based slurry casting. Our proposed approach will facilitate low-cost battery production by addressing the following gaps in present dry electrode processing: • Extend the dry electrode fabrication process to lithium-ion battery anode manufacturing • Increase the active material content for anodes and cathodes • Intensify the process through improved mixing, powder rheology and surface modifications • Enable processing of next-generation electrode materials that are not stable to solvent or ambient air exposure. The project objectives include the development of anode-compatible binder and binder fibrillization promoter for low irreversible capacity loss, low electrode binder content yet higher film mechanical strength, and the optimization of solvent-free anode and cathode process for low cost (>60% electrode cost reduction), high performance (10% increase in energy density without sacrificing cycle life) and high throughput to enable next generation lithium-ion battery electrode production. Solvent-free electrode manufacturing will also enable next-generation cell designs based on prelithiated anodes or solid-state electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2025

Spray Manufacturing Thermal Insulation Composites

Cellulose-based thermal insulation materials present significant potential for modern green building applications due to their inherent carbon sequestration properties. However, traditional manufacturing of composites often results in the limited thermal insulation performance and embodied carbon footprint due to an increased density from material shrinkage and higher energy consumption during the water-based slurry drying process. Here, we report solvent spraying coupled with dry powder feedstock to manufacture highly porous silica/straw insulation composites. The manufactured composite exhibits negligible shrinkage with the density of 0.08 g/cm 3 , thermal conductivity of 27.8 mW/(m·K), flexural modulus of 3.1 MPa, and compressive modulus of 0.89 MPa. Additionally, the prepared composite demonstrates fire retardancy (burning rate of 0.5 mm/min) and recyclability (99%). Furthermore, this solvent-spraying strategy opens up opportunities of energy-efficient insulation materials for carbon-sequestration building sectors.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Rare earth metals production using alternative feedstock that eliminates HF

This work reports the successful production of rare earth (RE) metal using Na-RE-F. Presently, RE metals are primarily produced using RE-fluoride due to its higher air and moisture stability compared to RE-chloride. However, its preparation requires the use of corrosive and hazardous chemicals, such as hydrofluoric acid (HF) or ammonium bifluoride (NH 4 HF 2 ). The present study demonstrates that Na-RE-F is an alternative salt to the typically used RE-fluoride. The Na-RE-F for this work is produced via a scalable hydrometallurgical approach using three different RE salts as feedstock, including acetate, nitrate, and chloride. HF is neither used nor generated during the salt preparation process. Furthermore, the Na-RE-F powder dries in air (without dry HF), and only water evolves during the drying process. Analyses of the Na-RE-F show that NaF liberates as a flux during the heating process, which lowers the salt reduction temperature to <900 °C, thus minimizing or eliminating the need for additional flux. Calciothermic reduction of the Na-RE-F salt is successfully employed to obtain RE metal. This work represents a safer, greener, and more widely deployable approach for producing the RE metals needed for permanent magnets which support the transition to a cleaner society through the decarbonization of the transportation industry.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Drying of strawberries with airborne ultrasound and other integrated dehydration mechanisms

This article presents a comprehensive investigation into the drying of strawberries using multiple dehydration methods with an emphasis on energy efficiency and sustainability. Initially, an airborne ultrasonic transducer with a frequency of 21 kHz was employed in batch operations to examine the effects of controlling parameters, including applied power, distance from the transducer plate, sample thickness, and sample holder type. The Energy Ratio, defined as the ratio of thermal energy required to evaporate moisture to ultrasonic energy, was observed to reach up to 2.2, particularly during the initial stages of drying. Subsequently, the Smart Dryer integrated airborne ultrasound (US) dehydration, slot jet reattachment (SJR) nozzle convective drying, infrared (IR) drying, and their combinations, enabling a systematic exploration of various drying conditions on the drying time and quality of strawberries. The integration of airborne US with SJR nozzles and IR drying demonstrates a promising approach for optimizing drying processes. This method not only preserves the quality of dried strawberries but also improves the energy factor to 0.88, reducing drying time by 89% compared with other conditions. Key quality attributes of the dried strawberries, such as color and water activity, were evaluated to understand the influence of each drying method. The findings highlight the potential of these integrated drying techniques as sustainable solutions for efficient and high-quality strawberry dehydration.

42 ENGINEERING↗
NASA NTRS1984

Crystal Microbalance Monitors Relative Humidity

Sensor monitors water evaporation in industrial drying processes. Measured adsorption isotherm for instrument essentially linear over entire range of relative humidity. Testing at each temperature setting less than half hour for full relative-humidity range, with estimated frequency response time less than 10 seconds. Used to measure relative humidity of ambient atmosphere near drying paper, food textile fabrics and pulp to optimize water-drying portion of processing cycle.

Yang, L. C.↗
DOE OSTI2025

Interface Engineering using Vapor Transport Deposited Perovskite Films for Solar Cells

The overarching goal of this project was to demonstrate the viability of vapor transport deposition (VTD) for the fabrication of efficient and stable metal-halide perovskite solar cells. VTD is a solvent-free alternative to conventional solution-processing of the light-absorbing, perovskite active layer. Since solution-processing frequently requires the use of toxic solvents, transition to a dry-processing approach has the potential to remove an obstacle to facile and economically meaningful commercialization. Further, VTD bears similarity to existing industrially-relevant processing approaches used for the production of thin-film CdTe solar modules, suggesting the potential for rapid adoption and transition to industry. The results described within this report offer design rules for the processing of metal-halide perovskites via VTD and new insights into the design of deposition systems to inform future applications.

14 SOLAR ENERGY↗
DOE OSTI2025

Influence of Water, Vacuum, and Temperature on Surface Conditions of a Zeolite‐based Molecular Sieve

Molecular sieves such as zeolite-based materials are ubiquitous in industrial separation processes. However, there is a significant gap in understanding the surface properties and adsorption mechanisms for commercial zeolites, as most research focuses on pure zeolite powders rather than industrially relevant forms. Here, this work addresses this gap in understanding by employing advanced characterization techniques, including positron annihilation spectroscopy, X-ray diffraction, scanning electron microscopy, X-ray fluorescence spectroscopy, X-ray photoelectron spectroscopy, liquid nitrogen sorption, and Fourier-transform infrared spectroscopy, to investigate the adsorption and desorption behavior of water in commercial zeolite 13X. Our research reveals insights into the pore-filling mechanisms, the impact of material binders on adsorption properties, and the dynamics of hydration and drying processes for zeolites. Monitoring changes on a minute scale allowed the distinction between fast and slow processes leading to sample drying. The identification of positronium bound to Na + ions indicated that water molecules remain in the vicinity of Na + ions after air-drying zeolite 13X. These findings highlight the importance of various environmental conditions in restoring zeolite properties to baseline after hydration, with significant implications for optimizing industrial processes. This work sets the direction for further research aimed at developing more efficient and robust separation techniques.

Beads Binder↗
DOE OSTI2024

Enhancing physicochemical, bioactive, and nutritional properties of sweet potatoes: Ultrasonic contact drying with slot jet nozzles compared to hot-air drying and freeze drying

Sweet potatoes are a rich source of nutrients and bioactive compounds, but their quality can be impacted by the drying process. This study investigates the impact of slot jet reattachment (SJR) nozzle and ultrasound (US) combined drying (SJR + US) on sweet potato quality, compared to freeze-drying (FD), SJR drying, and hot air drying (HAD). SJR + US drying at 50 °C closely resembled FD in enhancing quality attributes and outperformed HAD and SJR in key areas such as rehydration, shrinkage ratios, and nutritional composition. Notably, SJR + US at 50 °C produced the highest total starch (36.84 g/100 g), total dietary fiber (8.48 g/100 g), total phenolic content (158.19 mg GAE/100 g), total flavonoid content (119.08 mg QE/g), DPPH antioxidant activity (6.44 μmol TE/g), β-carotene (31.98 mg/100 g), and vitamin C (5.27 mg/100 g). It also exhibited higher glass transition temperatures (Tg: 14.49 °C), indicating better stability at room temperature. The hardness values for SJR + US samples were similar to FD, while HAD samples had the highest hardness. SJR + US at 50 °C resulted in the lowest total color changes (ΔE), indicating minimal impact on appearance. Additionally, FTIR analysis revealed that peaks in specific spectral regions indicated superior preservation of bioactive compounds in SJR + US samples compared to other methods, which was also confirmed by principal component analysis (PCA) and heatmap visualization. Overall, these findings suggest that SJR + US is an effective alternative to conventional drying techniques, significantly improving the quality of dried sweet potatoes.

Color↗
NASA NTRS2008

Improved Silica Aerogel Composite Materials

A family of aerogel-matrix composite materials having thermal-stability and mechanical- integrity properties better than those of neat aerogels has been developed. Aerogels are known to be excellent thermal- and acoustic-insulation materials because of their molecular-scale porosity, but heretofore, the use of aerogels has been inhibited by two factors: (1) Their brittleness makes processing and handling difficult. (2) They shrink during production and shrink more when heated to high temperatures during use. The shrinkage and the consequent cracking make it difficult to use them to encapsulate objects in thermal-insulation materials. The underlying concept of aerogel-matrix composites is not new; the novelty of the present family of materials lies in formulations and processes that result in superior properties, which include (1) much less shrinkage during a supercritical-drying process employed in producing a typical aerogel, (2) much less shrinkage during exposure to high temperatures, and (3) as a result of the reduction in shrinkage, much less or even no cracking.

Paik, Jong-Ah↗
DOE OSTI2024

Computational Methods for Multi-Physics Simulation of Melting in Steelmaking

Iron and steel production accounts for approximately 8% of global carbon dioxide (CO) emissions. Pathways to decarbonize include replacing fossil fuels in iron ore reduction and electrifying other steelmaking processes. Iron pellets produced by hydrogen, called Hydrogen Direct Reduced Iron (HDRI), have property differences from those produced using conventional DRI processes. These differences may impact melting in electric arc furnaces (EAF) and other downstream processes. The physical properties of iron pellets vary significantly with temperature during heating, complicating predictions of their behavior. In this project, we seek to develop an integrated simulation, including the fluid flow and convective thermal transport around the pellet particle. We also examine conduction and phase changes within the particle as they impact the melting process. We use adaptive mesh refinement (AMR) to resolve both the changing size of the particle and the complex physics of the interaction between the pellet and the surrounding fluid. We base our simulations on the AMReX-incflo module, which allows large-scale Navier-Stokes simulation while resolving the changing particle size during melting. As we advance our numerical tools, we anticipate an improved understanding of the dynamics of HDRI melting, which will, in turn, accelerate the adoption of low-carbon technologies in the steelmaking industry.

AMReX↗
DOE OSTI2025

Impact of processing humidity on ionomer film structure and performance in hydroxide exchange membrane electrolyzers

Hydroxide exchange membrane electrolyzers (HEMELs) enable hydrogen production using low-cost, earth-abundant materials. Improving electrode fabrication is integral to enhancing device performance, and ionomer-responsible for transporting hydroxide and mechanically supporting the catalyst-is a major component. Here, we use experiments and computation to study the effects of relative humidity (RH) during the drying process of poly(aryl piperidinium) ionomer films on HEMEL electrodes. Broadly, the drying environments determine the physical structure and electrochemical traits of the ionomer network. High RH drying yields a highly porous network with excessive water uptake, structural defects, washout, and 64% reduction in hydroxide conductivity. Extremely low RH drying produces an overly compact pore network that hinders hydroxide mobility. In contrast, moderately low RH drying (9% RH) creates an ionomer film with well-balanced traits: excellent mechanical stability and connectivity needed for catalyst retention and hydroxide transport, which improves HEMEL performance by 40% at 1.8 V compared to suboptimal RHs. This research advances HEMEL manufacturing by providing a simple, scalable, and low-cost approach to optimize electrode ionomer films.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Stability Enhancement of Polymeric Sensing Films Using Fillers

Experiments have shown the stability enhancement of polymeric sensing films on mixing the polymer with colloidal filler particles (submicron-sized) of carbon black, silver, titanium dioxide, and fumed silicon dioxide. The polymer films are candidates for potential use as sensing media in micro/nano chemical sensor devices. The need for stability enhancement of polymer sensing films arises because such films have been found to exhibit unpredictable changes in sensing activity over time, which could result in a possible failure of the sensor device. The changes in the physical properties of a polymer sensing film caused by the sorption of a target molecule can be measured by any of several established transduction techniques: electrochemical, optical, calorimetric, or piezoelectric, for example. The transduction technique used in the current polymer stability experiments is based on piezoelectric principles using a quartz-crystal microbalance (QCM). The surface of the QCM is coated with the polymer, and the mass uptake by the polymer film causes a change in the oscillating frequency of the quartz crystal. The polymer used for the current study is ethyl cellulose. The polymer/ polymer composite solutions were prepared in 1,3 dioxolane solvent. The filler concentration was fixed at 10 weight percent for the composites. The polymer or polymer composite solutions were cast on the quartz crystal having a fundamental frequency of about 6 MHz. The coated crystal was subjected to a multistage drying process to remove all measurable traces of the solvent. In each experiment, the frequency of oscillation was measured while the QCM was exposed to clean, dry, flowing air for about 30 minutes, then to air containing a known concentration of isopropanol for about 30 minutes, then again to clean dry air for about 30 minutes, and so forth. This cycle of measurements for varying isopropanol concentrations was repeated at intervals for several months. The figure depicts some of the sensing film stability results for ethyl cellulose polymer, ethyl cellulose-carbon black, and ethyl cellulose-silicon dioxide composite systems. An ethyl cellulose film exhibited a marked decline in response in the first few months of study and settled to a steady average response after about four months. However, response varied widely around the average response for ethyl cellulose film. In contrast, ethyl cellulose- carbon black and ethyl cellulose-silicon dioxide composites also declined in the early months, but showed more repeatable sensing film activity after the initial decline. Similar trends were observed in experiments for ethyl cellulose-titanium dioxide and ethyl cellulose-silver composites.

Lin, Brian↗
DOE OSTI2024

Impact of temperature and concentration on flow behaviour of reconstituted lactose and protein–rich dairy powders

To help with designing the drying process, this study investigated the flow behaviour of lactose and protein-rich reconstituted dairy powders at 25°C and 50°C. Lactose-rich samples, 50% dried whey (DW) and 60% whey protein concentrate (WPC35) did not follow the Herschel–Bulkley model because of presence of lactose crystals. Reconstituted 50% skim milk powder (SMP) and protein-rich dairy powders exhibited shear-thinning behaviour (n < 0.3). With increasing concentration, whey protein concentrate/isolate (WPC80/WPI) and micellar casein concentrate high-solid dispersions exhibited more shear-thinning behaviour (n < 0.4). Furthermore, understanding shear-thinning behaviour of lactose-rich and protein-rich reconstituted dairy powders will provide basis for optimising drying parameters.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Easy Meal

The woman pictured below is sitting down to a nutritious, easily-prepared meal similar to those consumed by Apollo astronauts. The appetizing dishes shown were created simply by adding water to the contents of a Mountain House* Easy Meal package of freeze dried food. The Easy Meal line is produced by Oregon Freeze Dry Foods, Inc., Albany, Oreaon, a pioneer in freeze drying technology and a company long associated with NASA in developing suitable preparations for use on manned spacecraft. Designed to provide nutritionally balanced, attractive hot meals for senior adults, Easy Meal is an offshoot of a 1975-77 demonstration project managed by Johnson Space Center and called Meal System for the Elderly. The project sought ways to help the estimated 3.5 million elderly Americans who are unable to take advantage of existing meal programs. Such services are provided by federal, state and local agencies, but they are not available to many who live in rural areas, or others who are handicapped, temporarily ill or homebound for other reasons. Oregon Freeze Dry Foods was a participant in that multi-agency cooperative project. With its Easy Meal assortment of convenience foods pictured above left, the company is making commercially available meal packages similar to those distributed in the Meal System for the Elderly program. In the freeze drying process, water is extracted from freshly-cooked foods by dehydration at very low temperatures, as low as 50 I degrees below zero. Flavor is locked in by packaging the dried food in pouches which block out moisture and oxygen, the principal causes of food deterioration; thus the food can be stored for long periods without refrigeration. Meals are reconstituted by adding hot or cold water, depending on the type of food, and they are table ready in five to 10 minutes. Oregon Freeze Dry Foods offers five different meal packages and plans to expand the line.

Source record↗
DOE OSTI2024

Hierarchical Biogenic-Based Thermal Insulation Foam

Biogenic-based foam, renowned for its sustainable and eco-friendly properties, is emerging as a promising thermal insulating material with the potential to significantly enhance energy efficiency and sustainability in building applications. However, its relatively high thermal conductivity, large-pore configurations, and energy-intensive manufacturing processes hinder its widespread use. Here, we report on the scalable, one-pot synthesis of biogenic foams achieved by integrating recycled paper pulp and in situ nanoporous silica formation, resulting in a hierarchical structure comprising both micropores and nanopores. Ambient solvent-exchange drying can preserve the pore structure by reducing the capillary forces during the drying process. The resulting flame-retardant and hydrophobic foam exhibits low density (0.110 g/cm 3 ), ideal porosity (70.69%), excellent thermal conductivity (0.033 W/(m·K)), and impressive compressive strength (1.48 MPa at 80% strain). Furthermore, this recyclable biogenic foam, with its hierarchical pore structure and environmental durability, shows great potential for energy-efficient building applications.

36 MATERIALS SCIENCE↗
NASA NTRS1989

Improved silicon carbide for advanced heat engines. I - Process development for injection molding

Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.

Whalen, Thomas J.↗
NASA NTRS1981

A unique approach to fabricating precision space structures elements

A procedure of fabricating graphite epoxy columns used in the assembly of large space platforms is described. The requirement for precise dimensional control led to a unique hot resin injection process. Dry, high modulus fiber is wound over a vertically mounted steam-heated mandrel. A steam-heated sleeve or caul is slipped over the wound mandrel and resin is injected and cured in place. Approximately 200 column elements have been fabricated using this efficient process.

Cohan, H.↗
NASA NTRS1979

High density circuit technology

Polyimide dielectric materials were acquired for comparative and evaluative studies in double layer metal processes. Preliminary experiments were performed. Also, the literature indicates that sputtered aluminum films may be successfully patterned using the left-off technique provided the substrate temperature remains low and the argon pressure in the chamber is relatively high at the time of sputtering. Vendors associated with dry processing equipment are identified. A literature search relative to future trends in VLSI fabrication techniques is described.

Wade, T. E.↗