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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
NASA NTRS1979

Dedicated nuclear facilities for electrolytic hydrogen production

An advanced technology, fully dedicated nuclear-electrolytic hydrogen production facility is presented. This plant will produce hydrogen and oxygen only and no electrical power will be generated for off-plant use. The conceptual design was based on hydrogen production to fill a pipeline at 1000 psi and a 3000 MW nuclear base, and the base-line facility nuclear-to-shaftpower and shaftpower-to-electricity subsystems, the water treatment subsystem, electricity-to-hydrogen subsystem, hydrogen compression, efficiency, and hydrogen production cost are discussed. The final conceptual design integrates a 3000 MWth high-temperature gas-cooled reactor operating at 980 C helium reactor-out temperature, direct dc electricity generation via acyclic generators, and high-current density, high-pressure electrolyzers based on the solid polymer electrolyte approach. All subsystems are close-coupled and optimally interfaced and pipeline hydrogen is produced at 1000 psi. Hydrogen costs were about half of the conventional nuclear electrolysis process.

Foh, S. E.↗
NASA NTRS1990

Effects of grain size and grain boundary on critical current density of high T(sub c) superconducting oxides

By means of adding impurity elements in high T sub c oxides, the effects were studied of grain size and grain boundary on the critical current density of the following systems: YBa2Cu3O(7-y) and Bi-Pr-Sr-Ca-Cu-O. In order to only change the microstructure instead of the superconductivity of the grains in the samples, the impurity elements were added into the systems in terms of the methods like this: (1) substituting Y with the lanthanide except Pr, Ce, and Tb in YBa2Cu3O(7-y) system to finning down grains in the samples, therefore, the effect can be investigated of the grain size on the critical current density of 1:2:3 compounds; (2) mixing the high T sub c oxides with the metal elements, such as Ag, according to the composition of (high T sub c oxide)1-xAgx to metallize the grain boundaries in the samples, studying the effect of the electric conductivity of the grain boundaries on the critical current density; (3) adding SiO2, PbO2, and SnO2 into the high T sub c oxide to form impurity phases in the grain boundaries, trying to find out the effects of the impurity phases or metalloid grain boundaries on the critical current density of the high T sub c superconductors. The experimental results indicate that in the case of of the presence of the metalloid grain boundaries finning down grains fails to enhance the j sub c, but restrains it strongly, the granular high T sub c superconductors with the small size grains coupled weakly is always the low j sub c system.

Zhao, Y.↗
DOE OSTI2024

Failure Process During Fast Charging of Lithium Metal Batteries with Weakly Solvating Fluoroether Electrolytes

While improving the lithium metal (Li) Coulombic efficiency has been a focus for electrolyte design, the performance under high current densities is less studied yet highly relevant for practical applications. Here, we evaluate the charge-rate-dependent cycling stability using three types of weakly solvating fluoroether electrolytes. Although good cycle life was achieved in all three electrolytes under low current densities, they all exhibited a soft shorting behavior above various threshold current densities (between 2 and 5.2 mA cm –2 ). In this study, we attributed the current-dependent electrode morphology to both Li growth and residual solid electrolyte interface (rSEI) growth processes. In early cycles, Li morphology guided the formation of rSEI structures. In later cycles, the rSEI structure partially impacted Li growth. Under low current densities, the rSEI was inhomogeneous with large voids for subsequent bulky lithium growth. Under high current densities, the rSEI became more dense, which aggravated the high-surface/volume-ratio Li growth through and on the top of the rSEI. Among the three weakly solvating fluoroether electrolytes, the ones with lower ionic conductivity were observed to short within fewer cycles and at lower charge current densities. Our work suggests that fast ion transport in electrolytes may be a desirable feature for the stable operation at >1C charging in high-energy-density lithium metal batteries.

25 ENERGY STORAGE↗
NASA NTRS1989

Characteristic parameters of superconductor-coolant interaction including high Tc current density limits

In the area of basic mechanisms of helium heat transfer and related influence on super-conducting magnet stability, thermal boundary conditions are important constraints. Characteristic lengths are considered along with other parameters of the superconducting composite-coolant system. Based on helium temperature range developments, limiting critical current densities are assessed at low fields for high transition temperature superconductors.

Frederking, T. H. K.↗
DOE OSTI2024

Interpenetrating 3D Electrodes for High-Rate Alkaline Water Splitting

Mass transfer is critical for the reaction kinetics and efficiency of alkaline water splitting (AWS). For AWS to operate at high current densities (hundreds of mA/cm 2 ), the device architecture must ensure a large catalytic surface area, rapid ion diffusion, and minimal solution and charge transfer resistances. Effective electrodes should also facilitate gas bubble detachment and release. 3D-printed electrodes have shown promise, but stacking them increases the ion diffusion length and solution resistance. Here we demonstrate a new device architecture with interpenetrating gyroid electrodes, providing a large ion-accessible surface area and gas diffusion channels. This design significantly reduces the interelectrode distance, lowering ion diffusion length and solution resistance. Simulations show faster ion diffusion and higher current density in the interpenetrating configuration compared with separate electrodes. This improved performance, especially at low temperatures and high current densities, highlights a promising strategy for enhancing AWS and other electrochemical systems limited by slow ion diffusion.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Surface-Treated Composite Polymer as a Stable Artificial Solid Electrolyte Interphase Layer for Lithium Metal Anodes

Lithium (Li) metal batteries (LMBs) are one of the most promising high energy density batteries to meet the demands of electric transportation. However, the practical applications of LMBs are hindered by short cycle life and safety concern, mainly associated with side reactions between Li metal anode and liquid electrolyte and the growth of Li dendrites during cycling. In this study, we develop a stable artificial solid electrolyte interphase (aSEI), which consists of a surface-treated (S T ) PEO–Li 6.4 Ga 0.2 La 3 Zr 2 O 12 composite polymer coating layer (CPL) on Li metal anode. The developed aSEI is stable against selected electrolyte and enables a uniform electrodeposition of Li. Therefore, S T CPL@Li||LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cells exhibit improved cycling stability compared with bare Li||NMC811 cells at moderate to high current densities. Notably, using a 50 µm thick Li and a practical NMC811 cathode (~4.8 mAh cm -2 ), a capacity retention of 85% is obtained for S T CPL@Li||NMC811 cells at a current density of 2.4 mAcm -2 after 300 cycles compared with 24% for bare Li||NMC811 cells. Furthermore, S T CPL@Li||NMC811 cells demonstrate higher capacities at charge current densities of 2.4, 4.8 and 7.2 mAcm -2 compared with bare Li||NMC811 cells. Further, these findings suggest that S T CPL is promising for high current density practical LMBs.

25 ENERGY STORAGE↗
DOE OSTI2025

Effect of Electro-Sprayed Porous Electrodes on the Performance and Stability of Water Electrolysis

The efficiency of proton exchange membrane water electrolysis (PEMWE) is a critical issue in realizing the production of green hydrogen. Here, the coexistence of three phases in the catalyst layer of PEMWE causes the mass transport limitation at the interfaces between them. In particular, the vigorous production of gaseous hydrogen and oxygen derived from liquid water is generated in the form of bubbles that seriously deactivate the membrane-electrode assembly (MEA). In this study, we investigated the effect of porous structure in the electrode on the efficiency of hydrogen production at high current density, which is highly related to the mass transport limitation. A widely used commercial catalyst (IrO 2 ) were directly coated on the membrane by the electro-spray method. The porous electrodes on the membrane were formed by the charged catalyst particles that repulsed each other due to the electrostatic forces of the particles. Our membrane electrode assembly (MEA) exhibited outstanding electrolysis performances such as 5.3 A cm -2 and 3.2 A cm -2 at 2.0 V and 1.8 V, respectively, which are the highest values compared with the results published in the current studies. In addition to the porosity, it was confirmed that optimum binder contents positively affect the hydrophobicity and contact resistance of MEA. Through a simple porosity-controlled technique, the performance of PEMWE, in which three phases coexist, can be improved by more than 60 %. Accordingly, we expect that our systematic study on the role of porosity in the electrodes opens a new era to efficiently produce green hydrogen.

catalysts↗
NASA NTRS1991

Reduction in bearing size due to superconductors in magnetic bearings

A design concept that reduces the size of magnetic bearings is assessed. The small size will enable magnetic bearings to fit into limited available bearing volume of cryogenic machinery. The design concept, called SUPERC, uses (high Tc) superconductors or high-purity aluminum conductors in windings instead of copper. The relatively high-current density of these conductors reduces the slot radial thickness for windings, which reduces the size of the bearings. MTI developed a sizing program called SUPERC that translates the high-current density of these conductors into smaller sized bearings. This program was used to size a superconducting bearing to carry a 500 lb. load. The sizes of magnetic bearings needed by various design concepts are as follows: SUPERC design concept = 3.75 in.; magnet-bias design concept = 5.25 in.; and all electromagnet design concept = 7.0 in. These results indicate that the SUPERC design concept can significantly reduce the size of the bearing. This reduction, in turn, reduces the weight and yields a lighter bearing. Since the superconductors have inherently near-zero resistance, they are also expected to save power needed for operation considerably.

Rao, Dantam K.↗
NASA NTRS2011

Carbon Nanotube Based Nanotechnology for NASA Mission Needs and Societal Applications

Carbon nanotubes (CNT) exhibit extraordinary mechanical properties and unique electronic properties and therefore, have received much attention for more than a decade now for a variety of applications ranging from nanoelectronics, composites to meeting needs in energy, environmental and other sectors. In this talk, we focus on some near term potential of CNT applications for both NASA and other Agency/societal needs. The most promising and successful application to date is a nano chem sensor at TRL 6 that uses a 16-256 sensor array in the construction of an electronic nose. Pristine, doped, functionalized and metal-loaded SWCNTs are used as conducting materials to provide chemical variation across the individual elements of the sensor array. This miniaturized sensor has been incorporated in an iPhone for homeland security applications. Gases and vapors relevant to leak detection in crew vehicles, biomedical, mining, chemical threats, industrial spills and others have been demonstrated. SWCNTs also respond to radiation exposure via a change in conductivity and therefore, a similar strategy is being pursued to construct a radiation nose to identify radiation sources (gamma, protons, neutrons, X-ray, etc.) with their energy levels. Carbon nanofibers (CNFs) grown using plasma enhanced CVD typically are vertical, individual, freestanding structures and therefore, are ideal for construction of nanoelectrodes. A nanoelectrode array (NEA) can be the basis for an affinity-based biosensor to meet the needs in applications such as lab-on-a-chip, environmental monitoring, cancer diagnostics, biothreat monitoring, water and food safety and others. A couple of demonstrations including detection of e-coli and ricin will be discussed. The NEA is also useful for implantation in the brain for deep brain stimulation and neuroengineering applications. Miniaturization of payload such as science instrumentation and power sources is critical to reduce launch costs. High current density (greater than 100 mA/per square centimeters) field emission capabilities of CNTs can be exploited for construction of electron gun for electron microscopy and X-ray tubes for spectrometers and baggage screening. A CNT pillar array configuration has been demonstrated, not only meeting the high current density needs but more importantly providing long term emitter stability. Finally, supercapacitors hold the promise to combine the high energy density of a battery with the high power density of capacitors. Traditional graphite electrodes have not delivered this promise yet. A novel design and processing approach using MWCNTs has shown a record 550 F/g capacitance along with significant device endurance. This supercapacitor is suitable for railgun launch application for NASA, powering rovers and robots, consumer electronics and future hybrid vehicles.

Li, Jing↗
DOE OSTI2025

Pathways for Sustainable Reaction Kinetics in Li-CO2 Batteries

Lithium-carbon dioxide (Li-CO2) batteries hold great promise for high-energy-density storage applications. However, advancing this technology as a sustainable alternative to Li-ion systems requires a deeper understanding of the underlying reaction mechanisms, which remain elusive. A key challenge stems from the added complexity introduced by the presence of oxygen (O2) in CO2 environment. In this study, we employed a stable Cu3(VBi)0.5Se4 mid-entropy catalyst and conducted a comprehensive investigation to uncover the underlying reaction mechanisms in Li-CO2 batteries under varying CO2/O2 ratios. Under pure CO2 conditions, the battery exhibits excellent rechargeability, sustaining up to 1200 cycles. However, at high current densities, the discharge potential drops significantly (below 2.0 V), primarily due to sluggish reaction kinetics caused by solid carbon formation. Interestingly, introducing O2 mitigates this limitation, leading to a 58% increase of the discharge potential (from 1.7 V to 2.7 V) at the high current density of 0.8 mA/cm2, signifying a substantial boost in energy output. Our results reveal that the reactions follow distinct pathways, shifting from surface- to solution-based mechanism, and may even exhibit coexistence of both mechanisms, depending on the CO2/O2 ratio. These findings offer new insights for designing high-performance and sustainable Li-gas batteries utilizing CO2 and O2 mixtures.

Ngo, Anh [University of illinois Chicago]↗
DOE OSTI2025

Effect of cell compression on the performance and the structure of proton exchange membrane water electrolyzer (PEMWE) assembly

Here, in the field of water electrolysis, the proton exchange membrane water electrolyzer (PEMWE) is currently the most advanced technology for producing hydrogen without emitting CO 2 . Although PEMWE plants are already in operation, further research is needed to improve cell efficiency and reduce the use of rare materials, such as iridium oxide catalysts for the oxygen evolution reaction (OER). One of the main causes of performance loss in PEMWE is the relatively low electric conductivity of the porous transport layer (PTL) and of the anode catalyst layer, which results in ohmic losses and low catalyst utilization during high current density operation. The objective of this study is to investigate how optimization of the PTL and electrode interface can increase the cell performance. To this end, we tested different cell assemblies using fibrous and sintered PTLs, decreasing membrane thickness, reducing iridium loading, and inserting a microporous layer to increase contact surface area. Electrochemical characterization of each cell configuration was systematically performed at various compression levels as the pressure is a crucial parameter influencing the electrode/PTL contact area. In parallel, X-ray microcomputed tomography (micro-CT) was employed to investigate the effects of cell hydration and compression on the structure of PEMWE components. This study combining electrochemistry and micro-CT imaging presents how optimizing the electrode/PTL contact surface area, minimizes ohmic losses, and enables PEMWE operation with low iridium loading at high current densities.

Catalyst - PTL interface↗
NASA NTRS1989

The divergence characteristics of constrained-sheath optics systems for use with 5-eV atomic oxygen sources

The potential usefulness of the constrained sheath optics concept as a means of controlling the divergence of low energy, high current density ion beams is examined numerically and experimentally. Numerical results demonstrate that some control of the divergence of typical ion beamlets can be achieved at perveance levels of interest by contouring the surface of the constrained sheath properly. Experimental results demonstrate that a sheath can be constrained by a wire mesh attached to the screen plate of the ion optics system. The numerically predicted beamlet divergence characteristics are shown to depart from those measured experimentally, and additional numerical analysis is used to demonstrate that this departure is probably due to distortions of the sheath caused by the fact that it attempts to conform to the individual wires that make up the sheath constraining mesh. The concept is considered potentially useful in controlling the divergence of ion beamlets in applications where low divergence, low energy, high current density beamlets are being sought, but more work is required to demonstrate this for net beam ion energies as low as 5 eV.

Anderson, John R.↗
DOE OSTI2026

Confinement Reconstruction Unlocks Stable Ru Single Atom-Doped IrO x Anodes for Long-Term High-Rate CO 2 Electrolysis

IrO 2 is a commonly employed anode catalyst for CO 2 electrolysis in membrane electrode assembly (MEA) systems. However, under high current densities, its structural reconstruction leads to activity loss and stability degradation, limiting the industrial viability of CO 2 electrolysis. In this work, we demonstrated a confinement reconstruction strategy to precisely regulate the structural evolution during electrolysis. Ethylene glycol serves as a structural modulator, protecting the catalyst surface, suppressing soluble species formation, and promoting ordered structural evolution. Single-atom Ru acts as a stability enhancer, forming robust Ir–O–Ru bridging structures that facilitate an ordered transformation from a 4-fold [RuO 4 ]/[IrO 4 ] to a 6-fold symmetry [RuO 6 ]/[IrO 6 ] octahedral framework, thereby enhancing structural rigidity and long-term stability. As a result, in MEA-based CO 2 electrolysis, the catalyst achieves a stable operation at 200 mA cm –2 for 480 h, maintaining a CO selectivity above 80%. Theoretical calculations further elucidate that the enhanced stability originates from the suppression of oxygen vacancy formation, making the lattice-oxygen-mediated mechanism (LOM) potentially less favorable. This work provides insights into the structural evolution of the OER catalysts under high-current-density conditions, paving the way for large-scale CO 2 electrolysis commercialization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Pulsed Electrolysis Promotes Catalyst Activity in Dilute CO 2 Streams

Industrial CO 2 streams vary widely in composition, from pure to as low as 3%, posing challenges for purification or direct conversion. Electrochemical reduction offers a route for converting dilute CO 2 streams but faces severe mass transport limitations. This study demonstrates that pulsed electrolysis effectively overcomes these limitations, enhancing CO 2 electroreduction across variable feed compositions and current densities, particularly at low CO 2 concentrations and high current densities. At 25% CO 2 and 400 mA cm −2 , pulsing improved selectivity from 25.6 to 78.6%, production rate from 13.7 to 21.0 mol m −2 h −1 , and energy productivity from 0.77 to 2.59 mol kWh −1 . A dynamic, multiphysics continuum model confirms a 64% increase in CO 2 concentration within the catalyst layer during pulsing, resolving the transient chemical microenvironment. These findings establish pulsed electrolysis as a viable strategy for converting dilute industrial CO 2 streams into valuable feedstocks, bypassing costly pre-separation.

Orfali, Dania Muhieddine [New York University (NYU↗
NASA NTRS1984

The DE-AC accelerator system for high beam current density

A radically different ion accelerator system design has been developed to increase the extracted beam current density of ion thrusters. By independently controlling plasma ion extraction and acceleration, the Decoupled Extraction and Amplified Current (DE-AC) accelerator system gives higher beam currents at lower electric field stress levels. Results are presented for DE-AC grid system operation with the Test Bed Ion Engine. Using argon propellant, feasibility of a 60 mA/sq cm beam current density is shown. A discussion of power supply requirements, specific impulse operation and grid system geometrical design is presented also.

Aston, G.↗
NASA NTRS2010

Development and Testing of High Surface Area Iridium Anodes for Molten Oxide Electrolysis

Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600 C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.

Shchetkovskiy, Anatoliy↗
NASA NTRS2010

Development and Testing of High Surface Area Iridium Anodes for Molten Oxide Electrolysis

Processing of lunar regolith into oxygen for habitat and propulsion is needed to support future space missions. Direct electrochemical reduction of molten regolith is an attractive method of processing, because no additional chemical reagents are needed. The electrochemical processing of molten oxides requires high surface area, inert anodes. Such electrodes need to be structurally robust at elevated temperatures (1400-1600?C), be resistant to thermal shock, have good electrical conductivity, be resistant to attack by molten oxide (silicate), be electrochemically stable and support high current density. Iridium with its high melting point, good oxidation resistance, superior high temperature strength and ductility is the most promising candidate for anodes in high temperature electrochemical processes. Several innovative concepts for manufacturing such anodes by electrodeposition of iridium from molten salt electrolyte (EL-Form? process) were evaluated. Iridium electrodeposition to form of complex shape components and coating was investigated. Iridium coated graphite, porous iridium structure and solid iridium anodes were fabricated. Testing of electroformed iridium anodes shows no visible degradation. The result of development, manufacturing and testing of high surface, inert iridium anodes will be presented.

Shchetkovskiy, Anatoliy↗
NASA NTRS1982

Ion extraction capabilities of closely spaced grids

The ion extraction capabilities of accelerator systems with small screen hole diameters (less than 2.0 mm) are investigated at net-accelerating voltages of 100, 300, and 500 V. Results show that the impingement-limited perveance is not dramatically affected by reductions in screen hole diameter to 1.0 mm, but impingement-limited performance was found to be dependent on the grid separation distance, the discharge-to-total accelerating voltage ratio, and the net-to-total accelerating voltage ratio. Results obtained using small hole diameters and closely spaced grids indicate a new mode of grid operation where high current density operation can be achieved with a specified net acceleration voltage by operating the grids at a high rather than low net-to-total acceleration voltage. Beam current densities as high as 25 mA/sq cm were obtained using grids with 1.0 mm diameter holes operating at a net accelerating voltage of 500 V.

Rovang, D. C.↗