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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 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Characterization of Fe-6Si Soft Magnetic Alloy Produced by Laser-Directed Energy Deposition Additive Manufacturing

Abstract Commercial electrical steels, Fe-Si alloys with < 4 wt.% Si, are inexpensive and efficient materials for electrical power conversion. Further efficiency improvements require increasing the silicon concentration to 6 wt.%, at which point the material becomes brittle and difficult to form by conventional rolling and sheet fabrication methods. Additive manufacturing stands to overcome challenges with commercial manufacturing techniques by leveraging near-net-shape fabrication. The wide array of process conditions provides additive manufacturing with increased flexibility, enabling control over the microstructure and mechanical properties. This work explores the microstructures and magnetic properties of ring-shaped Fe-Si alloys produced using concentric and cross-hatch tool paths on a laser-directed energy deposition additive manufacturing system. Concentric-built samples exhibit elongated grain structures while cross-hatch-built samples comprise lower aspect ratio grain structures. Thermal finite element analysis simulations model the stress conditions produced by the different scan path geometries. Microhardness measurements probe the mechanical properties as a function of anneal temperature, providing a qualitative understanding of the intergranular defect density. Soft magnetic properties measured under quasistatic and AC conditions show frequency- and microstructure-dependent coercivity and permeability. Finally, analysis of the core loss quantifies how the build strategies and thermal treatments influence efficiency in electrical power conversion applications. Understanding the influences of scan path geometry and thermal treatment provides a pathway towards application of additively manufactured soft magnetic materials.

Adamczyk, Jesse M.↗
DOE OSTI2022

2,3-Diphenylthieno[3,4-b]pyrazines as Hole-Transporting Materials for Stable, High-Performance Perovskite Solar Cells

High-performance and durable perovskite solar cells (PSCs) have advanced rapidly, enabled in part by the development of superior interfacial hole-transporting layers (HTLs). Here, in this study, a new series of 2,3-diphenylthieno[3,4-b]pyrazine (DPTP)-based small molecules containing bis- and tetrakis-triphenyl amino donors (1–3) was synthesized from simple, low-cost, and readily available starting materials. The matched energy levels, ideal surface topographies, high hole mobilities of 8.57 × 10 –4 cm 2 V –1 S –1 , and stable chemical structures of DPTP-4D (3) make it an effective hole-transporting material, delivering a PCE of 20.18% with high environmental, thermal, and light-soaking stability when compared to the reference HTL materials, doped Spiro-OMeTAD and PTAA in PSC n-i-p planar devices. Overall, these DPTP-based molecules are promising HTM candidates for the fabrication of stable PSCs.

14 SOLAR ENERGY↗
DOE OSTI2020

Microreactor Agile Nonnuclear Experimental Testbed Test Plan

Microreactors are an attractive technology option for kick-starting nuclear innovation if they can be operated at high temperature, yielding high power conversion thermal efficiencies comparable or better than in commercial light water reactors. Microreactors are currently the smallest variation of Small Modular Reactors (SMRs). SMRs are “newer generation reactors designed to generate electric power up to 300 MWe and whose components and systems can be shop-fabricated and then transported as modules to the sites for installation as demand arises.” (IAEA, 2016). Vendors are developing microreactor designs to provide an affordable, potentially mobile source of electricity - see Fig. 1 for an example of a microreactor on a semi-truck. Various microreactor designs are possible including heat pipe- and gascooled options, which are the focus of the nonnuclear testing described in this document. In heat pipe microreactors, high-temperature heat pipes using liquid sodium or potassium working fluid transport fission heat from the core to a heat removal section which in turn transfers heat to the power conversion system working fluid. In a gas-cooled design, He or other gas will flow through a solid monolith of material and transfer heat as the temperature of the gas increases through a heat exchanger to a power conversion unit. The logistics of all these processes will be examined and tested through a series of articles at the nonnuclear test bed at Idaho National Laboratory (INL), the Microreactor Agile Nonnuclear Experiment Testbed (MAGNET) facility. Microreactors designed to produce power of 0.1-20 MWt offer the potential for more affordable nuclear energy for a range of applications. In a heat pipe microreactor, heat pipes, fuel rods, and/or moderator are intermixed in the reactor core assembly. Heat pipes extend from the core region into the heat removal section where the power conversion unit working fluid flows through holes or channels, transferring heat from the heat pipes to the working fluid. In a gas-cooled microreactor, gas flows through the solid monolith region and up into the heat exchanger region, transferring heat to the working fluid. For initial testing, the heat removal working fluid can be a low pressure gas for testing that addresses thermal stresses. In the final application, heat addition to the power conversion working fluid typically occurs at high pressure, supporting operation of an air-Brayton, supercritical CO 2 (SCO2), or He-recuperated Brayton cycle. Various stages of the steps above will be demonstrated through the tests described in this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Self-powered Heating: Efficiency Analysis

Conventional fuel-fired heating devices such as furnaces, boilers, and water heaters have fuel efficiency less than 100% on the basis of higher heating value. They also require electricity from the electric grid to power parasitic loads such as blowers, pumps, fans, and ignitors. The primary energy efficiency of the device accounts for both fuel used on-site and primary energy used off-site to produce electric power used by the device. This work compares conventional fuel-fired heating devices to two types of self-powered devices. A self-powered device (SPD) integrates a power cycle onboard to eliminate consumption of grid electricity. We assume that all heat rejected by the onboard power cycle is added to the process fluid, so that, compared with a conventional device, the same amount of heat is provided to the process fluid and the same amount of fuel is consumed, but grid electricity consumption is eliminated. The first SPD type is the basic one: exactly the electricity required is generated. The second type considered is the SPD with heat pump (SPD-HP), in which the power cycle generates more electricity than needed for parasitic loads, and the excess electricity is used to power a heat pump. The heat pump extracts additional heat from the ambient to boost efficiency. Both SPD and SPD-HP self-consume all the generated electricity, in contrast to combined heat and power (CHP) systems that export electricity. In this work, equations are derived to express the efficiency of three classes of heating devices: conventional (consuming grid electricity), self-powered (consuming no grid electricity), and self-powered with heat pump. The efficiency of each is derived as a function of up to six factors: (1) the fraction of combustion heat captured, (2) the rate of parasitic power consumption, (3) the fraction of electric energy dissipated as useful heat, (4) the power cycle conversion efficiency, (5) the grid efficiency, when applicable, and (6) the heat pump COP, when applicable. Scenarios are identified in which it is possible to achieve efficiency greater than 100% on a higher heating value basis. Plausible configurations using existing technology options are outlined.

Gluesenkamp, Kyle↗
DOE OSTI2022

Analyzing Production Rate and Carbon Utilization Trade-offs in CO 2 RR Electrolyzers

Carbon utilization is a crucially important performance characteristic of CO 2 electrolyzers; however, applications of simple and accurate descriptive models to experimental data on this topic are currently lacking. Here, we apply a simple analytical reactor model to parameterize single-pass conversion as a function of feed-gas flow rate and show that it captures a wide body of experimental data in the literature exceptionally well. In doing so, we demonstrate that this simple conceptual approach can characterize progress and capture recent innovations in reactor design. To validate the extracted parameters, we employ a well-established comprehensive model to confirm that the results agree with physical expectations. Lastly, we explore the implications of the descriptive model by examining the inherent trade-off between single-pass conversion efficiency and reactor productivity. Understanding such trade-offs is crucially important for advancing this electrolyzer technology toward commercial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hydrogen from Sunlight and Water: A Side-by-Side Comparison between Photoelectrochemical and Solar Thermochemical Water-Splitting

Photoelectrochemical (PEC) and solar thermochemical (STCH) water-splitting represent two promising pathways for direct solar hydrogen generation. PEC water-splitting integrates multiple functional materials and utilizes energetic electrons and holes generated from sunlight to produce hydrogen and oxygen in two half-reactions, while STCH water-splitting couples a series of consecutive chemical reactions and uses absorbed heat from sunlight to generate hydrogen and oxygen in two full reactions. In this Focus Review, the basic operating principles, sunlight utilization, device architecture, reactor design, instantaneous and annually averaged solar-to-hydrogen (STH) conversion efficiency, and the operating conditions and constraints of both pathways are compared. A side-by-side comparison addresses some common sources of confusion and misinterpretation, especially in the evaluation of STH conversion efficiencies, and reveals distinct features and challenges in both PEC and STCH technologies. Furthermore, this Focus Review also addresses materials and device challenges in PEC and STCH for cost-competitive hydrogen generation.

08 HYDROGEN↗
DOE OSTI2023

Hierarchical Control and Stability Analysis for a Nonisolated Grid-Tied DC Energy Router Integrating Energy Storage and Partial Distributed Generation

This article proposes a nonisolated dc converter-based energy router (dc-ER) and its operating strategy. Here, the intent is to integrate energy storage (ES), distributed generation (DG), local load, and dc power grid in an autonomous and more efficient way. The ES/DG power ports are coupled with each other in partial-type connections, which obtains higher voltage supply gain and direct input–output power transmission. High-voltage supply gain allows a wide solar power tracking range and the possibility of optimal battery charging/discharging. Direct input–output power transmission improves the energy conversion efficiency. In this article, the operating modes of dc-ER are first analyzed, followed by the optimal hardware design counting the DG current ripple minimization and the limitation caused by the power flow direction. Second, the mathematical model of dc-ER is deduced. The hierarchical control is then proposed to manage port energy in a flexible manner. The stability is analyzed by using impedance modeling. Finally, experimental and simulation results verify the superiorities of the proposed topology in terms of flexible operating mode transition and high-power conversion efficiency.

25 ENERGY STORAGE↗
DOE OSTI2024

Mixed Self-Assembled Monolayers for High-Photovoltage Tin Perovskite Solar Cells

Self-assembled monolayers (SAMs) are used as potent hole transport layers (HTLs) in lead-based perovskite solar cells, enabling large quasi-Fermi level splitting for high photovoltage (>1.1 V) with a deficit of <0.5 V. However, tin-based perovskite solar cells (TPSCs) with SAM HTLs suffer from low photovoltage (<0.65 V) with a deficit of >0.7 V. Herein we employ a holistic approach to tackle this significant challenge by designing a mixed SAM, engineering a compatible tin perovskite thin film, and leveraging an efficient electron transport layer. Consequently, high photovoltage of 0.829 V is achieved with an efficiency of 9.4%, which is a record to our knowledge among TPSCs using SAMs as sole HTLs. Finally, while SAMs have been little used in TPSCs thus far, our holistic approach should catalyze their future advancements toward outperformance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

19.28% Efficiency and Stable Polymer Solar Cells Enabled by Introducing an NIR–Absorbing Guest Acceptor

Here, a near-infrared (NIR)-absorbing small-molecule acceptor (SMA) Y-SeNF with strong intermolecular interaction and crystallinity is developed by combining selenophene-fused core with naphthalene-containing end-group, and then as a custom-tailor guest acceptor is incorporated into the binary PM6:L8-BO host system. Y-SeNF shows a 65 nm red-shifted absorption compared to L8-BO. Thanks to the strong crystallinity and intermolecular interaction of Y-SeNF, the morphology of PM6:L8-BO:Y-SeNF can be precisely regulated by introducing Y-SeNF, achieving improved charge-transporting and suppressed non-radiative energy loss. Consequently, ternary polymer solar cells (PSCs) offer an impressive device efficiency of 19.28% with both high photovoltage (0.873 V) and photocurrent (27.88 mA cm –2 ), which is one of the highest efficiencies in reported single-junction PSCs. Notably, ternary PSC has excellent stability under maximum-power-point tracking for even over 200 h, which is better than its parental binary devices. The study provides a novel strategy to construct NIR-absorbing SMA for efficient and stable PSCs toward practical applications.

14 SOLAR ENERGY↗
DOE OSTI2022

Elucidating Diiodomethane-Induced Improvement in Photonically Cured MAPbI 3 Solar Cells

Diiodomethane (CH 2 I 2 ) has been reported to improve the photonically cured perovskite solar cell (PSC) device performance by reducing pinholes. Here we show that even for pinhole-free methylammonium lead iodide (MAPbI 3 ) made by photonic curing, adding CH 2 I 2 promotes significant performance improvement. We elucidate the mechanisms behind the observed improvement. In addition to current-density versus voltage measurements, we perform a wide variety of characterization to compare the crystallinity, grain structure, optical, chemical, and electrical properties of the photonically cured samples with and without CH 2 I 2 in the MAPbI 3 layer to those of thermally annealed devices. Here, the addition of CH 2 I 2 promotes grain growth in the vertical direction, increases the I/Pb ratio in the final film, and removes the I - ionic diffusion and defect signature associated with iodine interstitials. As a result, we achieve a champion efficiency of 15.04% with MAPbI 3 conversion time of 20 ms, comparable to PSCs that have MAPbI 3 layer thermally annealed for 10 min. Understanding the mechanisms behind additive-induced improvements for non-thermal annealing processes is critical to enabling high-speed PSC manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2024

Connecting Interfacial Mechanical Adhesion, Efficiency, and Operational Stability in High Performance Inverted Perovskite Solar Cells

Carbazole-based self-assembled monolayers (SAMs) at the interface between the metal-halide perovskite (MHP) and the transparent conducting oxide (TCO) serve the function of hole-transport layers in p-i-n "inverted" perovskite solar cells (PSCs). In this report we show that the use of an iodine-terminated carbazole-based SAM increases the interfacial mechanical adhesion dramatically (2.6-fold) and that this is responsible for substantial improvements in the interfacial morphology, photocarrier transport, and operational stability. While the improved morphology and optoelectronic properties impart high efficiency (up to 25.39%) to the PSCs, the enhanced adhesion suppresses nucleation and propagation of pores/cracks during PSC operation, resulting in the retention of 96% of the initial efficiency after 1000 h of continuous-illumination testing at the maximum power-point. This demonstrates the strong connection between judicious interfacial adhesion toughening and simultaneous enhancement in the efficiency and operational stability of p-i-n PSCs, with broader implications for the reliability and durability of perovskite photovoltaics before they can be commercialized.

14 SOLAR ENERGY↗
DOE OSTI2022

A Top-Down Strategy to Engineer ActiveLayer Morphology for Highly Efficient and Stable All-Polymer Solar Cells

A major challenge hindering the further development of all-polymer solar cells (all-PSCs) employing polymerized small-molecule acceptors is the relatively low fill factor (FF) due to the difficulty in controlling the active-layer morphology. The issues typically arise from oversized phase separation resulting from the thermodynamically unfavorable mixing between two macromolecular species, and disordered molecular orientation/packing of highly anisotropic polymer chains. Herein, a facile top-down controlling strategy to engineer the morphology of all-polymer blends is developed by leveraging the layer-by-layer (LBL) deposition. Optimal intermixing of polymer components can be achieved in the two-step process by tuning the bottom-layer polymer swelling during top-layer deposition. Consequently, both the molecular orientation/packing of the bottom layer and the molecular ordering of the top layer can be optimized with a suitable top-layer processing solvent. A favorable morphology with gradient vertical composition distribution for efficient charge transport and extraction is therefore realized, affording a high all-PSC efficiency of 17.0% with a FF of 76.1%. The derived devices also possess excellent long-term thermal stability and can retain >90% of their initial efficiencies after being annealed at 65 °C for 1300 h. In conclusion, these results validate the distinct advantages of employing an LBL processing protocol to fabricate high-performance all-PSCs.

14 SOLAR ENERGY↗
DOE OSTI2022

High-Performance Non-fullerene organic solar cells enabled by noncovalent Conformational locks and Side-Chain engineering

Three novel small molecular acceptors (SMAs) BO-2F, BO-C8-2F and BO-C2C6-C8-2F were designed and synthesized. These acceptors all possess planar molecular backbone because of the introduction of intramolecular noncovalent interaction. Among them, BO-C2C6-C8-2F with four side chains, which has the highest solubility, can form more appropriate nanomorphology when blending with PBDB-T. Hence, organic solar cells (OSCs) based on PBDB-T:BO-C2C6-C8-2F displayed an outstanding power convesion efficiency (PCE) of 14.25%, which is higher than BO-2F and BO-C8-2F based ones. To the best of our knowledge, the PCE of 14.25% is one of the highest for the OSCs based on A-π-D-π-A type SMAs. Finally, our results have demonstrated that the combination of side-chain engineering and intramolecular conformation lock has a great prospect in the design of high performance SMAs for OSCs.

14 SOLAR ENERGY↗
DOE OSTI2024

Artificial Intelligence for Conjugated Polymers

Conjugated polymers have garnered significant attention due to their diverse applications in electronics, photonics, and energy storage. However, realizing their full potential poses a formidable challenge, as their design has historically relied on iterative adjustments and continuous inspiration from researchers. Traditional methods often struggle to efficiently navigate their vast chemical landscape. In this work, the application of artificial intelligence (AI), specifically machine learning (ML), needs to be discussed in the realm of conjugated polymers. Our paper emphasizes the importance of understanding the structure–property relationships of these polymers and how ML can facilitate property prediction and inverse-design. We delve into various chemical fingerprints, structural descriptors, and ML algorithms, showcasing their utility across a spectrum of applications, including simulations, glass transition temperature determination, photovoltaics, reorganization energy for charge transport, photocatalysts, and sensors. Finally, we give some outlooks in this filed and propose unexplored areas within the field that hold the potential to benefit from ML techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

An autonomous robot for shell and tube heat exchanger inspection

Shell and tube heat exchangers (STHEs) are critical to energy conversion efficiency of power plants. Eddy current examination is a way to evaluate working conditions of these tubes. However, the current testing apparatus requires human to manually insert an eddy current testing (ECT) probe into and extract it out of individual tubes, and meanwhile monitor measurement results for diagnosis. It is a time-consuming and labor-intensive procedure even for an experienced technician. To tackle this challenge, in this study, we developed a robot enabled ECT system for autonomous inspection of STHEs. The robotic platform employs Mecanum wheeled chassis for high mobility, machine vision to locate tube bundle and tube inlets, a rotational Cartesian mechanism to operate at planes with all possible inclinations, and a task-specific mechanism for ECT probe delivery. Machine vision locates tube bundle and tube inlets by an April tag detection algorithm and a Circle Hough Transform algorithm, respectively. Assisted by a guiding cone, the ECT probe is continuously fed into the tubes with a fill factor of 0.819. In conclusion, during this process, the eddy current data are automatically collected and real-time analyzed by convolutional neural networks, showing accuracy of nearly 100% for identifying defective and nondefective tubes and 85% for four types of defective tubes and nondefective tubes.

42 ENGINEERING↗