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DOE OSTI2025

High-Power Impulse Magnetron Sputter Deposition of Boron Carbide with Full-Face Erosion Magnetron and Mixed Ar-Ne Plasma

Boron carbide (B 4 C) is an attractive inertial confinement fusion ablator material. The fabrication of B4C ablators by magnetron sputtering requires process optimization. To increase process flexibility, here we explore high-power impulse magnetron sputter (HiPIMS) deposition of B 4 C in pure Ar and mixed Ar-Ne plasmas. Here, the results show that higher plasma discharge currents can be reached with a mixed Ar-Ne plasma in the entire working pressure range studied (5 𝑡𝑜 50 mTorr). At 45 mTorr with 10% of Ne in the Ar-Ne mix, high peak target current densities of ~1 A cm −2 were demonstrated. Films deposited with such a mixed Ar-Ne plasma with a full-face erosion magnetron source on substrates biased at −25 V exhibited higher density and improved mechanical properties, albeit with higher compressive residual stresses compared to the case of HiPIMS deposition in a pure Ar plasma. This work demonstrates additional process flexibility of the HiPIMS discharge mode for the deposition of B 4 C coatings.

Ablator capsule↗

DOE OSTI2023

Multifunctional Coatings on Sulfide‐Based Solid Electrolyte Powders with Enhanced Processability, Stability, and Performance for Solid‐State Batteries

Abstract Sulfide‐based solid‐state electrolytes (SSEs) exhibit many tantalizing properties including high ionic conductivity and favorable mechanical properties for next‐generation solid‐state batteries. Widespread adoption of these materials is hindered by their intrinsic instability under ambient conditions, which makes them difficult to process at scale, and instability at the Li||SSE and cathode||SSE interfaces, which limits cell performance and lifetime. Atomic layer deposition is leveraged to grow thin Al 2 O 3 coatings on Li 6 PS 5 Cl powders to address both issues simultaneously. These coatings can be directly grown onto Li 6 PS 5 Cl particles with negligible chemical modification of the underlying material and enable exposure of powders to pure and H 2 O‐saturated oxygen environments for ≥4 h with minimal reactivity, compared with significant degradation of the uncoated powder. Pellets fabricated from coated powders exhibit ionic conductivities up to 2× higher than those made from uncoated material, with a simultaneous decrease in electronic conductivity and significant suppression of chemical reactivity at the Li‐SSE interface. These benefits result in significantly improved room temperature cycle life at high capacity and current density. It is hypothesized that this enhanced performance derives from improved intergranular properties and improved Li metal adhesion. This work points to a completely new framework for designing active, stable, and scalable materials for next‐generation solid‐state batteries.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Precious metal oxygen-evolving anodes for electrolytic reduction of metal oxides in molten LiCl-Li 2 O electrolyte

Understanding the electrochemical stability of oxygen-evolving anode materials in molten salt electrolytes is essential to enable decarbonized electrolytic reduction of metal oxides (e.g., used nuclear oxide fuels). Here, this work investigated three precious metals (Ir, Ru, and Pt) as oxygen-evolving anodes in molten LiCl-Li 2 O (99.0-1.0 wt%) at 650 °C. For consistent measurements, this work employed a three-electrode cell comprised of a two-phase Li-Bi (65-35 at%) reference electrode and a NiO counter electrode. Anodic polarization behavior of each anode was investigated via cyclic voltammetry (CV) and chronoamperometry. The onset potential for oxygen evolution was observed at E > 2.9 V (vs. Li/Li + ) for the Ir and Ru anodes and anodic current density was as high as 1.0 A cm -2 at 3.23 V. The dimensional stability of each anode was evaluated from long-term electrolysis experiments (10.0-32.1 h) at 3.23 V. Rapid consumption of the Pt anode was observed after the application of 26,453 C cm -2 with a reduction in diameter of about 15.8% due to the formation of a non-protective Li 2 PtO 3 compound. The formation of this compound was also observed during CV measurements as additional anodic waves at potentials more negative than that of oxygen evolution. In contrast, both the Ir and Ru anodes exhibited excellent dimensional stability with a reduction in diameter or thickness of less than 1.5% even after applying greater charge density of ~41,100 C cm -2 , demonstrating superior stability during oxygen evolution in the LiCl-Li 2 O electrolyte.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Elucidating facet dependent electronic and electrochemical properties of Cu 2 O nanocrystals using AFM/SCEM and DFT

Cuprous oxide (Cu 2 O) has extensively been studied owing to its excellent optical, magnetic, and catalytic properties. Many of these properties are facet-dependent and have not been well elucidated. This work synthesized cubic, cuboctahedral, octahedral, and rhombic dodecahedral shaped Cu 2 O nanocrystals of ~300 nm in size to evaluate the facet-dependent electrochemical activities. Here, cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) were firstly used to reveal the average electrochemical activities at the ensemble level. Atomic force microscopy-scanning electrochemical microscopy (AFM-SECM) was further used to assess the electrochemical activities of different Cu 2 O nanocrystals at the facet level. Hexaammineruthenium (III) chloride ({Ru(NH 3 ) 6 }Cl 3 ) was employed as the probe molecules that reacted with four different Cu 2 O nanocrystals under —400mV and yielded ~300 pA current between the probing tip and the nanocrystal surface. The tip-current mapping results indicate that rhombic dodecahedral Cu 2 O exhibits higher electrocatalytic activity than other shaped Cu 2 O, due to the presence of dominant exposed facet of {110} as indicated by the relatively high tip current. Density-functional theory (DFT) calculations confirmed the facet dependence of local surface energy and electronic structure of Cu 2 O nanocrystals. Besides electrochemical activity, the surface work function and adsorptive properties were both observed to vary with the shape and dominant exposed facets of Cu 2 O. This study presented a unique experimental and computational chemistry approach to analyze surface electrochemical properties of Cu 2 O crystals at a crystalline facet level.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Oxidation in Ca/K-1144 iron-based superconductors polycrystalline compounds

Iron-based superconductors (IBSCs) are a class of material under investigation for the development of superconducting wires in the low-temperature-high magnetic fields power application. Among the various families of IBSCs, the 1144 CaKFe$_4$As$_4$ compound is a promising material able to achieve outstanding superconducting properties with a cheap and simple chemical composition. Oxidation, in these compounds, is considered an obstacle for high intergranular critical current density, J c,GB . A study devoted to the evaluation of oxidation phenomena and their effects on the superconducting properties is thus needed in order to fully understand the involved mechanisms. From the evaluation of polycrystalline samples obtained by a mechanochemically assisted synthesis route, a degradation of the critical temperature and critical currents has been observed concurrently with oxygen accumulation at grain boundaries in open porosities. However, the crystalline structure at an atomic level seems not affected, as well as intragranular superconducting properties assessed by means of calorimetric methods. These results suggest that loss of superconducting properties in Ca/K-1144 compounds following oxidation is significantly associated with the worsening of grain connectivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Pulsed-Potential Electrolysis Enhances Electrochemical C–N Coupling by Reorienting Interfacial Ions

The electrochemical processing of anthropogenic CO 2 is an emerging technology aimed at utilizing renewable energies to synthesize valuable chemicals. Recently, developments in broadening the scope of the CO 2 reduction reaction (CO 2 RR) by enabling heteroatom coupling have surged with a focus on C–N bond formation. Herein, we investigate the factors that govern the selectivity and activity in synthesizing urea from environmentally malignant chemical feedstocks (CO 2 and NO 3 – ). Through a combination of electrolyte optimization and pulsed potential electrolysis, electrochemical urea production was optimized to a Faradaic efficiency of 60.4% with current densities reaching as high as 310 μA cm –2 . This work was further supported by in situ surface enhanced infrared absorbance spectroscopy that reveals the formation of C–N-related species at low overpotentials. Density functional theory calculations revealed that the reaction progresses between early reduction intermediates for the CO 2 RR and NO 3 RR and offered insights into the impacts of pulsed-potential on substrate transport.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Light extraction in tandem organic light emitting diodes

Since the invention of organic light emitting diodes (OLEDs), great research efforts have been dedicated to improving their efficiency and lifetime. For high-brightness applications, tandem OLED structures have advantages because of the lower current densities required to achieve high brightness. With the successful development of highly efficient charge generation layers, high brightness tandem OLEDs are used in displays and lighting. However, the major challenge for tandem OLEDs is the low light extraction efficiency, because about 50% of the light is trapped inside the device as waveguide modes. In this Perspective, we first review the recent works done on light extraction, analyze different waveguide mode extraction structures, and then identify the key factors determining the extraction efficiencies in tandem OLEDs.

42 ENGINEERING↗

DOE OSTI2025

An experimental platform for investigating astrophysically relevant magnetized plasma jets on the COBRA facility

A new platform has been developed for the 1-MA COBRA generator to investigate the physical processes affecting the formation, collimation, and stability of high-speed outflows in magnetically driven laboratory plasma jets. Such experiments serve as diagnostically accessible surrogates for astrophysical jets under the assumption that the underlying dynamics are scale invariant. In contrast to previous current driven high energy density laboratory jet experiments that use radial/conical wire arrays or foils, the platform described here uses azimuthally symmetric gas-puff injection. This avoids the ablation phase from a solid target, allowing the jets to develop earlier and be driven longer without depleting their mass source and disrupting. A permanent magnet provides an initial poloidal magnetic field, which links the two concentric electrodes and mimics the boundary conditions of a star-accretion disk system. Extended magnetohydrodynamic effects can be assessed using a polarity convolute, which allows for reversal of the electrode bias. The resulting plasma jets exhibit remarkable stability, persisting for hundreds of nanoseconds and achieving aspect ratios ≳30:1.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Advanced CMOS Reliability Update: Sub 20nm FinFET Assessment

Advances in FinFET design and fabrication enable manufacturing of denser, more compact integrated circuits (ICs) with substantially reduced leakage while shortening the channel-lengths. The same stress-induced leakage and breakdown degradation mechanisms that affect planar transistors also impact FinFET devices. Reliability concerns such as Bias Temperature Instability (BTI), Time Dependent Dielectric Breakdown (TDDB), and Hot Carrier Injection (HCI) become very important with changes to transistor geometry and fin sidewall crystal orientation. Recent testing has shown that FinFETs respond differently to radiation (radiation effects such as total ionizing dose) when compared to planar transistors. These reliability and radiation effects issues become very important when changing transistor geometry and scaling FinFETs towards smaller feature sizes (22-nm, 16-nm, 14- nm, 10-nm, and smaller critical dimensions). The comparable 2019 state of the art transistor densities in current high-volume manufacturing silicon-based foundries is 7-nm (ISMC, Samsung) and 10-nm (Intel) [www.anandtech.com,fuse.wikichip.org]. Released products include supporting components for the cellphone and commercial microprocessor markets respectively. Extensive development in the foundry industry is driving to a 5-nm technology node in late 2020.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

CRADA Final Report: Ultralong Cycle Life and Ultrafast Charging Batteries to Electrify High Duty-Cycle, Mobile Platforms

As part of the Cyclotron Road program, Tyfast Energy Corp. aimed to investigate the Li 3 V 2 O 5 (LVO) anode material for next generation lithium batteries. State of the art and fast charging lithium-ion batteries are based on the lithium titanate or Li 4 Ti 5 O 12 (LTO) anode chemistry. LTO cells demonstrate fast charging times (<6 mins), long cycle life (>20,000 cycles), but at the expense of very low energy density (<200Wh/L, <80Wh/kg). Silicon anodes have the promise of achieving fast charging times, however, issues with cycling stability in combination with fast charging is unknown. LVO has unique properties that enable new performance window for lithium batteries. First, LVO operates at an average potential of 0.6V vs. Li/Li + , well above the Li-metal plating region allowing ultrafast charge capability without sacrificing safety. Second, the LVO has a high specific capacity of 250 mAh/g making battery pack energy density equivalent with current high-energy Li-ion chemistries.

25 ENERGY STORAGE↗

NASA NTRS1970

Oxygen-hydrogen fuel cell with an iodine-iodide cathode - A concept

Fuel cell uses a porous cathode through which is fed a solution of iodine in aqueous iodide solution, the anode is a hydrogen electrode. No activation polarization appears on the cathode because of the high exchange-current density of the iodine-iodide electrode.

Javet, P.↗

NASA NTRS1978

Chemical vapor deposition of high T sub c superconductors

The results are reported of an investigation into the synthesis and properties of high temperature superconducting materials. A chemical vapor deposition apparatus was designed and built which is suitable for the preparation of multicomponent metal films This apparatus was used to prepare a series of high T sub c A-15 structure superconducting films in the binary system Nb-Ge. The effect on T sub c of a variety of substrate materials was investigated. An extensive series of ternary alloys were also prepared. Conditions allowing the brittle high T sub c (approximately 18 K) A-15 structure superconductor Nb3A1 to be prepared in a low T sub c but ductile form were found. Some of the ways that the ductile (bcc) form can be cold worked or machined are described. Measurements of rate of transformation of cold worked bcc material to the high T sub c A-15 structure with low temperature annealing are given. Preliminary measurements indicate that this material has attractive high field critical current densities.

Webb, G. W.↗

NASA NTRS1981

Performance of a magnetic multipole line-cusp argon ion thruster

The performance of a 17-cm diameter line-cusp ion thruster, using argon and xenon propellants, is investigated. Basic optimization of the thruster was accomplished without ion extraction and tests were conducted with small vacuum facilities and power supplies. The evaluation of the sensitivity of the performance to changes in discharge electrode configurations and the magnetic circuit is discussed. Final optimization results show that an argon propellant utilization efficiency of 0.9, at 260 W of discharge power per beam ampere, was obtained with a thruster having 20 rows of magnets and 10 tubular anodes. The average ion beam current densities were as high as 13 mA/sq cm. The results are considered to be the highest yet achieved with argon propellant.

Sovey, J. S.↗

NASA NTRS1985

Study of high performance alloy electroforming

The nickel-manganese experimental electrolyte was hydrogen peroxide treated and carbon purified for removal of residual sodium saccharin and related organic decomposition products from the plating of previous test panels. The saccharin additive was used to reduce stress where high concentrations of manganese and high pulse peak current densities were used. A large quantity of nickel-manganese alloy plates containing 0.35 to 0.40 percent by weight manganese was electroformed for testing to supply data for a mechanical property data table. The aluminum billet required for the machining of the subscale SSME main combustion chamber was acquired.

Malone, G. A.↗

NASA NTRS1989

Barium-Dispenser Thermionic Cathode

Improved reservoir cathode serves as intense source of electrons required for high-frequency and often high-output-power, linear-beam tubes, for which long operating lifetime important consideration. High emission-current densities obtained through use of emitting surface of relatively-low effective work function and narrow work-function distribution, consisting of coat of W/Os deposited by sputtering. Lower operating temperatures and enhanced electron emission consequently possible.

Wintucky, Edwin G.↗

NASA NTRS1989

Non-noble electrocatalysts for alkaline fuel cells

Carbons activated with macrocyclics have attracted increasing attention as alternative electrocatalysts for oxygen reduction. Initial activity of these catalysts is good, but performance declines rapidly. Pyrolyzing the macrocyclic on the carbon support leads to enhanced stability and the catalysts retain good activity. The approach described is designed to develop bulk doped catalysts with similar structures to pyrolyzed macrocyclic catalysts. The transition metal and coordinated ligands are dispersed throughout the bulk of the conductive carbon skeleton. Two approaches to realizing this concept are being pursued, both involving the doping of carbon precursors. In one approach, the precursor is a solid phase carbon-containing ion-exchange resin. The precursor is doped with a transition metal and/or nitrogen, and the resulting mixture is pyrolyzed. In the other approach, the precursor is a gas-phase hydrocarbon. This is introduced with a transition metal species and nitrogen species into a reactor and pyrolyzed. Several studies have been conducted to determine if there is a synergistic effect between the transition metal and nitrogen and the effect of different methods of introducing the metal-nitrogen (M-N) coordination on performance. One approach was to introduce the metal and nitrogen separately, for example, by sequentially doping FeCl3 and NH4OH into the resin. Catalysts were prepared from an undoped ion-exchange resin, a resin doped only with N, a resin doped only with Fe, and a resin doped with both Fe and N. Introduction of nitrogen alone has no beneficial effect on the performance of the catalysts. The introduction of the Fe alone significantly improves the performance in both the high and low current density regions. When both Fe and N are introduced, the performance at lower current densities (catalytic activity) is increased beyond that of the Fe-doped carbon, but the performance at higher current densities is similar to the carbon containing only Fe. Catalysts prepared from resins-Fe(bipy)3SO4 precursors have performance that is only slightly less then CoTMPP adsorbed and pyroloyzed on Vulcan XC-72. Their performance is much better than carbons which have had the N and Fe introduced separately.

Sarangapani, S.↗

NASA NTRS1992

TBD(exp 3)

When asked by the Aeronautical Engineering staff to design a viable supersonic commercial transport, most of the students were well aware that Boeing, McDonnell Douglas, and other aircraft companies had been studying a cadre of transports for more than 30 years and had yet to present a viable aircraft. In the spirit of aviation progress and with much creative license, the TBD design team spearheaded the problem with the full intention of presenting a marketable high speed civil transport in spring of 1992. The project commenced with various studies of future market demands. With the market expansion of American business overseas, the airline industry projects a boom of over 200 million passengers by the year 2000. This will create a much higher demand for time efficient and cost effective inter-continental travel; this is the challenge of the high speed civil transport. The TBD(exp 3), a 269 passenger, long-range civil transport was designed to cruise at Mach 3.0 utilizing technology predicted to be available in 2005. Unlike other contemporary commercial airplane designs, the TBD(exp 3) incorporates a variable geometry wing for optimum performance. This design characteristic enabled the TBD(exp 3) to be efficient in both subsonic and supersonic flight. The TBD(exp 3) was designed to be economically viable for commercial airline purchase, be comfortable for passengers, meet FAR Part 25, and the current FAR 36 Stage 3 noise requirements. The TBD(exp 3) was designed to exhibit a long service life, maximize safety, ease of maintenance, as well as be fully compatible with all current high-traffic density airport facilities.

Baughan, Jim↗

NASA NTRS1992

Pressure dependence of the oxygen reduction reaction at the platinum microelectrode/nafion interface - Electrode kinetics and mass transport

The investigation of oxygen reduction kinetics at the platinum/Nafion interface is of great importance in the advancement of proton-exchange-membrane (PEM) fuel-cell technology. This study focuses on the dependence of the oxygen reduction kinetics on oxygen pressure. Conventional Tafel analysis of the data shows that the reaction order with respect to oxygen is unity at both high and low current densities. Chronoamperometric measurements of the transport parameters for oxygen in Nafion show that oxygen dissolution follows Henry's isotherm. The diffusion coefficient of oxygen is invariant with pressure; however, the diffusion coefficient for oxygen is lower when air is used as the equilibrating gas as compared to when oxygen is used for equilibration. These results are of value in understanding the influence of O2 partial pressure on the performance of PEM fuel cells and also in elucidating the mechanism of oxygen reduction at the platinum/Nafion interface.

Parthasarathy, Arvind↗