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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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This report examines the development and use of coal-plastic composite (CPC) materials for use in building applications. CPC formulations were developed at bench scale and evaluated for decking applications. CPC decking boards were designed, manufactured, and evaluated. Techno-economic and lifecycle analyses for CPC decking are also reported.
The generation of high magnetic fields requires materials with high electric conductivity and good strength properties. Cu/Nb composites are considered to be good candidates for this purpose. In this work, we aim to predict, from theory, the dependence of electric conductivity on the microstructure, most notably on the layer thickness and grain sizes. We also conducted experiments to calibrate and validate our simulations. Bimetal interfaces and grain boundaries are confirmed to have the largest impact on conductivity in this composite material. In this approach, a distribution of the layer thickness is accounted for in order to better model the experimentally observed microstructure. Because layer thicknesses below the mean free path of Cu significantly degrade the conductivity, an average layer thickness larger than expected may be needed to meet conductivity requirements in order to minimize these smaller layers in the distribution. We also investigate the effect of variations in volume fraction of Nb and temperature on the material’s conductivity.
Metal Amorphous Nanocomposite (MANC) materials offer low losses at high magnetic switching frequency, enabling high power density motors with increased rotational speed. While MANCs have high strength, they are brittle. The use of motor components such as a rotor consisting of brittle material presents a reliability concern. Here, a promising MANC alloy is subjected to tensile tests and failure is observed with high-speed photography. A method is developed to prepare tensile specimens of laminated MANC and epoxy layers, simulating the stacking of an epoxy-impregnated tape-wound core. Tensile tests are conducted for single layer ribbon and for five- and ten-layer stacks of laminated material with thin layers of thermosetting epoxy. Failure distributions are shown to have increasing Weibull modulus with increasing layer count. The composite MANC material system is modeled using chain-of-bundles models. Using a k-failure model, we show that single ribbon strength distribution data can be used to predict well the failure distribution of laminated stacks. The agreement occurs when the assumed ineffective length, over which load is recovered in a failed layer, is comparable to the observed interlaminar separation length.
Sandia’s contribution to the FY23/Q4 GNG milestone was met: Demonstrate one composite hydride material with experimental data showing reversibility (50 cycles) and volumetric capacity ≥ 350 bar compressed gas.
Solid-state batteries (SSBs) fabricated using sulfide solid electrolytes (SSEs) typically require cell stack-pressures in the range of tens to hundreds of megapascals to maintain effective interfacial contact and lithium-ion mobility across the full cell stack. These relatively high cell stack-pressures necessarily require additional cell components that reduce the delivered volumetric and gravimetric capacities of SSBs. This work has developed a novel sulfur polymer (polyS) that improves lithium-ion conductivity in SSBs at low cell stack-pressures, thereby directly targeting this technological limitation. Specifically, this work shows that polyS can be combined with the argyrodite Li6PS5Cl (LPSC) to form a stable composite SSE. By combining LPSC particles with a flexible additive that enhances interfacial contact at low pressures, this new polyS LPSC composite SSE material greatly improves ionic conductivity at cell stack-pressures below 2.0 MPa in comparison to conventional LPSC composites. Furthermore, this polyS LPSC composite can be used to fabricate a full SSB that cycles reversibly at only 1.6 MPa. Finally, this composite SSE exhibits self-healing behavior when combined with a lithium metal electrode, wherein lithium dendrites are oxidized to form passivating Li2S species that recover the cell from shorting.
Harvesting solar energy, preventing hot spots in electronics, transport of temperature-sensitive materials, and capture and repurposing of thermal energy require a latent heat thermal energy storage (TES) system to store/discharge heat repeatedly. For the practical application of phase change material (PCM) composites within TES systems, reliable thermal performance throughout its operational lifetime is essential. Nevertheless, the reliability of thermal conductivity in multi-phase composites over relevant numbers (>10 3 ) of melt/freeze cycles has barely been studied, particularly for composites containing fillers for thermal conductivity enhancement. Here, we introduce a preform-type expanded graphite (EG)/paraffin wax composite possessing highly robust heat transfer and storage properties even after 10,000 melt/freeze cycles. To achieve such excellent reliability, comparative studies on the combined influence of fabrication process, particle size, EG vol%, binder amount, and compaction on both magnitude and robustness of thermal conductivity were undertaken. Our parametric study has yielded a trade-off between thermal conductivity and latent heat. Based on our modeling, 20 vol% EG approaches the case where all EG particles are well-connected thermally while 10 vol% EG is close to loosely connected fillers in the matrix. Thermal conductivity of our paraffin composites containing 20 vol% EG (25.1 W·m -1 ·K -1 ) is highest among other EG/paraffin composites without aligned EG in the literature. After 10,000 thermal cycling, negligible conductivity fading was observed for the 10 vol% EG composite, while reduction in latent heat remained within 10% for all 10, 14, 17 and 20 vol% EG samples. Here we anticipate this work provides insight on suitable recipe for desirable magnitude and robustness of thermal conductivity of EG/paraffin composites.
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The broader application of nickel-rich layered oxides as positive electrode materials for lithium-ion batteries has been hindered by their high manufacturing cost and inferior cycling stability. Thermal processing, which is integral to electrode materials manufacturing and fundamental in materials science, has not been fully utilized to design advanced positive electrode materials. Herein, we demonstrate the capability of using quenching heat treatment to regulate Li distribution and modulate electronic structure near particle surface. The resulting materials exhibit less parasitic reactions with the electrolyte and an improved charge distribution homogeneity in secondary particles, leading to more stable cycling performance at high voltages (4.5 V vs Li/Li + ). Our synchrotron X-ray analyses reveal the underlying interplay between surface structure and bulk charge distribution in positive electrode materials particles. While strategies used to stabilize positive electrode materials through compositional control, surface modification, and electrolyte engineering have become mature, thermal processing can be advantageous to further improve positive electrode materials manufacturing.
In the course of four funding cycles of this project, its research focused on the exploration and understanding of spin-dependent electronic processes in organic semiconductors. It aimed to investigate the potential of harnessing the spin degree of freedom in organic materials for various applications such as spin electronics, quantum information, sensors, and as well as quantum coherent spin phenomena of charge carrier states in organic semiconductors, with the aim to develop room-temperature-based quantum applications. Specifically, the project aimed to: Apply new diagnostic tools, i.e. spin spectroscopy techniques, for paramagnetic charge carrier states in organic semiconductors, based on coherent control with pulsed electron spin resonance to understand spin relaxation and spin mixing mechanisms in organic semiconductor materials and devices such as OLEDs. Explore the nature of charge carrier spin-coupling and pathways for its manipulation to control the physical behaviors of these materials. This involves investigating spin interactions through materials structure, composition, morphological dependencies, isotopic effects, and externally applied electric and magnetic fields, with the goal to manipulate electrical and optical material properties by adjusting spin-orbit, spin-dipolar, spin-exchange, as well as spin-hyperfine interactions to open up this materials class for new applications. Study spin-dependent charge carrier transport and recombination and how these observables are governed by spin-propagation, especially coherent spin propagation as well as collective spin-effects such as the spin-Dicke effect and resonant multi-photon magnetic dipole transitions. The project utilized pulsed electrically detected magnetic resonance (pEDMR) and pulsed optically detected magnetic resonance (pODMR) techniques over a wide frequency range. These techniques enabled the observation and quantification of various spin-spin coupling types, including spin-exchange, spin-dipolar, hyperfine, and spin-orbit interactions. The project will leverage low- to mid-frequency pEDMR/pODMR facilities and collaboration with the National High Magnetic Field Laboratory.
The objective of this project was to evaluate material-based hydrogen storage solutions as a replacement for high-pressure hydrogen gas or liquid hydrogen on Class 7 or 8 tractor fuel cell electric vehicles. The project focused on low-density main-group hydrides, a well-known class of materials for hydrogen storage. Prior research has considered metal amides as storage materials for light-duty vehicles but not for heavy-duty applications. The project established the basis for further development of storage systems of this type for heavy duty vehicles (HDV). Systems analysis of an HDV storage system comprised of a tank and associated balance of plant (piping, coolant tubes, burner) was performed to determine the usable hydrogen capacity. A composite storage material comprised of a metal hydride mixed with a high thermal-conductivity carbon is predicted to have a usable hydrogen volumetric capacity comparable to or exceeding that of 700 bar pressurized hydrogen gas. The gravimetric capacity of this material is also predicted to be competitive with pressurized gas, particularly if costly carbon fiber composite Type III or Type IV tanks are excluded. The storage system design parameters and material properties served as inputs to a second model that simulates fuel cell operation in conjunction with the storage system during an HDV drive cycle. The results show that sufficient hydrogen pressure can be produced to operate a Class 8 HDV, yielding a range of ~480 miles. These results are particularly relevant for high-impact regions, such as the South Coast Air Quality Management District, for which an economical vehicular hydrogen storage system with minimal impact on cargo capacity could accelerate adoption of heavy-duty fuel cell electric vehicles. An additional benefit is that knowledge generated by this project can assist in development of material-based storage for stationary applications such as microgrids and backup power for data centers.
The technical objective of this project was to develop sorption enhanced mixed matrix membranes with H 2 permeance of 500 gas permeance units (GPU) and H 2 /CO 2 selectivity of 30 at 150-200 °C. These membranes will be the central component in the design of membrane based systems for 90% capture of CO 2 from coal-derived syngas, with 95% CO 2 purity at a cost of electricity 30% less than baseline capture approaches. The unique approach in this proposal is to design crosslinked polymers containing Pd-based nanoparticles achieving strong H 2 sorption and size sieving ability and thus H 2 /CO 2 selectivity. The specific objectives for each budget period (BP) are described below. BP 1: Identify polymer matrix with strong size sieving ability and palladium (Pd)-containing nanomaterials to prepare freestanding mixed matrix films with H 2 permeability of 50 Barrer and H 2 /CO 2 selectivity of 30 at 150-200°C with simulated syngas. BP 2: Prepare and optimize thin film mixed matrix composite membranes materials with H 2 permeance of 500 GPU and H 2 /CO 2 selectivity of 30 at 150-200 °C, and complete the modification of the membrane test unit for the field test in the BP 3. BP 3: Conduct a 20-day field test of the membranes with real syngas at Center for Advanced Energy Research (CAER) of the University of Kentucky (UKy). During the BP2, we have successfully prepared thin-film composite (TFC) membranes based on mixed matrix materials (MMMs) containing Pd nanoparticles in polymers, and demonstrated their superior and robust performance for H 2 /CO 2 separation at 150 – 225 °C. (1) Production of the Pd based nanoparticles with a diameter of 4 nm has been scaled up to 200 mg/day. (2) We have prepared TFC membranes with H 2 permeance above 500 GPU and H 2 /CO 2 selectivity above 30 at temperatures up to 225 °C, which meet the targets for the BP2. (3) We have conducted parametric studies of TFC membranes with a mixed gas containing H 2 S and H 2 O and demonstrated the stability of the membranes. (4) We have established a new testing plan at the Center for Advanced Energy Studies (CAER) at the University of Kentucky because NCCC decided to shut down their gasifier. During this project, four Ph.D. students received the inter-disciplinary training and graduated, including Shailesh Konda, Maryam Omidvar, Deqiang Yin, and Lingxiang Zhu. One postdoctoral researcher (Dr. Liang Huang) and two Ph.D. students (Abhishek Kumar and Hien Nguyen) are involved in this project. The project leads to one provisional patent application, eight peer-reviewed articles, and one manuscript in preparation. The details are shown below.
Modeling of heterogeneous materials and media is a problem of fundamental importance to a wide class of phenomena and systems, ranging from condensed matter physics, soft materials, and composite media to porous media, biological systems, geosystems, ceramic engineering, pharmaceutical science and even in space discoveries. Among the most important materials are granular systems, which have received intense interest from the engineering, physics, and mathematics communities. In this review paper, the recent developments and new advances in experimental, and computational methods on a variety of scales and physics that extend understanding to a wide range of materials and phenomena are reviewed. Experimental advances include computed neutron and nanometer-scale tomography, magnetic resonance imaging, refractive index matching, digital image correlation, acoustic emission analysis, and the most recent 4D techniques. Furthermore, a tremendous shift has occurred from the continuum scale to micro-scale and developing multiscale approaches. As such, various computational methods, including, constitutive modeling, discrete modeling, and multiscale approaches, have been developed. In conclusion, aside from all these evolutions, more complicated modeling called coupled, or multiphysics, systems representing a simultaneous presence of heat, fluid, chemical variation, and mechanical effect are also explored.
This paper delineates the feasibility of incorporating microencapsulated phase change materials (mPCM) into 3D printable cementitious composite materials. A comprehensive experimental program was carried out to evaluate the impacts of mPCM on the printability, microstructures, mechanical and thermal properties of cementitious 3D printing ‘inks’. Results showed that the mPCM affected the printability of the cementitious ink material based on its physical properties (e.g., particle size) and volume loading – at lower volume loadings, mPCM increased the flowability of the cementitious ink material while leading to increased compressive strength and thermal conductivity for the hardened printed material. However, further increase in mPCM dosage led to a decrease in printability and, therefore, decrease in compressive strength and thermal conductivity as compared to the reference mixture. Here the results also showed that the inclusion of mPCM influence the printing parameters. In general, the inclusion of higher volume contents of mPCM necessitates a higher extrusion rate to achieve a desirable extrudability. Lastly, a thermal network model was formulated for 3D printed mPCM charged building components (e.g., wall). The study shows that microencapsulated PCM materials have good potential to be used in 3D printable cementitious mixtures for improving the thermal and energy performance of 3D printed buildings.
High-entropy materials with compositional and structural complexities introduce a transformative opportunity for catalysis.
Mid-infrared (MIR) spectroscopy has been used with great success to quantitatively determine the mineralogy of geologic samples. It has been employed in a variety of contexts from determining bulk composition of powdered samples to spectroscopic imaging of rock thin sections via micro-Fourier transform infrared (micro-FTIR) imaging spectroscopy. Recent advances allow for IR measurements at the nanoscale. Near field nanoscale infrared imaging and spectroscopy with a broadband source (nano-FTIR) enable understanding of the spatial relationships between compositionally distinct materials within a sample. This will be of particular use when analyzing returned samples from Bennu and Ryugu, which are thought to be compositionally like CI or CM1/2 carbonaceous chondrites. Returned samples will likely contain olivine/pyroxene chondrules that have been transformed into hydrous phyllosilicates, sulfides, carbonates, and other alteration phases. The use of near-field infrared techniques to probe the boundaries between once pristine chondrules and alteration phases at the nanoscale is a novel approach to furthering our understanding of the compositional evolution of carbonaceous asteroids and the processes that drive their evolution. Here we report the results of nano-FTIR spectroscopy and imaging measurements performed on the carbonaceous chondrite Allan Hills (ALH) 83100 (CM1/2). We show with nanoscale resolution that spatially resolved Fe-Mg variations exist within the phyllosilicates around a chondrule rim. We also present effects of crystal orientation on the nano-FTIR spectra to account for the spectral differences between the meteorite and mineral spectra.
Non-stoichiometric compounds may develop a composition gradient when they are formed by reactive diffusional processes. This paper reports an interesting phenomenon that in compounds with low bulk diffusivities, which rely mainly on grain boundary diffusion for their growth, the final bulk compositions may be far from equilibrium, with a very low bulk diffusivity leading to fixed (persistent) compositions – one such example is Nb 3 Sn, a superconductor. We investigated the microchemistry at the reactive interface using atom probe tomography to clarify the diffusion reaction mechanism for this low-bulk-diffusivity case and thus propose a theory for what determines the compound composition, using Nb 3 Sn as an example for concreteness. Using certain approximations, we derive an explicit analytical equation that illustrates what factors determine its composition profile. We compare our model with the known facts of Nb 3 Sn and see good agreement. In particular, this model predicts that internal oxidation may lead to higher Sn contents than conventional, non-oxidized Nb 3 Sn. Our measurements show that this is indeed true, and that the internally-oxidized Nb 3 Sn also has higher upper critical fields, achieving up to 28.2 T at 4.2 K. We discuss the general applicability of this model to non-stoichiometric compounds with low bulk diffusivity, and propose it as a tool to help in the design and processing of such materials for compositional control.
Improvements in additive manufacturing technologies will enable multiple-material and advanced material capabilities, creating opportunities to improve and expand the nuclear fuel fabrication process. Additive manufacturing can allow fuel to have complex geometries and contain composites of materials that would otherwise be difficult or impossible to make with traditional manufacturing methods. This opportunity also has implications for nuclear proliferation, as nuclear parts may be printed and more easily acquired. Here, we present a survey of additive manufacturing technologies and relevant signatures that could be used to identify processes, materials, or part properties.