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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Critical Practices in Rigorously Assessing the Inherent Activity of Nanoparticle Electrocatalysts

Accurate activity measurements for electrocatalytic materials are the backbone of impactful electrocatalyst research. Inherent to accurate measurements is the correct accounting of the active catalyst sites and the design of experiments to ensure that these sites are participating in the measured reaction. Improvements in electrocatalyst activity for fuel cell reactions (hydrogen oxidation and oxygen reduction) are essential for the widespread adoption of this carbon-neutral energy source. Activities for these half-reactions can be reported in a variety of ways including specific activities, mass activities, volumetric activities, and half-wave potentials. These values are traditionally measured with a rotating disk electrode (RDE) in which the electrocatalyst is supported on a porous active layer film attached to the RDE. To accurately measure electrocatalyst activity with an RDE, two major sources of errors must be addressed: (i) accurate electrochemical surface area (ECSA) quantification and (ii) fast diffusion of reactants through the active layer film. In this contribution, we first aim to detail through RDE experiments and mass transport modeling the potential errors that can be observed when these factors are not properly addressed. We then present recommendations and discuss techniques for properly constructing electrocatalyst thin films and characterizing the ECSA on monometallic and novel alloy electrocatalysts. These practices, when adopted, ensure greater confidence and reliability in reports of electrocatalyst activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Platinum-complexed phosphorous-doped carbon nitride for electrocatalytic hydrogen evolution

Sustainable hydrogen gas production is critical for future fuel infrastructure. Here, a series of phosphorous-doped carbon nitride materials were synthesized by thermal annealing of urea and ammonium hexafluorophosphate, and platinum was atomically dispersed within the structural scaffold by thermal refluxing with Zeise's salt forming Pt–N/P/Cl coordination interactions, as manifested in X-ray photoelectron and absorption spectroscopic measurements. The resulting materials were found to exhibit markedly enhanced electrocatalytic activity towards the hydrogen evolution reaction (HER) in acidic media, as compared to the P-free counterpart. This was accounted for by P doping that led to a significantly improved charge carrier density within C 3 N 4 , and the sample with the optimal P content showed an overpotential of only –22 mV to reach the current density of 10 mA cm –2 , lower than that of commercial Pt/C (–26 mV), and a mass activity (7.1 mA μg –1 Pt at –70 mV vs. reversible hydrogen electrode) nearly triple that of the latter. Finally, results from the present study highlight the significance of P doping in the manipulation of the electronic structures of metal/carbon nitride nanocomposites for high-performance HER electrocatalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Heterostructured Au–Ir Catalysts for Enhanced Oxygen Evolution Reaction

Electrochemical water splitting operated under acidic conditions provides a clean approach to generate hydrogen fuels. Currently, the sluggish kinetics of oxygen evolution reaction (OER) at the anode is a bottleneck limiting the acidic water splitting. Here, we report that the OER activity of Ir, one of the most commonly used OER catalysts, can be boosted by forming phase boundaries with Au. Mixed Au and Ir catalysts were synthesized on carbon paper electrodes, which underwent structural evolution under the OER environment to form an Au-Ir interface-rich structure. Compared with Ir catalyst, which requires an overpotential of ~393 mV to achieve a current density of 10 mA/cm 2 in 0.1 M HClO 4 electrolyte, the evolved Au-Ir catalyst shows a lower overpotential at ~351 mV. X-ray photoelectronic spectrum (XPS) study, in conjunction with electrochemical analysis on the surface-site-normalized activity, reveals that the improved OER performance is due to the presence of Au/Ir interfaces in the catalysts. In addition to Ir, the strategy of accelerating OER via Au/Ir interfaces has been further applied to IrCo, IrNi, and IrCu alloy catalysts. Here, with the broad applicability of the strategy demonstrated, this study opens a new route to design OER catalysts for efficient acidic water splitting.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Contaminant Cation Effect on Oxygen Transport through the Ionomers of Polymer Electrolyte Membrane Fuel Cells

We characterized the effects of cobalt (Co 2+ ) and other cation contaminants on the oxygen (O 2 ) transport properties of the PFSA ionomer used in polymer electrolyte membrane fuel cells (PEMFCs) and gained insight into the mechanisms by which contaminant cations inhibit O 2 transport. Such cations can be released by alloy catalysts and environmental conditions and pose a significant challenge to maintaining high current density performance with low platinum (Pt) loadings. We used a test cell capable of isolating the ionomer from the membrane electrode assembly (MEA), allowing for O 2 transport resistance (R O2 ) measurements using a limiting current technique. We contaminated ionomer membranes with Li + , Na + , Ni 2+ , Co 2+ , and Ce 3+ and found a general increase in R O2 for increased contamination levels and decreased water activity. In addition, our Co 2+ results indicated distinct concentration-dependent regimes. The other cation-form ionomers allowed us to separate the impacts of ion pair strength, multivalency, and reduced water uptake. We believe that these factors cause a more compressed hydrophilic domain and tortuous O 2 diffusion path, and a commensurate increase in R O2 . Lastly, we studied the impact of Co 2+ on an operating PEMFC and found an increase in R O2 consistent with the results of our isolated membrane tests.

25 ENERGY STORAGE↗
DOE OSTI2024

Electrochemically driven carbon dioxide separation

This project explored the viability of a Ni(OH) 2 based hydroxide exchange membrane carbon capture (HEMCC) device for direct air capture. It is built off an H 2 fuel cell based HEMCC previously developed in the Yushan Yan group at University of Delaware. Taking the same membrane-based, electrochemically driven pH gradient concept, similar flux performance was able to be seen in the Ni(OH) 2 system as the H 2 system when using comparable current densities. The project produced two types of membrane electrode assemblies (MEA). The first was a traditional MEA with two electrodes and a membrane, the second was a flow-through membrane MEA. Consistent performance was achieved with the traditional MEA with an energy cost of 1.1 MWh∙ton -1 and flux of 82 kg∙m -2 ∙yr -1 . This was the most stable of the two designs. This project investigated strategies to improve performance with a flow-through membrane design. Two designs were made, one with a cast phase inversion membrane, and one with powdered membrane layer. The template phase inversion membrane achieved low pressure drop but had performance limitations due to a skin layer of membrane limiting CO 2 gas transport. The powdered membrane layer had better performance but higher pressure drop. Finally, using the powdered membrane, commercial battery materials were able to be used in order to achieve higher flux. This showed that the flow through membrane design does have the capability to overcome flux inefficiencies in the traditional MEA. Moreover, the process design of the system is proposed and given in this project. The process mass and energy balances were calculated for a reference plant of 1000 t/yr CO 2 capture, which contains several subsystems, e.g. air processing subsystem, electrical subsystem, and CO 2 purification and compression subsystem is designed and evaluated. Based on our calculation, When the power consumption for stack is 1 MWh t -1 CO 2 , Additional 382 kWh t -1 CO 2 will be consumed by other subsystem of the plant, i.e. The total power consumption of 1.38 MWh t -1 CO 2 , lower than the final milestone of 1.5 MWh t -1 CO 2 in this project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Thin Cation-Exchange Layers Enable High-Current-Density Bipolar Membrane Electrolyzers via Improved Water Transport

With suitable water dissociation (WD) catalysts, bipolar membranes (BPMs) can efficiently dissociate water into H + and OH – at the junction between anion- and cation-exchange layers (AEL and CEL, respectively). First, however, water must be transported through the AEL or CEL and thus against the outward flow of hydrated H + and OH – . This is a challenge intrinsic to the BPM architecture and limits operation to current densities typically less than ~0.5 A·cm –2 . Here we explore how water transport affects durability and performance in reference alkaline and acidic membrane electrolyzers, and we use the insight gained to design BPMs with improved water transport. We demonstrate a thin-CEL BPM (2-μm Nafion CEL|~200 nm TiO 2 |~200 nm NiO + ionomer|50 μm Sustainion AEL) which maintains a pH difference of ~14 units between the anode and cathode for current densities of up to 3.4 A·cm –2 with a total water electrolysis voltage of ~4 V and an estimated WD overpotential of ~1.5 V. Finally, such high-current-density operation is crucial for key emerging BPM applications, including in water and carbon-dioxide electrolyzers and in (regenerative) fuel cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Critical Parameter Identification of Fuel-Cell Models Using Sensitivity Analysis

Numerical modeling has been a vital tool in proton-exchange-membrane fuel-cell (PEMFC) analysis; however, the predictive capabilities of these models depend on the input physical parameters, several of which are either not experimentally measured or have large scatter in measured values. This article presents an uncertainty propagation-based sensitivity analysis to identify the model parameters that impact the model predictions most. A comprehensive 2-D membrane electrode assembly (MEA) model is used to perform local sensitivity analysis at multiple operating conditions, which encompass the range of environments and operating conditions a cell can encounter. While at lower humidities, cathode kinetics and membrane-ohmic-loss related parameters are crucial, gas transport and porous-media saturation behavior are more important at humidified conditions. Several of these findings are different from previous studies presented in literature. Identifying the crucial parameters helps focus future material and cell optimization studies as well as experimental studies to quantify these parameters with higher accuracy.

25 ENERGY STORAGE↗
DOE OSTI2023

Understanding the limits of Li-NMC811 half-cells

As we push the boundaries of state-of-the-art lithium-ion intercalation materials, such as nickel-rich chemistries, the ability to isolate and understand specific degradation and performance limitations is becoming increasingly important. Half-cells, wherein lithium metal is employed as a dual counter and reference electrode, are commonly used in industry and academia for this purpose. However, the high reactivity of lithium metal drives premature electrolyte degradation and limits cell lifetime, bringing into question the reliability and validity of this cell configuration. Here we explore the limitations of half-cell studies of LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) electrodes with commercially relevant loading. We identify the failure mechanism of this cell configuration through a combination of electrochemical, chemical, and spectroscopic techniques and show that the Li has a direct detrimental impact on the NMC811 chemistry. Our measurements show that vinylene carbonate is critical for these half-cell studies and underpins the cycle limits. Furthermore, we demonstrate the use of Li 4 Ti 5 O 12 (LTO) as an alternative counter electrode for understanding the performance of NMC positive electrode materials, due to its high coulombic efficiency and low reactivity with the organic carbonates routinely employed in lithium-ion battery cell chemistries. These data confirm that NMC811 electrodes can tolerate high voltages (stressed) conditions and that cell failure is mainly a result of crossover effects.

25 ENERGY STORAGE↗
DOE OSTI2021

Investigation of Membrane Chemical Degradation as a Function of Catalyst Platinum Loading

Membrane chemical degradation is one of many factors that can impact fuel cell durability. Additionally, the fuel cell’s lifetime heavily depends on the membrane and its ability to maintain chemical and mechanical integrity. Previous studies indicate that chemical degradation is due to the formation of hydroxyl radicals that attack the polymer structure resulting in membrane thinning, pinhole formation, and the release of fluoride and sulfate ions. Membrane durability was investigated using ultra-low Pt electrode loadings (≤ 0.1 mg Pt cm -2 ). Accelerated stress testing (US-DOE protocols) demonstrated that the degradation rate was found to increase with higher Pt loadings. This is most likely due to more heterogeneous sites for radical formation due to hydrogen crossover to the cathode. We also explored membrane degradation rates while varying catalyst layer thickness, ionomer to carbon ratio, and types of carbon support. All of the aforementioned variables impact the membrane degradation rates.

25 ENERGY STORAGE↗
DOE OSTI2023

Direct Air Capture of Carbon Dioxide Using Nickel Hydroxide Batteries in a Membrane Electrode Assembly

Direct air capture (DAC) is a growing field responding to the need to remove carbon dioxide from the atmosphere. Several technologies are being developed today attempting to meet this need. The technology furthest in development are temperature swing adsorption technologies which have recently moved out of the pilot plant scale.1 This presentation looks to present an electrochemical device as alternative to these technologies. The electrochemical device proposed is a pair of nickel hydroxide (Ni(OH)2) battery electrodes which produce hydroxide (OH-). The hydroxide reacts with carbon dioxide (CO2) to create carbonate (CO32-) and bicarbonate (HCO3-). These carbonates can be transported from the cathode across an anion exchange membrane to the anode where they are evolved back into CO2 due to a pH reduction at the anode. This builds on work that optimized a Hydroxide Exchange Membrane Fuel Cell (HEMFC) for CO2 capture, showing the efficacy of an electrochemically mediated pH swing carbon capture device.2,3 The benefit of the nickel hydroxide battery approach is the low energy cost associated with separation. Because a pair of nickel hydroxide batteries undergo the same electrochemical reaction, low potentials, and thus low energy cost is required. Experiments have shown device level energy requirements of less than 1 MWh ton-1CO2. Most of the energy required by the device produces the pH gradient used to capture and release CO2. The biggest hurdle for this electrochemical approach is increasing the flux of CO2 to allow for more compact devices. Strategies for managing the transient charge and discharge behavior of the battery system will be discussed. Focus will be on improving flux to reduce the overall cost of the device.

Buchen, James↗
DOE OSTI2021

Brine Availability Test in Salt (BATS) FY21 Update

This report summarizes the 2021 fiscal year (FY21) status of ongoing borehole heater tests in salt funded by the disposal research and development (R&D) program of the Office of Spent Fuel & Waste Science and Technology (SFWST) of the US Department of Energy’s Office of Nuclear Energy’s (DOE-NE) Office of Spent Fuel and Waste Disposition (SFWD). This report satisfies SFWST milestone M2SF- 21SN010303052 by summarizing test activities and data collected during FY21. The Brine Availability Test in Salt (BATS) is fielded in a pair of similar arrays of horizontal boreholes in an experimental area at the Waste Isolation Pilot Plant (WIPP). One array is heated, the other unheated. Each array consists of 14 boreholes, including a central borehole with gas circulation to measure water production, a cement seal exposure test, thermocouples to measure temperature, electrodes to infer resistivity, a packer-isolated borehole to add tracers, fiber optics to measure temperature and strain, and piezoelectric transducers to measure acoustic emissions. The key new data collected during FY21 include a series of gas tracer tests (BATS phase 1b), a pair of liquid tracer tests (BATS phase 1c), and data collected under ambient conditions (including a period with limited access due to the ongoing pandemic) since BATS phase 1a in 2020. A comparison of heated and unheated gas tracer test results clearly shows a decrease in permeability of the salt upon heating (i.e., thermal expansion closes fractures, which reduces permeability).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Assessing Nonlinear Polarization in Electrochemical Cells using AC Impedance Spectroscopy

AC impedance spectroscopy is widely used to evaluate performance limitations in energy storage and conversion devices (e.g., batteries, supercapacitors, and fuel cells). This work shows that integrating the resistive elements in an equivalent circuit as functions of steady-state current enables one to recover overpotentials associated with different processes (e.g., ion migration, charge transfer, and diffusion) in nonlinear electrochemical power supplies. Closed form expressions for diffusion overpotentials are derived using this method for transmissive and reflective boundary conditions and three electrode symmetries (planar, cylindrical, and spherical). Discussion is also extended to macroscopically homogenous porous electrodes which are relevant for most real-world devices. Overall, the approach described herein is a powerful tool to identify rate-limiting steps and guide material/component design.

25 ENERGY STORAGE↗
DOE OSTI2020

Roll-to-Roll Direct Coating of Catalyst Inks on Membrane Films: Progress and Challenges

Further development of low temperature electrolysis (LTE) systems is of importance to ensure the renewable hydrogen production for hydrogen-based energy systems. The membrane electrode assembly (MEA) is a key component of the LTE system and typically contains a catalyst coated membrane (CCM). To enable the U.S. Department of Energy's hydrogen production cost goal of $2/kg, high volume manufacturing processes will be required to lower manufacturing costs of the CCM. A promising way for high-throughput manufacturing of CCM is using roll-to-roll (R2R) methods that allow the direct coating of electrodes on membrane films. However, there are many challenges with this methodology, both in the coating process as well as with web handling. In this talk, we discuss the membrane-ink interaction by evaluating the solvent uptake of a Nafion membrane system and verify the coatability of various inks through lab-scale coatings onto this system. Furthermore, rheology and surface tension data of the ink will be discussed together with the resulting morphology of the coated electrodes. The R2R-processed CCMs will finally be analyzed using electrochemical performance data and the results put in context with the challenges that the mass production of CCMs for LTE system faces to date.

39 EE - Hydrogen and Fuel Cell Technologies (EE-3F↗
DOE OSTI2023

Tuning the thermal activation atmosphere breaks the activity–stability trade-off of Fe–N–C oxygen reduction fuel cell catalysts

Fe–N–C catalysts are the most promising platinum group metal-free oxygen-reduction catalysts, but they suffer from a low density of active metal sites and the so-called activity–stability trade-off. Here we report an Fe–N–C catalyst prepared by adding an optimal amount of H 2 to the traditional inert atmosphere during the thermal activation. The presence of H 2 significantly increases the total density of FeN 4 sites, suppressing the unstable pyrrolic-N-coordinated S1 sites and favouring the stable pyridinic-N-coordinated S2 sites with shortened Fe–N bond lengths. Here, we propose that the intrinsically stable S2 sites are probably arranged in well-graphitized carbon layers, and the S1 sites exist in less-graphitized carbon. H 2 could remove unstable S1 sites and retain stable S2 sites during the pyrolysis to break the challenging activity–stability trade-off. The Fe–N–C catalyst in membrane electrode assemblies maintains a current density of 67 mA cm -2 at 0.8 V (H 2 –air) after 30,000 voltage cycles (0.60 to 0.95 V under H 2 –air), achieving encouraging durability and performance simultaneously.

25 ENERGY STORAGE↗
DOE OSTI2021

Fast Charging of Li-Ion Cells: Part V. Design and Demonstration of Protocols to Avoid Li-Plating

Fast charging of Li-ion batteries would make “fueling” of electric vehicles comparable in time to fueling of gasoline-powered cars, increasing consumer appeal of the new technology. Taking the US Department of Energy goal of safe 6 C charging to 80% capacity as a guide, we describe approaches that can mitigate Li plating on the graphite anode. To make this possible, a variable-rate anode potential charging protocol has been implemented by using a microprobe reference electrode to continuously monitor and adjust the current, in this way avoiding low anode potentials that favor Li deposition. Various implementations of the anode potential control are considered using electrochemical modeling and compared with the experimental data. For charge to 80% capacity at 30 °C, an average C-rate of 4.97 C was obtained for an NCM523/graphite cell with 70 μ m thick graphite electrode and 7.40 C for a cell with 47 μ m thick graphite electrode. Our electrochemical model accounts for these observations and provides a means to extrapolate the approach to other cell designs and operation regimes, drawing the maximum average fast charging rates that can still avoid Li plating.

25 ENERGY STORAGE↗
DOE OSTI2022

A Superior Carbonate Electrolyte for Stable Cycling Li Metal Batteries Using High Ni Cathode

Li metal batteries pairing Li metal anode with high-nickel layer structured oxide cathode are a promising energy storage technology to achieve high energy density. To obtain long cycling life for Li metal batteries, the electrolyte plays a pivotal role in stabilizing both the Li metal anode and the high-nickel cathode upon electrochemical cycling. Herein, we report a carbonate electrolyte that enables a Li||LiNi 0.8 Mn 0.1 Co 0.1 O 2 pouch cell to achieve a high gravimetric energy density of 366 Wh/kg and unprecedented cycling stability with 80% capacity retention after 335 cycles. Here, the 19 F quantitative nuclear magnetic resonance spectroscopy and interface characterization demonstrate that FEC and LiDFOB can reduce the consumption rate of each other and the electrolyte, form a robust LiF-rich SEI on Li metal anode, and improve the microstructure integrity of the high-nickel cathode.

25 ENERGY STORAGE↗
DOE OSTI2025

Nano-Engineered Interfaces in Dual-Layer Electrodes for Protonic Ceramic Cells with Enhanced Stability and Kinetics

Enhancing interfacial stability and charge transfer in protonic ceramic cells (PCCs) remains a critical challenge, as structural degradation and interfacial resistance often compromise durability and efficiency. Here, we report a nanoengineered dual-layer oxygen electrode architecture designed to address these limitations by introducing a fine-grained nanoparticle interfacial contact layer beneath a porous catalytic backbone. The nanoscale powders, through enhanced sintering activity, densify into a robust interfacial layer that promotes strong chemical bonding, uniform adhesion, and continuous ionic/electronic pathways with the BCZYYb electrolyte. This hierarchical architecture mitigates delamination, redistributes mechanical stress, and establishes efficient charge and mass transport channels without relying on corrosive surface treatments. Electrochemical evaluation demonstrates that the dual-layer design markedly reduces interfacial polarization resistance and accelerates electrode kinetics. Compared to the single-layer counterpart, the architecture achieves a peel strength of 44.53 N/cm 2 , a 40% improvement in peak power density (0.96 W cm –2 at 600 °C), and a 130% enhancement in electrolysis current density (4.78 A cm –2 at 1.57 V). Faradaic efficiency remains as high as 88% under high steam concentrations, underscoring minimal charge loss during practical operation. Notably, the electrode retains stability across 450–600 °C and under transient voltage cycling, with impedance spectra confirming suppressed interfacial resistance growth over prolonged use. These results highlight nanoscale interface engineering as a powerful route to enhance both mechanical robustness and electrochemical kinetics in PCCs. The demonstrated scalability and durability of this architecture provide a versatile platform for advancing solid-state electrochemical systems, including reversible fuel cells and high-efficiency hydrogen production technologies.

Faradaic efficiency↗
DOE OSTI2026

Relief Zones Enhance the Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) use ultrathin (≤15 μm-thick) polymer electrolyte membranes, susceptible to mechanical degradation from stress concentrations arising from device-level integration. Herein, relief zones were developed to mitigate mechanical degradation by alleviating excess and nonuniform compression across active areas. Relief zones, created through ablation of carbonaceous diffusion media, enable seamless adaptation across MEA dimensions without need for hardware modifications. Demonstrated using fuel cells as a case study, accelerated stress tests revealed a 6-fold lifetime improvement (∼1500 h) compared to conventional edge-protected MEAs, decoupling device-level engineering effects from material limitations.

accelerated stress test↗