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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 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Reversible Intercalation of Fluoride-Anion Receptor Complexes in Graphite

We have demonstrated a route to reversibly intercalate fluoride-anion receptor complexes in graphite via a nonaqueous electrochemical process. This approach may find application for a rechargeable lithium-fluoride dual-ion intercalating battery with high specific energy. The cell chemistry presented here uses graphite cathodes with LiF dissolved in a nonaqueous solvent through the aid of anion receptors. Cells have been demonstrated with reversible cathode specific capacity of approximately 80 mAh/g at discharge plateaus of upward of 4.8 V, with graphite staging of the intercalant observed via in situ synchrotron X-ray diffraction during charging. Electrochemical impedance spectroscopy and B-11 nuclear magnetic resonance studies suggest that cointercalation of the anion receptor with the fluoride occurs during charging, which likely limits the cathode specific capacity. The anion receptor type dictates the extent of graphite fluorination, and must be further optimized to realize high theoretical fluorination levels. To find these optimal anion receptors, we have designed an ab initio calculations-based scheme aimed at identifying receptors with favorable fluoride binding and release properties.

electrolytes↗
NASA NTRS2023

Performance Modeling of Urban Air Mobility Vehicles to Support Air Traffic Management Research

The recent emergence of Urban Air Mobility (UAM) vehicles has resulted in a need for flight performance models that enable comprehensive simulation-based research on air traffic management topics such as route structure, scheduling, and separation standards. Successful performance modeling methods exist for a wide range of traditional aircraft designs. However, comparable modeling methods appropriate for UAM vehicles that combine fixed-wing and rotorcraft performance have not yet been established. One challenge to progress has been the lack of available data capturing the performance characteristics and unique flight profiles of these aircraft. This paper describes methods used to generate the required performance data and the development of performance models for UAM vehicles. Included is a review of the energy and power equations often used in developing performance models for traditional aircraft as well as a discussion of their applicability to UAM vehicles. The challenge of generating realistic performance data in over-actuated vehicles transitioning from hover to cruise flight is also addressed through an approach based on objective function optimization. A table-based performance model format adapted to UAM configurations is described, as well as parametric models intended to accompany the performance table to allow detailed modeling of power and fuel consumption during accelerated flight, turning flight, or flight at an arbitrary climb or descent rate. A discussion of future work is also provided, including the need for refinement of UAM performance modeling methods and formats, especially in conjunction with improvements to aerodynamic modeling of vehicles with complex designs where strong interaction effects may dominate important regions of the flight envelope.

Performance Modeling↗
NASA NTRS2023

Performance Modeling of Urban Air Mobility Vehicles to Support Air Traffic Management Research

The recent emergence of Urban Air Mobility (UAM) vehicles has resulted in a need for flight performance models that enable comprehensive simulation-based research on air traffic management topics such as route structure, scheduling, and separation standards. Successful performance modeling methods exist for a wide range of traditional aircraft designs. However, comparable modeling methods appropriate for UAM vehicles that combine fixed-wing and rotorcraft performance have not yet been established. One challenge to progress has been the lack of available data capturing the performance characteristics and unique flight profiles of these aircraft. This paper describes methods used to generate the required performance data and the development of performance models for UAM vehicles. Included is a review of the energy and power equations often used in developing performance models for traditional aircraft as well as a discussion of their applicability to UAM vehicles. The challenge of generating realistic performance data in over-actuated vehicles transitioning from hover to cruise flight is also addressed through an approach based on objective function optimization. A table-based performance model format adapted to UAM configurations is described, as well as parametric models intended to accompany the performance table to allow detailed modeling of power and fuel consumption during accelerated flight, turning flight, or flight at an arbitrary climb or descent rate. A discussion of future work is also provided, including the need for refinement of UAM performance modeling methods and formats, especially in conjunction with improvements to aerodynamic modeling of vehicles with complex designs where strong interaction effects may dominate important regions of the flight envelope.

Performance Modeling↗
DOE OSTI2025

Electrifying Airport GSE: Monte Carlo Grid Impacts

Airports globally are shifting from ICE-powered to electric Ground Support Equipment (eGSE) to enhance efficiency, reduce operational costs, and improve operator health. Leveraging predictable routes, flat terrain, and low operational speeds, airports provide ideal conditions for electrification. This study evaluates freight GSE electrification at Dallas-Fort Worth International Airport (DFW), USA, using the Agile@ platform, which integrates three analytical methods: Freight Facility Model (FFM), Activity-Structure-Intensity-Fuel (ASIF), and Monte Carlo simulations. Results from 10,000 simulations indicate modest but critical increases in electricity demand and significant variability in GSE energy consumption. These insights emphasize the importance of data-driven scheduling, targeted maintenance, and strategic infrastructure planning. For high-uncertainty scenarios, airports are advised to deploy buffer energy storage systems (battery banks), implement demand-response charging strategies, schedule flexible workforce shifts, and prioritize proactive maintenance-particularly for equipment with higher operational uncertainty, such as tug tractors with trailers. Agile@ thus offers a robust, scalable, and data-driven framework to optimize long-term GSE planning and enhance reliability across diverse airport environments.

Bose, Ranjan [ORNL] (ORCID:0009000791026327)↗
DOE OSTI2024

Volatile fatty acid extraction from fermentation broth using a hydrophobic ionic liquid and in situ enzymatic esterification

Efficient recovery of volatile fatty acids (VFAs) from fermentation broth is a challenge due to low VFA titers and thus limits the commercialization of VFA production using biological routes. Liquid–liquid extraction using hydrophobic ionic liquids (ILs) shows great promise for the extraction and esterification of hydrophilic VFAs. In this study, several ILs were evaluated to select a water-immiscible and efficient extraction solvent. The selected IL, trihexyltetradecyl phosphonium dibutylphosphate ([P 666,14 ][DBP]), gave a cumulative VFA extraction of around 842.8 mg per g IL. The predicted excess enthalpy (H E ) and logarithmic activity coefficients ln(γ) using the COSMO-RS model were validated with the experimentally obtained VFA recovery from fermentation broth. To understand the extraction mechanism of VFAs, quantum theory of atoms in molecules (QTAIM) and noncovalent interaction (NCI) were performed. The results suggest that long chain fatty acids exhibit strong van der Waals interaction with the DBP anion leading to higher VFA extraction. The enzymatic esterification of VFAs with ethanol in [P 666,14 ][DBP] was optimized using the Box–Behnken response surface design of experiment. Under the optimized conditions, up to 83.7% of hexanoic acid was converted to ethyl esters, while other shorter chain VFAs have lower conversion efficiency (38.3–63.2%).

09 BIOMASS FUELS↗
NASA NTRS2005

Reactions of Air Transport Flight Crews to Displays of Weather During Simulated Flight

Display of information in the cockpit has long been a challenge for aircraft designers. Given the limited space in which to present information, designers have had to be extremely selective about the types and amount of flight related information to present to pilots. The general goal of cockpit display design and implementation is to ensure that displays present information that is timely, useful, and helpful. This suggests that displays should facilitate the management of perceived workload, and should allow maximal situation awareness. The formatting of current and projected weather displays represents a unique challenge. As technologies have been developed to increase the variety and capabilities of weather information available to flight crews, factors such as conflicting weather representations and increased decision importance have increased the likelihood for errors. However, if formatted optimally, it is possible that next generation weather displays could allow for clearer indications of weather trends such as developing or decaying weather patterns. Important issues to address include the integration of weather information sources, flight crew trust of displayed weather information, and the teamed reactivity of flight crews to displays of weather. Past studies of weather display reactivity and formatting have not adequately addressed these issues; in part because experimental stimuli have not approximated the complexity of modern weather displays, and in part because they have not used realistic experimental tasks or participants. The goal of the research reported here was to investigate the influence of onboard and NEXRAD agreement, range to the simulated potential weather event, and the pilot flying on flight crew deviation decisions, perceived workload, and perceived situation awareness. Fifteen pilot-copilot teams were required to fly a simulated route while reacting to weather events presented in two graphical formats on a separate visual display. Measures of flight crew reactions included performance-based measures such as deviation decision accuracy, and judgment-based measures such as perceived decision confidence, workload, situation awareness, and display trust. Results demonstrated that pilots adopted a conservative reaction strategy, often choosing to deviate from weather rather than ride through it. When onboard and NEXRAD displays did not agree, flight crews reacted in a complex manner, trusting the onboard system more but using the NEXRAD system to augment their situation awareness. Distance to weather reduced situation awareness and heightened workload levels. Overall, flight crews tended to adopt a participative leadership style marked by open communication. These results suggest that future weather displays should exploit the existing benefits of NEXRAD presentation for situation awareness while retaining the display structure and logic inherent in the onboard system.

Bliss, James P.↗
DOE OSTI2022

One-step production of renewable adipic acid esters from mucic acid over an Ir–ReO x /C catalyst with low Ir loading

The production of adipic acid, a large-volume platform chemical, from biomass represents a petroleum-free route to manufacturing nylon and other polymers more sustainably. In this study, a one-step conversion of bioderived mucic acid to adipates is reported over a heterogeneous, bifunctional Ir–ReO x /C catalyst via deoxydehydration (DODH) and catalytic transfer hydrogenation (CTH) using isopropanol as a green solvent and reductant. With very low Ir content (0.05 wt%), the catalyst provides a low-cost option for the tandem DODH–CTH process, while still enabling reuse and regeneration for at least five cycles. The reported catalytic system generates adipates in good yield (63%) without the need for additives (acids or halogens) or high pressure H 2 . Through model reactions and spectroscopic analyses, a bifunctional DODH–CTH mechanism was supported, with the Re VI/IV redox pair as the active DODH species and Ir0 saturating the dialkene intermediate via CTH. Thermal treatment in catalyst preparation and regeneration was optimized to limit metal leaching while maintaining good activity. Further, the present work outlines a one-step deoxygenation of an aldaric acid substrate from biomass using a bimetallic catalyst of low noble metal content to an important monomer for the polymer industry. This system facilitates use in future syntheses of sustainable chemicals from renewable oxygenates where the catalyst is reusable and affordable.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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↗
NASA NTRS2013

Covalent Crosslinking of Carbon Nanotube Materials for Improved Tensile Strength

Carbon nanotubes have attracted much interest in recent years due to their exceptional mechanical properties. Currently, the tensile properties of bulk carbon nanotube-based materials (yarns, sheets, etc.) fall far short of those of the individual nanotube elements. The premature failure in these materials under tensile load has been attributed to inter-tube sliding, which requires far less force than that needed to fracture individual nanotubes.1,2 In order for nanotube materials to achieve their full potential, methods are needed to restrict this tube-tube shear and increase inter-tube forces.Our group is examining covalent crosslinking between the nanotubes as a means to increase the tensile properties of carbon nanotube materials. We are working with multi-walled carbon nanotube (MWCNT) sheet and yarn materials obtained from commercial sources. Several routes to functionalize the nanotubes have been examined including nitrene, aryl diazonium, and epoxide chemistries. The functional nanotubes were crosslinked through small molecule or polymeric bridges. Additionally, electron beam irradiation induced crosslinking of the non-functional and functional nanotube materials was conducted. For example, a nanotube sheet material containing approximately 3.5 mol amine functional groups exhibited a tensile strength of 75 MPa and a tensile modulus of 1.16 GPa, compared to 49 MPa and 0.57 GPa, respectively, for the as-received material. Electron beam irradiation (2.2x 1017 ecm2) of the same amine-functional sheet material further increased the tensile strength to 120 MPa and the modulus to 2.61 GPa. This represents approximately a 150 increase in tensile strength and a 360 increase in tensile modulus over the as-received material with only a 25 increase in material mass. Once we have optimized the nanotube crosslinking methods, the performance of these materials in polymer matrix composites will be evaluated.

polymer matrix composites↗
NASA NTRS2019

Scenario Complexity for Unmanned Aircraft System Traffic

This work introduces an approach to estimate the complexity of a low-altitude air traffic scenario involving multiple UASs using mathematical programming. Given a set of multi-point UAS flight trajectories, vehicle dynamics, and a conflict resolution algorithm, an abstract model is developed such that it can be solved quickly using a mathematical programming optimization software without running high-fidelity simulations that can be computationally expensive and may not suit real-time apA quick and accurate assessment of complexity for a given traffic scenario can help plan and schedule flights to alleviate traffic bottleneck and mitigate operation risks, especially for unmanned aerial system traffic management where high traffic density or complexity is expected. This work introduces a traffic scenario complexity metric that was constructed based on the number of potential conflicts weighted by the conflict resolution cost associated. The cost associated with a conflict is calculated based on the corresponding conflict resolution maneuvers. To obtain the conflict resolution maneuvers, a MILP-based optimization was formulated with the vehicle model and conflict management parameters incorporated. To evaluate the complexity metrics, an approach of using measurements from high-fidelity simulations was proposed. The scenario complexity measurements for 920 random-generated scenarios were obtained through high-fidelity simulations and treated as the ground truth. Two statistics methods: Pearson and Alternative Conditional Expectations were applied for analysis. The results showed that the number of flights has low correlation with the scenario complexity according to the correlation coefficients calculated by both methods. The Alternative Conditional Expectations method shows that the proposed scenario complexity metric has better correlation with the ground truth than the number of potential conflicts.plications. In the abstract model, each vehicle is represented by a time-varied vector associated with position, speed, and heading information. The total extra distance that aircraft need to divert from their original routes to avoid collisions is computed and used to setup a quadratic programming formula. The metrics including the number of conflicts and extra distances travelled by all vehicles are then utilized to estimate the complexity of a given UAS flight scenario. Results and verification against high-fidelity simulations will be provided in the final draft.

traffic complexity↗
DOE OSTI2025

Barriers and Benefits: Understanding Riders’ Views on Pooled Rideshare in the U.S.

This manuscript provides actionable recommendations to enhance user satisfaction and address existing barriers regarding pooled rideshare (PR) in the United States. Despite PR’s intended benefits, such as reduced traffic congestion and cost savings, its adoption remains limited. To identify these actionable items, a U.S. nationwide survey with 5385 participants explored transportation preferences, barriers, and motivators for PR use in the summer of 2021. First, two factor analyses were conducted. The first factor analysis identified the five factors associated with one’s willingness to consider PR (time/cost, traffic/environment, safety, privacy, and service experience). The second factor analysis revealed the four factors related to ways to optimize one’s PR experience (comfort/ease of use, convenience, vehicle technology/accessibility, and passenger safety). Privacy concerns, for instance, were found to reduce the likelihood of PR adoption by 77%, and convenience had the potential to increase it by 156%. A structural equation model evaluated the relationships among these nine key factors influencing PR usage to develop the Pooled Rideshare Acceptance Model (PRAM). The privacy, safety, trust service, and convenience factors each had a significant large effect (Cohen’s f 2 > 0.35) on the model. PRAM was extended using multigroup analyses to reveal the nuanced impact of 16 demographics, including gender, generation, rideshare experience, etc., highlighting the need for tailored strategies to improve PR acceptance through the Pooled Rideshare Acceptance Model Multigroup Analyses (PRAMMAs). Multiple workshops were held with diverse audiences to translate the team’s findings to date into 84 actionable recommendations, categorized across topical areas like safety, routing, driver and passenger selection, user education, etc. These findings are a foundation for a future study to determine which items resonate with different user groups. In the meantime, the actional items serve as a user-driven resource for policymakers, transportation network companies, and researchers, offering a roadmap to potential improvements to PR services to address existing concerns with the goal of increasing the usage of PR.

actionable recommendations↗
DOE OSTI2026

Influence of fabrication on microstructure and heat affected zone width in weldments of nuclear reactor pressure vessel steel

Advanced manufacturing routes such as electron beam welding and powder metallurgy with hot isostatic pressing are increasingly used across energy and aerospace industries, where the reliable prediction of weld behavior and heat affected zone (HAZ) evolution is critical. This study examines how fabrication routes and post-weld heat treatments influence phase distribution, crystallite size, microstrain, and dislocation density in nuclear reactor pressure vessel steels using synchrotron X-ray diffraction (SXRD). Retained austenite occurs only in samples that did not undergo austenitization, whereas an austenitizing heat treatment fully eliminates retained austenite and produces a more uniform microstructure across the weldment in terms of phase fraction, dislocation density, and microstrain. The Rosenthal solution underestimates the HAZ width for powder metallurgy samples. A newly proposed modified Rosenthal solution, reducing density by accounting for porosity, matches the SXRD-measured HAZ width with a 0.65% error. Structure–property correlations reveal that dislocation density correlates strongly with nanohardness in homogenous microstructures, while in heterogenous weldments nanohardness is further influenced by the presence of dissimilar phase boundaries. These findings provide new insight into the thermal and microstructural response of powder metallurgy fabricated steels and offer a framework for optimizing welding procedures and heat treatments in advanced manufacturing applications.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Erbium-Implanted WS 2 Flakes with Room-Temperature Photon Emission at Telecom Wavelengths

Optically addressable spin impurities in crystals along with device engineering provide an attractive route to realizing quantum technologies in the solid state, but reconciling disparate emitter and host material constraints for a given target application is often challenging. Rare-earth ions in two-dimensional (2D) materials could mitigate this problem given the atomic-like transitions of the emitters and the versatile nature of van der Waals systems. Here we combine ion implantation, confocal microscopy, and ab initio calculations to examine the photon emission of Er-doped WS 2 flakes. Optical spectroscopy reveals narrow, long-lived photoluminescence lines in the telecom band, which we activate after low-temperature thermal annealing. Spectroscopic and polarization-selective measurements show a uniform response across the ensemble, while the fluorescence brightness remains mostly unchanged with temperature, suggesting nonradiative relaxation channels are inefficient. Our results create opportunities for novel solid state devices coupling 2D-hosted, telecom-band emitters to photonic heterostructures separately optimized for photon manipulation.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

Investigating Kinetic Mechanisms of Soot Formation in Plasma Pyrolysis of Methane via Active Learning (Final Technical Report)

Plasma pyrolysis of methane is an effective route for zero-carbon hydrogen production. Yet, soot generated from pyrolysis of hydrocarbons is detrimental to the climate and human health. There is ample experimental and theoretical evidence that suggests polycyclic aromatic hydrocarbons (PAHs) are the molecular precursors to soot particles. The reaction pathways of PAH formation are intricately dependent on a multitude of process parameters, whose kinetic mechanisms are not well-understood in plasma pyrolysis. This project aims to leverage advances in the kinetic modeling of soot formation in combustion, as well as in surrogate modeling and active learning, to systematically investigate the effects of process parameter on the kinetics of PAH formation in plasma pyrolysis of methane. To this end, we propose to use the PAH formation kinetics model developed by the PPPL/PU group based on the well-established ABF and HACA mechanisms, coupled with low-temperature plasma models. We will develop an active learning (AL) framework based on Bayesian optimization to systematically and data-efficiently explore the complex and multivariable parameter space of plasma pyrolysis in order to quantify the effects of plasma and feed parameters on the ABF and HACA kinetic pathways. AL is the branch of machine learning concerned with systematically querying samples from a system (experimental or computational) to train a data-driven model that maps design parameters to a performance criterion. We will use the data generated via AL to perform global sensitivity analysis, combined with uncertainty quantification, to elucidate the impact of different reaction pathways on minimizing formation of soot precursors. This study will result in an improved understanding of kinetics of PAH formation in plasma pyrolysis and can pave the way for more advanced mechanistic studies (e.g., soot nucleation mechanisms). Additionally, the findings will be useful for establishing practical strategies for increasing the pyrolysis efficiency and producing high-grade carbon for synthesis of nanomaterials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Multi-Sensor Optimal Motion Planning for Radiological Contamination Surveys by Using Prediction-Difference Maps

Distributed and networked mobile sensor platforms using unmanned aerial and/or ground vehicles to survey areas of interest offer a safer and more efficient method for radiological contamination mapping; however, most applications rely on uniformly sweeping of the area in a raster-type motion without utilizing the information available in a dynamic sense. We have developed a fully autonomous optimal motion planning procedure for networks with two or more mobile sensors. The procedure utilizes well-established concepts of Gaussian processes in combination with control laws based on centroidal Voronoi tessellations to achieve optimal next-iteration sensor movements. A new method of informing optimal motion planning is proposed, whereby the absolute difference between the prior and current full-map prediction, referred to as the prediction-difference map, is used as the spatial density function within each Voronoi cell, providing immediate and iterative feedback for dynamic use of available information. The Gaussian process regression model used to estimate the contamination in unvisited locations also provides prediction uncertainties, and can be used as a quantitative metric to assess the confidence in the calculated contamination map; these estimates and prediction uncertainties are unavailable for standard uniform survey routines as they can only produce maps in the vicinity of observed locations. We present through simulation the achievable performance gains from using this new method by directly comparing to a uniform survey method. Results show that using the prediction-difference maps to inform motion planning procedures offers a faster rate of producing an accurate and convergent map relative to a uniform survey route.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Energy efficient integrated photonic systems based on inverse design

The energy footprint of modern information processing and communications systems is immense and utilizes a significant fraction of total global energy usage. Data centers alone consume over 70 billion kilowatt-hours per year. Much of this energy usage is intrinsic to the use of electronic wiring, making optical-based technologies a necessary and promising route to mitigating energy consumption in short- to medium-distance communication links. In this project, we developed and implemented a framework for the design of optical components, based on machine learning, which enables optical components relevant to optical information processing to be realized at their physical performance limits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Thermal stability and coalescence dynamics of exsolved metal nanoparticles at charged perovskite surfaces

Exsolution reactions enable the synthesis of oxide-supported metal nanoparticles, which are desirable as catalysts in green energy conversion technologies. It is crucial to precisely tailor the nanoparticle characteristics to optimize the catalysts’ functionality, and to maintain the catalytic performance under operation conditions. We use chemical (co)-doping to modify the defect chemistry of exsolution-active perovskite oxides and examine its influence on the mass transfer kinetics of Ni dopants towards the oxide surface and on the subsequent coalescence behavior of the exsolved nanoparticles during a continuous thermal reduction treatment. Nanoparticles that exsolve at the surface of the acceptor-type fast-oxygen-ion-conductor SrTi 0.95 Ni 0.05 O 3–δ (STNi) show a high surface mobility leading to a very low thermal stability compared to nanoparticles that exsolve at the surface of donor-type SrTi 0.9 Nb 0.05 Ni 0.05 O 3–δ (STNNi). Our analysis indicates that the low thermal stability of exsolved nanoparticles at the acceptor-doped perovskite surface is linked to a high oxygen vacancy concentration at the nanoparticle-oxide interface. For catalysts that require fast oxygen exchange kinetics, exsolution synthesis routes in dry hydrogen conditions may hence lead to accelerated degradation, while humid reaction conditions may mitigate this failure mechanism.

25 ENERGY STORAGE↗
DOE OSTI2025

Rheo–Electric Foundations and Engineering of Carbon Slurry Flow Electrodes

Flowable carbon slurry electrodes promise continuous, scalable electrochemical desalination and energy storage when their rheology (flow and stability) and electronic connectivity are jointly optimized. This report integrates six complementary thrusts that we executed under the Laboratory Directed Research and Development (LDRD) project: (i) a fast, ex situ, centrifuge-compatible method to quantify pellet (packed slurry) electronic conductivity, with a validated cell constant (“shape factor”) and quantitative structure–property insights for carbon mixtures; (ii) a controlled circulation study showing that peristaltic pumping can irreversibly alter particle size and morphology over laboratory-relevant durations; (iii) development of a miniature jet pump that preserves particle integrity while achieving entrainment ratios of 2–4 at practical flow rates; (iv) a comprehensive mapping of how a representative non-ionic surfactant (Tween 20) collapses the carbon gel network, separating network-percolation losses from intrinsic particle contact resistance; (v) in-situ visualization revealing how gravitational settling and flow-driven mixing compete to control charge transport, with dynamic bed layers preventing saturation while achieving 30-fold local concentration enhancement; and (vi) a simple, widely adoptable fabrication route to structured, gas-nitrided titanium nitride (TiN) titanium current collectors that dramatically lower interfacial losses and enable geometry-driven performance gains. Together, these results provide a coherent toolchain and design rules to accelerate formulation screening, de-risk device prototyping, and standardize characterization for carbon slurry electrodes in flow-electrode capacitive deionization (FCDI), electrochemical flow capacitor (EFC), and related systems.

25 ENERGY STORAGE↗