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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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

High-Resolution Three-Dimensional Sculpting of Two-Dimensional Graphene Oxide by E-Beam Direct Write

On demand switchable additive/subtractive patterning of 2D nanomaterials is an essential capability for developing new concepts of functional nanomaterials and their device realizations. Traditionally, this is performed via a multi-step process using photoresist coating and patterning by conventional photo or electron beam lithography, which is followed by bulk dry/wet etch or deposition. This limits the range of functionalities and structural topologies that can be achieved, as well as increases the complexity, cost, and possibility of contamination which are significant barriers to device fabrication from highly sensitive 2D materials. Focused electron beam induced processing (FEBIP) enables a material chemistry/site-specific, high-resolution multi-mode atomic scale processing and provides unprecedented opportunities for direct-write, single-step surface patterning of 2D nanomaterials with an in-situ imaging capability. It allows for realizing a rapid multi-scale/multi-mode approach, ranging from an atomic scale manipulation (e.g., via targeted defect introduction as an active site) to a large-area surface modification on nano and micro scales, including patterned doping and material removal/deposition with 2D (in-plane)/3D (out-of-plane) control. In this work, we report on a new capability of FEBIP for nanoscale patterning of graphene oxide via removal of oxygenated carbon moieties with no use of reactive gas required for etching complemented by carbon atom deposition using focused electron beam. The mechanism of experimentally observed phenomena is explored using the density functional theory (DFT) calculations, revealing that interactions of e-beam liberated reactive oxygen radicals with carbon atoms on graphene basal plane lead to creation of atomic vacancies in the material. The reaction by-products are volatile carbon di-oxides, which are dissociated and volatilized from the graphene oxide surface functional groups by interactions with an energetic focused electron beam. Along with selective “subtractive” patterning of graphene oxide, the same electron beam with increased irradiation doses can deposit out-of-plane 3D carbon nanostructures on top of or around the 2D etched pattern, thus forming a hybrid 2D/3D nanocomposite with feature control down to a few nanometers. Furthermore, this in-operando dual nanofabrication capability of FEBIP is unmatched by any other nanopatterning techniques and opens a new design window for forming 2D/3D complex nanostructures and functional nanodevices.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Performance Evaluation of LPBF Manufactured 316H Components

This work represents the continuation of a benchmark study that includes modeling, fabrication and characterization as demonstration to support industry’s adoption of advanced manufacturing processes in a variety of structures. This comprehensive study investigated the feasibility of using additive manufacturing (AM) technologies, specifically Laser Powder Direct Energy Deposition (LP-DED) and Laser Powder Bed Fusion (LPBF), to produce complex nuclear microreactor components using 316H stainless steel. The research focused on manufacturing an expanded elbow pipe component with transitioning sections, which are traditionally difficult and costly to produce through conventional manufacturing methods. The overall study’s primary objectives are therefore demonstrating AM viability for nuclear applications, optimizing process parameters, developing comprehensive material characterization protocols, validating computational modeling approaches, and establishing manufacturing guidelines for complex geometries. Although the initial work included the phased approach of cubical, upscaled cylindrical components, it is to enable to obtain more knowledge for the printing of the expanded elbow structure. The project achieved significant progress in process development by successfully optimizing LP-DED parameters to achieve 99.16-99.97% relative density in 316H stainless steel components. Through systematic evaluation of sixteen cube samples with varied laser powers (400-700W) and scan speeds (600-900 mm/min), optimal processing windows were identified at 500-550W with 600-700 mm/min or 650-700W with 650-900 mm/min scan speeds. The DED manufactured 316H demonstrated mechanical properties comparable or superior to wrought materials, with Young's modulus ranging from 153-208 GPa and controlled microstructural characteristics including greater than 95% face-centered cubic (FCC) phases and engineered cellular structures with sizes between 3.23-6.17 µm.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Controlled exfoliation of (100) GaAs-based devices by spalling fracture

The importance of exfoliation techniques increases as the semiconductor industry progresses toward thinner devices as a way to reduce material costs and improve performance. Here, the controlled spalling technique is a recently developed substrate removal process that utilizes the physics of fracture to create wafer cleavage parallel to the surface at a precise depth. In this letter, we apply principles of linear elastic fracture mechanics to predict the process conditions needed to exfoliate (100) GaAs of a desired thickness. Spalling can be initiated in a controllable manner, by depositing a stressor film of a residual stress value just below the threshold value to induce a spontaneous spall. Experimental data show process window requirements to controllably spall (100) GaAs. Additionally, experimental spall depth in (100) GaAs compares well to spalling mechanics predictions when the effects of wafer thickness and modulus are considered. To test spalled material quality, III-V single junction photovoltaic devices are lifted off of a (100)-GaAs substrate by spalling methods and electrical characteristics are recorded. No degradation is observed in the spalled device, illustrating the potential of this method to rapidly produce thin, high quality devices.

14 SOLAR ENERGY↗
DOE OSTI2018

Polymethine Thiopyrylium Fluorophores with Absorption beyond 1000 nm for Biological Imaging in the Second Near-infrared Sub-window

Small-molecule fluorescence imaging in the second near-infrared (NIR-II, 1000-1700 nm) window has gained increasing interest in clinical application. Till now, very few studies have been exploited in the small-molecule fluorophores with both excitation and emission in the NIR-II window. Inspired by indocyanine green structure, a series of polymethine dyes with both absorption and emission in NIR-II window have been developed for NIR-II imaging, providing the feasibility to directly compare optical imaging in NIR-IIa (1300-1400 nm) sub-window under 1064 nm excitation with that in NIR-II window under 808 nm excitation. The signal-background ratio (SBR) and tumor to normal tissue ratio (T/NT) achieved great improvement under 1064 nm excitation in the imaging of mouse blood pool and U87 glioma tumors. Furthermore, our study not only introduces a broadband emission fluorophore for both NIR-II and NIR-IIa imaging, but also reveals the advantages of NIR-II excitation over NIR-I in in vivo imaging.

36 MATERIALS SCIENCE↗
DOE OSTI2023

3D-Printed Graded Electrode with Ultrahigh MnO 2 Loading for Non-Aqueous Electrochemical Energy Storage

Electrolytic manganese dioxide is one of the promising cathode candidates for electrochemical energy storage devices due to its high redox capacity and ease of synthesis. Yet, high-loading MnO 2 often suffers from sluggish reaction kinetics, especially in non-aqueous electrolytes. The non-uniform deposition of MnO 2 on a porous current collectors also makes it difficult to fully utilize the active materials at high mass loading. Here, a 3D printed graded graphene aerogel (3D GA) that contains sparsely separated exterior ligaments is developed to create large open channels for mass transport as well as densely arranged interior ligaments providing large ion-accessible active surface. The unique structural design homogenizes the thickness of electro deposited MnO 2 even at an ultrahigh mass loading of ≈70 mg cm -2 . The electrode achieves a remarkable volumetric capacity of 29.1 mA h cm -3 in the non-aqueous electrolyte. A Li-ion hybrid capacitor device assembled with a graded 3D GA/MnO2 cathode and graded 3D GA/VO x anode exhibits a wide voltage window of 0–4 V and a superior volumetric energy density of 20.2 W h L -1 . The findings offer guidance on 3D printed electrode design for supporting ultrahigh loading of active materials and developments of high energy density energy storage devices.

electrochemical energy storage↗
DOE OSTI2013

A comparative study of SrO and BaO doping to CeO{sub 2}-ZrO{sub 2}: Characteristic and its catalytic performance for three-way catalysts

Graphical abstract: Display Omitted Highlights: ► The prepared materials have a face-centered cubic structure and nanosize particles. ►Comparing to CZB, aged CZS has 494 μmol/g of OSC and 30 m{sup 2}/g of surface area. ► CZS and CZB have similar NO sorption and reductive properties and different H{sub 2} uptake. ► T{sub 50} of Pt-Rh/CZS/LA is as low as 199 °C for CO, 228 °C for NO, and 252 °C for C{sub 3}H{sub 8}. ► Pt-Rh/CZS/LA has wider working-window at 320 °C under different λ value. -- Abstract: Ceria-zirconia-strontia (Ce{sub 0.35}Zr{sub 0.55}Sr{sub 0.10}O{sub 1.9}) and ceria-zirconia-baria (Ce{sub 0.35}Zr{sub 0.55}Ba{sub 0.10}O{sub 1.9}) were synthesized using an oxidation-co-precipitation method with hydrogen peroxide (H{sub 2}O{sub 2}) as oxidant. The physical and chemical properties of the prepared materials were investigated using Brunauer–Emmett–Teller surface area characterization, transmission electron microscopy, X-ray diffraction, Raman spectra, X-ray photoelectron spectroscopy, and oxygen pulse reaction. The prepared materials were used in preparing three-way catalysts with low Pt and Rh content. Moreover, catalytic activities were evaluated at a fixed bed under a simulated gaseous mixture. The results are as follows: (1) the prepared materials have a face-centered cubic structure and are nano-sized; (2) aged Ce{sub 0.35}Zr{sub 0.55}Sr{sub 0.10}O{sub 1.9} has higher oxygen storage capacity (494 μmol/g), better thermal stability (30 m{sup 2}/g), good low-temperature reducibility, and high hydrogen uptake after TPR-redox cycles; (3) the light-off temperature (T{sub 50}) of Pt-Rh/CZS/LA can be as low as 199 °C for CO, 228 °C for NO, and 252 °C for C{sub 3}H{sub 8}; and (4) Pt-Rh/CZS/LA has a fairly wide working-window.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Discovery of Energy Storage Molecular Materials Using Quantum Chemistry-Guided Multiobjective Bayesian Optimization

Redox flow batteries (RFBs) are a promising technology for stationary energy storage applications due to their flexible design, scalability, and low cost. In RFBs, energy is carried in flowable redoxactive materials (redoxmers) which are stored externally and pumped to the cell during operation. Further improvements in the energy density of RFBs necessitates redoxmer designs with wider redox potential windows and higher solubility. Additionally, designing redoxmers with a fluorescence-enabled self-reporting functionality allows monitoring of the state of health of RFBs. To accelerate the discovery of redoxmers with desired properties, state-of-the- art machine learning ( ML) methods, such as multiobjective Bayesian optimization (MBO), are useful. Here, we first employed density functional theory calculations to generate a database of reduction potentials, solvation free energies, and absorption wavelengths for 1400 redoxmer molecules based on a 2,1,3-benzothiadiazole (BzNSN) core structure. From the computed properties, we identified 22 Pareto-optimal molecules that represent best trade-off among all of the desired properties. We further utilized these data to develop and benchmark an MBO approach to identify candidates quickly and efficiently with multiple targeted properties. With MBO, optimal candidates from the 1400-molecule data set can be identified at least 15 times more efficiently compared to the brute force or random selection approach. Importantly, we utilized this approach for discovering promising redoxmers from an unseen database of 1 million BzNSN-based molecules, where we discovered 16 new Pareto-optimal molecules with significant improvements in properties over the initial 1400 molecules. Furthermore, we anticipate that this active learning technique is general and can be utilized for the discovery of any class of functional materials that satisfies multiple desired property criteria.

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

Addendum to the REBUS Users Guide: REBUS-PC (V.1.5)

The Department of Energy (DOE) National Nuclear Security Administration (NNSA) Material Management and Minimization (M3) Reactor Conversion Program uses the REBUS-PC computer code to provide reactor physics and core design information such as neutron flux distributions in space, energy, and time, and to track isotopic changes in fuel and neutron absorbers with burnup. REBUS-PC has evolved from the original REBUS code, which was created starting in the 1960’s to study large liquid metal cooled fast reactors. In particular, additional outputs were added to improve user convenience and some inputs were modified to improve the functionality of the software. REBUS and REBUS-PC both model the external cycle, and are very general codes with 1D, 2D, and 3D neutronics capabilities, and with complete fuel shuffling capabilities. REBUS remains an extremely efficient reactor analysis tool for use in fast reactor systems, and so development has continued at Argonne National Laboratory (ANL) to this day for non-thermal reactor applications. While retaining the efficient computational engine of REBUS, REBUS-PC has evolved to its present status with continuous development since 1999. REBUS-PC has numerous changes and enhancements directed toward the needs of the thermal reactor analyst using Windows or Linux-based computational platforms.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Transparent, High‐Charge Capacity Metal Mesh Electrode for Reversible Metal Electrodeposition Dynamic Windows with Dark‐State Transmission <0.1%

Abstract Dynamic windows allow user control over light and heat flow to save energy and maximize comfort. Reversible metal electrodeposition (RME) dynamic windows can uniquely tint to a color‐neutral privacy state (0.1% visible light transmission). The design parameters of transparent metal mesh counter electrodes for high‐contrast RME dynamic windows: high transparency, charge capacity and surface area with low haze, sheet resistance and cost are discussed, concluding that woven metal meshes meet these design parameters. Electroplated current is measured on an indium tin oxide electrode and two meshes with different wire spacings, showing the meshes’ cylindrical geometry enable them to draw more current per square area. The mesh material composition is analyzed to ensure cycling durability in a CuBi electrolyte by developing a transparent mesh with an inert core (stainless steel, SS), a thin Au coating, and a high charge‐capacity (1.5 C cm −2 ) CuBi outer coating. The study demonstrates that the films maintain a consistent Cu:Bi ratio and optical properties after 250 privacy cycles or 1500 cycles to 10% transmission, showing that the Cu and Bi coating is effective in keeping the films from becoming Cu rich with cycling. Finally, a 100 cm 2 device with excellent uniformity and color neutrality is demonstrated.

Yeang, Andrew L.↗
DOE OSTI2017

Efficient Simulation and Abuse Modeling of Mechanical-Electrochemical-Thermal Phenomena in Lithium-Ion Batteries

NREL's Energy Storage team is exploring the effect of mechanical crush of lithium ion cells on their thermal and electrical safety. PHEV cells, fresh as well as ones aged over 8 months under different temperatures, voltage windows, and charging rates, were subjected to destructive physical analysis. Constitutive relationship and failure criteria were developed for the electrodes, separator as well as packaging material. The mechanical models capture well, the various modes of failure across different cell components. Cell level validation is being conducted by Sandia National Laboratories.

25 ENERGY STORAGE↗
DOE OSTI2017

U.S.-Origin Nuclear Material Removal Program - 17027

The United States (U.S.) Department of Energy (DOE) Office of Material Management and Minimization (M3) U.S.-Origin Nuclear Material Removal program, also known as the Foreign Research Reactor Spent Nuclear Fuel Acceptance Program (FRR SNF AP), was established by the U.S. Department of Energy in May 1996. The program's mission provides a disposition pathway for certain U.S. origin spent nuclear fuel and weapons-grade nuclear material. The program concluded on May 12, 2016. Irradiation must have been stopped by this date to remain eligible for return. An additional three year window is allowed for fuel cooldown and transportation of SNF elements. The end of this shipping window is May 12, 2019. This paper provides an update on recent program accomplishments, current program initiatives, and future activities. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2015

Large optics for the National Ignition Facility

The National Ignition Facility (NIF) laser with its 192 independent laser beams is not only the world’s largest laser, it is also the largest optical system ever built. With its 192 independent laser beams, the NIF requires a total of 7648 large-aperture (meter-sized) optics. One of the many challenges in designing and building NIF has been to carry out the research and development on optical materials, optics design, and optics manufacturing and metrology technologies needed to achieve NIF’s high output energies and precision beam quality. This paper describes the multiyear, multi-supplier, development effort that was undertaken to develop the advanced optical materials, coatings, fabrication technologies, and associated process improvements necessary to manufacture the wide range of NIF optics. The optics include neodymium-doped phosphate glass laser amplifiers; fused silica lenses, windows, and phase plates; mirrors and polarizers with multi-layer, high-reflectivity dielectric coatings deposited on BK7 substrates; and potassium di-hydrogen phosphate crystal optics for fast optical switches, frequency conversion, and polarization rotation. Also included is a discussion of optical specifications and custom metrology and quality-assurance tools designed, built, and fielded at supplier sites to verify compliance with the stringent NIF specifications. In addition, a brief description of the ongoing program to improve the operational lifetime (i.e., damage resistance) of optics exposed to high fluence in the 351-nm (3ω) is provided.

36 MATERIALS SCIENCE↗
DOE OSTI2019

MoS 2 Liquid Cell Electron Microscopy Through Clean and Fast Polymer-Free MoS 2 Transfer

Two dimensional (2D) materials have found various applications because of their unique physical properties. For example, graphene has been used as the electron transparent membrane for liquid cell transmission electron microscopy (TEM) due to its high mechanical strength and flexibility, single-atom thickness, chemical inertness, etc. Here, we report using 2D MoS 2 as a functional substrate as well as the membrane window for liquid cell TEM, which is enabled by our facile and polymer-free MoS 2 transfer process. This provides the opportunity to investigate the growth of Pt nanocrystals on MoS 2 substrates, which elucidates the formation mechanisms of such heterostructured 2D materials. We find that Pt nanocrystals formed in MoS 2 liquid cells have a strong tendency to align their crystal lattice with that of MoS 2 , suggesting a van der Waals epitaxial relationship. Importantly, we can study its impact on the kinetics of the nanocrystal formation. Here, the development of MoS 2 liquid cells will allow further study of various liquid phenomena on MoS 2 , and the polymer-free MoS 2 transfer process will be implemented in a wide range of applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Equilibrium-gated pattern formation: How molecular dissociation thermodynamics drive emergent behavior in dissipative polymeric systems

Emergent patterns in biological systems arise through dissipative processes that balance reaction and transport phenomena, producing highly functional properties from self-regulating mechanisms. Synthetic fabrication, by contrast, often relies on user-controlled, multistep methods that lack the self-organizing capabilities of natural systems. Inspired by nature, we sought chemical systems that integrate strongly coupled reaction and transport phenomena, identifying frontal ring-opening metathesis polymerization (FROMP) as a method capable of creating diverse forms and functions through reactive processing. By employing discrete molecular initiators, FROMP allows precise control of key reaction steps—inhibition, initiation, and propagation. Using an integrated computational and experimental framework, we uncover how near-equilibrium inhibition dynamics, coupled with far-from-equilibrium reaction kinetics, drive pattern formation in frontally polymerized synthetic materials. We propose the concept of equilibrium-gated pattern formation, demonstrating how initiator chemistry can be tuned to achieve programmable macroscale properties. Our study reveals a surprising insight: Emergent behavior in FROMP systems arises from the inhibition-dominated regime of resin composition, expanding prior observations that such behavior is confined to a narrow compositional space near the boundary between front quenching and uniform front propagation. We identify a broader compositional window, far from the quenching regime, where emergent behavior reliably manifests. This expanded design space significantly enhances the operational flexibility of reactive systems and their capacity for self-organization. Furthermore, these insights provide a roadmap for designing bioinspired materials with self-organizing capabilities, unlocking possibilities in synthetic manufacturing.

Architected Polymers↗
DOE OSTI2019

Collaborative Robots vs. Master/Slaves - 19522

This paper will discuss the feasibility, application, and economy of applying collaborative robots (co-bots) in lieu of traditional through-the-wall tele-operated manipulator systems, traditionally used within hazardous (radioactive) environments. Both fixed facility and mobile applications will be discussed. Both single- and dual-armed co-bot systems will be employed. The six-axis, plus gripper, single-armed co-bots will provide for machine vision enhanced pick-n-place applications within shielded rooms and also include force-reflecting (haptic) teleoperations controls for non-routine materials-handling operations. The dual-armed system will be mounted to a motorized stand with motorized adjustment both vertically and rotationally (around its base). To complement these co-bots, both two-dimensional and three-dimensional vision technologies will be implemented. The vision technologies, in these applications, are used in lieu of traditional radiation shielding windows. two-dimensional video systems will provide for large area viewing, incorporating pan, tilt, and zoom capabilities. Three-dimensional video systems will be mounted to the dual-armed robot stand and provide viewing, including depth-of-perception, to the operator, performing material handling and other tasks, from an operator workstation located outside the hazardous environment. The unique workstation used with the dual-armed systems will also be described. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗