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At least 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

High tensile alloy of copper to mitigate current collector deformation in silicon electrodes for lithium-ion batteries

The volumetric changes of silicon electrodes, along with the strong adhesive properties of certain binders, can lead to plastic deformation of the current collector and create damage in the electrode coating. Here, in this study, we report a detailed study of silicon coatings on a high-tensile alloy (HTA) foil of copper with strength over twice that of conventional copper foils. The HTA current collectors with high mechanical strength can mitigate plastic deformation upon continuous cycling. At moderate areal capacities (2.5–3 mAh cm −2 ), conventional copper foils show significant wrinkling after only a few electrochemical cycles, whereas the HTA foils remain intact. We demonstrate viability of the HTA foils in large format xx6395 pouch cells, in which the HTA current collectors remain intact even at an areal capacity of 4.5 mAh cm −2 ; in contrast, wrinkles form in conventional copper current collectors increasing the likelihood of lithium plating. Computational studies show that stresses generated during cycling of silicon electrodes are very high in the current collector and at the current collector-coating interface, explaining the wrinkling of conventional Cu foils. Our studies highlight importance of current collector to solve the electrochemical and chemo-mechanical performance challenges associated with high-loading silicon electrodes.

Chemo-mechanical degradation↗
DOE OSTI2025

Operando FTIR investigation of salt dynamics in Li-ion batteries during fast charging

Li-ion batteries, when charged at fast-charging rates ($>$2C), suffer from reduced lifetimes and can undergo catastrophic failure. During high-rate charging, Li-ions are unable to rapidly transport through high-loading electrodes ($>$4 mAh cm −2 ). This results in unequal charge distributions, potentials, and utilization of the active material, which can lead to Li plating. Li-ion concentration polarization, in which Li-ions deplete in the anode and accumulate in the cathode during charging, precedes Li plating. An operando FTIR-ATR graphite/NMC cell developed in this research captured Li-ion concentration polarization in real-time. During fast charging, decreases in Li-ion concentration ($>$95%) were measured at the back of the anode. This is the first verification of complete Li-ion depletion within the anode at high C-rates. The measurements also showed graphite stage transition. A P2D model was developed for comparison to the operando measurements. The measurements agreed with the model in some cases, but disparities existed at high C-rates and loadings. In the experiment, the Li-ion concentration often failed to recover to 1.2 M until several hours after charging, whereas the model Li-ion concentration rapidly recovered. The contrast between the model and experiment results indicates that further investigation is required to improve understanding of Li-ion concentration dynamics during fast charging.

25 - ENERGY STORAGE↗
DOE OSTI2023

Stable electrospray signal on a microfabricated glass chip with three-dimensional open edge and tiered depth geometries

This paper presents the microfabrication and performance of a three-dimensional electrospray ionization (ESI) emitter tip made from glass, which achieves stable current signals important for chemical analysis. Our novel microfabrication process and custom-built signal conditioning hardware provides the advantage of providing accurate features and steady signals. The fabrication process relies on standard microfabrication techniques (i.e., deposition, photolithography, and wet etching). This fabrication method involves the novel application of two layers of positive and negative photoresists in addition to Parafilm® wax tape. Open edge and tiered depth details were successfully created from a multilayer planar mask. This is a benefit for integrated miniaturized and microfluidic systems that often require micro features for their functionality but relatively large millimeter size features for their physical periphery. We demonstrate the fundamental performance of electrospray with this microfluidic chip. The emitter tip was fixed on a linear axis stage with high resolution (10 μm) to finely control the tip distance from a metal counter electrode plate. Further, a custom printed circuit board system was built to safely control four voltages applied to the microchip ports from a single high voltage power supply. To readily form the electrospray, non-aqueous solvents were used for their low viscosity and a constant voltage of +2.7 kV was applied to the sheath electrospray microchannel. The liquid being sprayed was 80/20 (v/v) methanol/acetonitrile with 0.1% acetic acid in the sheath microchannel and with ammonium acetate (10–40 mM) in its remaining microchannels. The electrospray signal was measured in response to varying the distance (1.4 to 1.6mm) between the electrospray emitter tip and a metal counter electrode plate in addition to the varying concentration of the background electrolyte, ammonium acetate. Stable and repeatable electrospray signal showed linear relationships with emitter tip distance and concentration (r 2 ≥ 0.95).

42 ENGINEERING↗
DOE OSTI2024

Generating Buoyancy-Driven Convection in Membrane Distillation

Membrane distillation (MD) is a thermally-driven desalination process that can treat hypersaline brines. Considerable MD literature has focused on mitigating temperature and concentration polarization. This literature largely neglects that temperature and concentration polarization increase the feed density near the membrane. With gravity properly oriented, this increase in density could trigger buoyancy-driven convection and increase permeate production. Convection could also be strengthened by heating the feed channel wall opposite the membrane. To investigate that possibility, we perform a series of experiments using a plate-and-frame direct contact MD system with an active membrane area of 300 cm2 and a feed channel wall heated using a resistive heater. The experiments measure the average transmembrane permeate flux for two gravitational orientations, feed Reynolds numbers between 128 and 1128, and wall heat fluxes up to 12 kW/m2. The results confirm that with gravity properly oriented, wall-heating can trigger buoyancy-driven convection for a wide range of feed Reynolds numbers, and increase permeate production between roughly 20 and 130 %. We estimate, however, that at high Reynolds numbers (Re > 800), more than 70 % of the wall heat is carried out of the MD system by the feed flow, without contributing to permeate production. This suggests the need for longer membranes and heat recovery steps in any future practical implementation.

buoyancy-driven convection↗
DOE OSTI2023

Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis

Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.

42 ENGINEERING↗
DOE OSTI2023

High-speed friction stir butt welding of 25.4 mm thick 7175-T79 aluminum alloy

This presents the first experimental demonstration of friction stir butt welding of 25.4 mm thick high-strength, precipitate-strengthened 7XXX aluminum alloy at a welding speed above 500 mm/min and penetration depth greater than 10 mm. Tool pin threads that terminate away from the shoulder region, helped mitigate nearby stress concentration during tool traversing, enabling a higher welding speed while avoiding pin fracture near shoulder. Two kinds of welds—one-sided with full penetration of the plate thickness and double-sided with partial penetration of the plate thickness—were conducted. Significant grain refinement (grain size 1.3 ± 0.8 µm) was evident at the junction of double-sided friction stir welding (FSW) compared to other regions of weld-nugget or base material. Cross-weld tensile testing with digital image correlation revealed high local strains at the junction of double-sided FSW before macro-yield. This strain concentration impeded the typical early necking on advancing/retreating sides of FSW joints, improving the yield strength of as-welded double-sided FSW by 20–24% over slow- to medium-speed one-sided FSW. In conclusion, the joint efficiency of as-welded, double-sided high-speed FSW was about 76% with respect to the base material’s ultimate tensile strength.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Self-seeded growth of very large open-structured zeolite nanosheet assemblies with extraordinary micropore accessibility

Zeolite nanosheets (ZNs) offer improved micropore accessibilities and transport properties for enhanced molecular catalysis and separations. However, practical application of the ZN materials is hampered by the lack of efficient synthesis methods. Here, in this work, a ZN self-seeded method is demonstrated for single-step reproduction of flower-like assemblies of very large MFI ZN plates. The ZN plates are ~60 nm-thick stacks of 4-nm-thick single-crystal sheets. The ZN flower growth involves terrace nucleation on the seed surfaces and subsequent ZN epitaxial growth in [010] orientation directed by a diquaternary agent. The open architecture of the assemblies prevented collapse and agglomeration of ZNs during thermal activation that effectively preserved the interconnected intra-sheet and inter-sheet micropore system. Thus, the ZN assemblies exhibited markedly enhanced molecular adsorption capacity and transport diffusivity for the probing xylene molecules as compared to the conventional crystals. The ZN assembly and its harvestable very large-sized ZNs have the potential for developing high-performance ZN adsorbents, catalysts, and molecular-sieve membranes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Relationship between ductility and the porosity of additively manufactured AlSi10Mg

Additive manufacturing via selective laser melting can result in variable levels of internal porosity both between build plates and within components from the same build. In this work, sample porosity levels were compared to tensile properties for 176 samples spanning eight different build plates. Sample porosity was measured both by Archimedes density, which provided an estimation of overall porosity, and by observation of voids in the fracture surface, which provided an estimation of the porosity at the failure plane. The porosity observed at the fracture surface consistently demonstrated higher porosity than that suggested by Archimedes density. The porosity values obtained from both methods were compared against the mechanical results. Sample porosity appears to have some correlation to the ultimate tensile strength, yield strength, and modulus, but the strongest relationship is observed between porosity and ductility. Three different models were used to relate the fracture surface porosity to the ductility. The first method was a simple linear regression analysis, while the other two models have been used to relate porosity to ductility in cast alloys. It is shown that all three models fit the data well over the observed porosity ranges, suggesting that the models taken from casting theory can extend to additively manufactured metals. Finally, it is proposed that the non-destructive Archimedes method could be used to estimate an approximate sample ductility through the use of correlations realized here. Such a relationship could prove useful for design and for a deeper understanding of the impact of pores on tensile behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Lithium metal stripping mechanisms revealed through electrochemical liquid cell electron microscopy

An understanding of lithium stripping is as important as that of lithium plating to achieve significant advances in using lithium metal anodes for high-energy rechargeable batteries. However, there have been limited studies on lithium stripping compared to lithium plating. Here we report the lithium stripping mechanisms revealed through in-situ electrochemical liquid cell transmission electron microscopy (TEM). We directly observe and compare the stripping behavior of the in-situ grown lithium dendrites and lithium nanograins covered by a lithium fluoride-rich solid-electrolyte interphase (SEI). Furthermore, we find the sporadic lithium stripping behavior and three important modes that can describe the stripping of individual lithium deposits, regardless of their morphology: (i) symmetric stripping, (ii) surface-preferred asymmetric stripping, and (iii) interface-preferred asymmetric stripping. In addition, SEI chemical mapping with high spatial resolution shows a remarkable SEI loss at the end of the lithium metal stripping, which illustrates the importance of SEI protection in the subsequent cycles.

25 ENERGY STORAGE↗
DOE OSTI2020

The CLAS12 High Threshold Cherenkov Counter

The High Threshold Cherenkov Counter (HTCC) is one of the detector systems of the CLAS12 spectrometer, and is used to generate a fast trigger signal in electron scattering experiments in the polar angle range from 5°to 35°. The HTCC is installed in front of the drift chambers and introduces a minimal amount of additional material within the acceptance. The HTCC is one unit whose core component is a multifocal mirror that consists of 60 lightweight ellipsoidal mirrors. It is important that the HTCC provides efficient coverage of the CLAS12 forward acceptance with no gaps. In order to achieve this, each sector of the CLAS12 Forward Detector is covered by 2 identical half-sector mirrors that focus Cherenkov light on 8 phototubes. The HTCC has a total of 48 channels with Electron Tubes 9823QKB photomultipliers that have a 5-in quartz face plate to detect Cherenkov light. The system provides rejection of charged -mesons with momenta below 4.8 GeV for the reliable identification of scattered electrons. In this paper the details of the design, construction, calibration, and performance results of the HTCC are presented

Sharabian, Y. G.↗
DOE OSTI2025

Design and commissioning of readout electronics for a $K$$^{0}_{L}$ and $μ$ detector at the Belle II experiment

The K-long and muon detector (KLM) constitutes the outer-most volume of the Belle II spectrometer at the interaction region of the SuperKEKB collider in Tsukuba, Japan. The KLM detector was partially upgraded since the Belle experiment by replacing many of its resistive-plate chambers with scintillators containing wavelength-shifting fibers and instrumenting it with silicon photomultipliers. Here, we describe the readout electronics, firmware, and software created to control and acquire data from the scintillators and resistive-plate chambers.

Belle II↗
DOE OSTI2022

Characterisation of divertor detachment onset in JET-ILW hydrogen, deuterium, tritium and deuterium–tritium low-confinement mode plasmas

Measurements of the ion currents to and plasma conditions at the low-field side (LFS) divertor target plate in low-confinement mode plasmas in the JET ITER-like wall materials configuration show that the core plasma density required to detach the LFS divertor plasma is independent of the hydrogenic species protium, deuterium and tritium, and a 40 %/60 % deuterium–tritium mixture. This observation applies to a divertor plasma configuration with the LFS strike line connected to the horizontal part of the LFS divertor chosen because of its superior diagnostic coverage. The finding is independent of the operational status of the JET cryogenic pump. The electron temperature (T e ) at the LFS strike line was markedly reduced from 25 eV to 5 eV over a narrow range of increasing core plasma density, and observed to be between 2 eV and 3 eV at the onset of detachment. The electron density (n e ) peaks across the LFS plasma when T e at the target plate is 1 eV, and spatially moves to the X-point for higher core densities. The density limit was found approximately 20 % higher in protium than in tritium and deuterium–tritium plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

First feedback-controlled divertor detachment in W7-X: Experience from TDU operation and prospects for operation with actively cooled divertor

In the last experimental campaign (OP1.2b) of the stellarator Wendelstein 7-X (W7-X), boronisation as a mean for first wall conditioning was applied for the first time which led to strongly reduced impurity fluxes from plasma-facing components. Thermal detachment at the uncooled target plates of the test divertor unit (TDU) was reached at higher plasma densities and was accompanied by high recycling of neutrals at the target plate. A feedback control system was established in W7-X to actively control the gas injection (actuator) for plasma fuelling and impurity seeding [3] through the divertors. It allowed very successful stabilisation of the detached plasma condition state as well as mitigation of thermal overloads to some baffle tiles. Different routinely available diagnostic signals were used as input parameters (sensors). We describe the setup of the feedback control system, its performance and provide some example results with the main focus on the development of the control scheme which led to the detachment stabilisation over the entire longest (30 s) high-power discharge at W7-X so far. In view of the achieved very successful detachment stabilisation and the necessity to include simultaneous optimisation of the core performance in the future, the feedback control system is being upgraded for the upcoming campaign (OP2.1) in which the water cooled and hereby inherently steady-state capable divertor has been currently installed. The prospects and some experiment ideas for active detachment control are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Influence of preheating on tungsten damage under pulsed hydrogen plasma exposure

Preheated tungsten plate behavior under multiple pulsed hydrogen plasma irradiations in the PW-7 plasma accelerator was investigated. The preheating temperature was 973 K, which is above the ductile to brittle transition temperature (DBTT ≈ 673 K). The plate was exposed to three consecutive series of 13 plasma pulses each. Preheating sufficiently suppressed surface cracking at the early irradiation stage: after 13 pulses, cracks were rare, localized, and did not form extensive fractures. During subsequent irradiation series, the area fraction of fine cracks increased by ∼ 2% due to accumulation of dislocations around the pre-existing defects. However, their width remained nearly constant, averaging 0.2–0.3 μm, with rare cracks up to 1 μm in size. Repeated plasma exposure resulted in pronounced surface roughening associated with multiple melting cycles, crater formation and blister rupture, with roughness reaching ∼ 204 nm and a recorded sample mass loss of ∼ 2.8 mg. These results indicate that controlling tungsten preheating well above DBTT effectively reduces damage. However, the surface condition during initial irradiation significantly influences its subsequent morphological evolution. Preheating to 773 K, selected regarding the minimum DBTT value, has previously been demonstrated to be an effective approach for limiting crack growth. A further increase in temperature of approximately ∼ 1000 K did not qualitatively improve results: crack still formed and widths did not decrease. At the same time, the absence of further crack coarsening indicates that the limiting effect of preheating has been reached. Considering the increased energy costs, further increasing the preheating temperature seems unjustified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Comparative study with two reduced test facilities for air-cooled RCCS scaling law

Korea Atomic Energy Research Institute (KAERI) and Argonne National Laboratory (ANL) conducted steady-state tests at constant heat flux conditions to investigate the scale effect on heat removal behavior of the air-cooled Reactor Cavity Cooling System (RCCS). Two differently scaled-down test facilities were used in this study, KAERI’s ¼ scale with 4.0-m cavity height, and ANL’s ½ scale with 6.8-m cavity height. Two scaling laws were proposed to simulate the radiation across the cavity and the buoyancy-driven duct flow in the riser, respectively. The test matrix for KAERI and ANL test facilities focused on the scaling effect of the heated riser length with constant heat flux at the PMR200 RCCS design. The test results showed that mixed convection in the riser duct is an important factor for accurately extrapolating the thermo-fluid behavior in the prototype from the test results in the scale-down facilities. The system analysis code, GAMMA+, with improved heat transfer models predicted fairly well the air-cooled RCCS test data from two facilities. GAMMA+ analysis results showed that the predicted radiation fractions on the heated plate in the scale-down test conditions were larger than those on the reactor vessel in the prototype. The scaling law for air-cooled RCCS was improved by considering the mixed convection in the riser duct and the same radiation fraction on the heated plate. The mixed convection effect was calculated by the height ratio. The same radiation fraction provided a conservative extrapolation from the scale-down test results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Development of an accelerator-based neutron source to prototype Mo-99 production, part I: A liquid LBE windowless target

In this article, Molybdenum-99 (Mo-99)’s decay product, technetium-99 (Tc-99 m), is one of the most critical isotopes for medical diagnostics. To provide U.S. domestic supply of Mo-99 without using high-enriched uranium (HEU), a subcritical uranium target assembly (UTA) is irradiated by an accelerator-based neutron source to create Mo-99 through fission. This study discusses the development of the accelerator-based neutron source. The high-energy electrons from the accelerator irradiate a liquid lead-bismuth eutectic (LBE) target to produce neutrons. Part I of this work focuses on numerical and experimental analysis towards the development of a liquid LBE windowless target. Unlike the existing windowless targets in literature, the current design creates a vertical free surface for a beam to irradiate. First, a hydrodynamic analysis of the LBE windowless target is performed. Simplified analytical calculations are assisted by 2D computational fluid dynamics (CFD) simulations to design the target, with the focus on eliminating recirculation zones and avoiding cavitation. With the optimized geometry, the experimental study is performed to investigate the flow hydrodynamics using liquid LBE. The experiments (1) compare pressure drop in the system to correlation predictions; (2) visualize the free surface liquid LBE flow from the beam view; (3) validate the LBE flow profile using temperature sensitive paint from the side view; and (4) validate the liquid LBE film thickness using gamma densitometer measurements. Second, the power handling capability of the designed windowless target is investigated. The divider plate in the current design is susceptible to overheating due to the thin LBE film in front. As LBE erosion and corrosion is likely to occur at an LBE velocity of 2.0 m/s and temperature above 500 °C, a power limit of 10 kW of beam power was established to prevent this corrosion from occurring, which is calculated by a Nusselt number correlation. The divider plate surface temperature at 10 kW agrees well with the 3D CFD simulation results. Part I demonstrates the fundamental physics in liquid LBE windowless target design and associated testing. A companion paper, Part II will demonstrate how to couple this windowless target into the Mo-99 production system, including an accelerator system operating under an ultra-high vacuum and the UTA cooled by water at room temperature.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Effects of Casting Parameters and Impurity Concentrations on As-Cast U–10Mo

This work investigates the effects of casting parameter changes on as-cast uranium-10 wt% molybdenum alloys on a 1-2kg scale. A commercial tilt-pour vacuum induction melting system was utilized to study the effects of casting atmosphere, total heating time, hold time at maximum temperature, mold temperature, and crucible type on the as-cast microstructure of U-10Mo. Ten thin plates (5.08 mm thick) and four thick plates (25.4 mm and 63.5 mm thick) were cast and analyzed for carbon, oxygen, hydrogen, and nitrogen impurities. Additionally, molybdenum content and primary dendrite length (PDL) of the microstructure was quantified. A statistical evaluation was performed to identify key carbon and oxygen relationships with operating parameters, impurities, and primary dendrite length. Additional factors investigated include: crucible material, time at maximum temperature, total heating time, and pour temperature. Zirconia crucibles reduced carbon content on average by 35%. Additionally, there was a significant statistical association between carbon and oxygen content, between oxygen content and maximum temperature hold time, between mold temperature and PDL, and between PDL, maximum temperature hold time and mold temperature.

Huber, Zachary F.↗
DOE OSTI2026

Depletion benchmark for a high-assay low-enriched uranium fuel experiment in the advanced test reactor

Reactor physics depletion benchmarks for high-assay low-enriched uranium (HALEU) fuel are limited in number. In particular, there is limited data for HALEU benchmarks for U-10Mo (uranium-10% molybdenum) plate fuel that is being developed for use in the United States’ high performance research reactors including the Advanced Test Reactor (ATR), Advanced Test Reactor Critical Facility (ATR-C), High Flux Isotope Reactor (HFIR), Massachusetts Institute of Technology Reactor (MITR), University of Missouri Research Reactor (MURR), National Bureau of Standards Reactor (NBSR). These six reactors currently operate with highly enriched uranium dispersed fuel in an aluminum matrix. In support of conversion to a HALEU fuel, qualification of U-10Mo formed into a monolithic foil is being performed. Fuel qualification involves irradiating fuel specimens in the ATR. The irradiation tests provide an opportunity to benchmark depletion capabilities of reactor physics codes in support of the ATR operation, as well as develop benchmarks that can be used by other institutions to benchmark other reactor physics codes. This paper documents the development of a benchmark model of the irradiation of the ATR Full-size plate In center flux trap Position 7 (AFIP-7) experiment using the depletion codes MC21 and Advanced Dimensional Depletion for Engineering of Reactors (ADDER).

Nielsen, Joseph W. [Idaho National Laboratory (INL↗