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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 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Heat Transfer Characteristics of Particle Flow Through Additively Manufactured (SS 316L) Lattice Frame Material Based on Octet-Shape Topology

Abstract This paper presents experimentally obtained heat transfer characteristics of additively manufactured lattice frame material based on Octet-shaped unit cell. Binder jetting technology was used to print lattices in Stainless Steel 316L material. Lattice porosities ranging from 0.75 to 0.9 were investigated where thermal transport characteristics were obtained for void space occupied by air and particles. Particle diameters were varied from 266–966 microns. Effective thermal conductivity and averaged heat transfer coefficient was calculated through steady-state experiments. It was found that presence of lattice enhances the effective thermal conductivity by 2–4 times when compared to packed bed of particles alone. Furthermore, for gravity-assisted particle flow through lattice panel, significantly high convective heat transfer coefficients ranging from 200–400 W/m2K were obtained for the range of particle diameters tested. The superior thermal transport properties of Octet-shape based lattice frame material for particle flow through them makes it a very promising candidate for particle-to-supercritical carbon dioxide (sCO2) heat exchanger in concentrating solar power (CSP) application.

Aider, Youssef↗
DOE OSTI2022

Coupled diffusion-deformation-damage model for polymers used in hydrogen infrastructure

The soft materials used in the infrastructure of hydrogen storage and distribution systems are vulnerable because exposure to high-pressure hydrogen can lead to mechanical damage and property degradation. Some materials, such as polymers, can undergo mechanical failure due to a phenomenon wherein hydrogen gas diffuses through the polymer chains and occupies preexisting cavities or voids inside the polymer material. If the hydrogen gas pressure is reduced more quickly than hydrogen can diffuse back out of the polymer which is necessary for some applications, the trapped hydrogen gas instead escapes by rupturing the material, causing surface blistering or permanent damage. In this study, a continuum mechanics-based fully coupled diffusion-deformation model with damage is developed to predict the stress distribution and damage propagation while the polymer undergoes rapid decompression failure. The hyperelastic material model, along with the maximum principal strain failure theory, was chosen for this study as it represents the nonlinear material response with brittle failure observed in uniaxial tensile tests perfectly. EPDM polymer was chosen for this study because of its commercial availability and common use in hydrogen storage and distribution system. It has superior mechanical properties, high and low temperature resistance, and certain compounds work well in hydrogen gas. This work is useful for design engineers to alter the parameters while manufacturing polymer composites to increase their performance in a high-pressure hydrogen environment.

Kulkarni, Shank S.↗
DOE OSTI2024

Quantifying Trapped Powder in Electron Beam Powder Bed Fusion

Abstract Electron beam powder bed fusion (PBF-EB) shows great potential for manufacturing complex parts including those with internal cavities for heat exchanger, manifold systems, or energy absorption purposes. PBF-EB allows for the manufacture of channel geometries without the need for support structures. Due to the nature of the powder spreading process, powder feedstock is often trapped in intentionally manufactured cavities. This trapped powder can often be difficult to remove and can disturb the intended flow of fluid through the cavity or damage downstream components in its use case. These trapped powder particles present a risk of contamination and component failure if not completely evacuated. Ti6Al4V is a choice material for aerospace applications due to its high strength to weight ratio and its composition as a nonferrous metal; however, in weight sensitive applications excess entrapped powders or powders loosely attached to the surface could cause undesirable weight increases. The inherent spreading process of PBF-EB is different than laser powder bed fusion (PBF-LB) in its operational temperature, sintering. In addition, PBF-EB is less commonly studied in literature compared to its PBF-LB counterpart, and as a result the complexity of the semi-sintered powder and its spreading behavior are not well understood. Prior work has investigated the difficulty in removing trapped powder from PBF-EB, but these studies do not address how to quantify the amount of trapped powder in the cavity. Thus, an accurate method to measure the amount of trapped powder in the cavity must be investigated. In this work, Ti6Al4V coupons were manufactured with horizontal and vertical cavities of three different sizes. Archimedes testing allows for the determination of density differences caused by porosity and trapped powders by measuring mass and volumetric dispersion. Computed tomography (CT) is well suited for segmenting the internal structure and features of a part and has been studied for applications including voids, porosity, and dross. Thus, CT was explored as a method for evaluating trapped powder content in this work. The volumetric representation of the segmentation of the reconstructed CT volume can vary greatly depending on the input filter and thresholding methods. In this study, four different types of segmentation approaches were evaluated to determine the best approach for segmenting the volume as compared to an operator labeled ground truth. The percentage density results from the Archimedes testing were compared to the volumetric percent density from the computed tomography approach. Differences in packing density between two different internal channel features were investigated. Overall, this work sought to validate the use of computed tomography for the detection of trapped powders and present a framework for volumetric segmentation.

Johnstone, Brian↗
DOE OSTI2023

Comparative Study on Deep Learning Methods for Defect Identification and Classification in Composite Aerostructure Material

Aircraft structures are required to have a high level of quality to satisfy their need for light weight, efficient flight, and withstanding high loads over their lifespan. These aerostructures are typically made from composite material due to their good tensile strength and resistance to compression. To ensure their structural integrity, the composite material requires inspection for common flaws such as porosity, delaminations, voids, foreign object debris, and other defects. Ultrasonic testing (UT) is a popular non-destructive inspection (NDI) technique used for effectively evaluating composite material. Current inspection methods rely heavily on human experience and are extremely time consuming. Therefore, there is a need for the development of techniques to reduce the manual inspection time. This work compares the performance of different deep learning-based methods in the identification and classification of defects. Deep learning has shown great promise in numerous fields, and we show its effectiveness in the evaluation of composite aerostructure material. Furthermore, the methods developed here are both highly reliable with a top recall value of 98.63% as well as extremely efficient requiring an average of 4 seconds during the inferencing stage to evaluate new composites.

composites↗
DOE OSTI2020

Tutorial on forming through-silicon vias

Through-silicon vias (TSVs) are a critical technology for three-dimensional integrated circuit technology. These through-substrate interconnects allow electronic devices to be stacked vertically for a broad range of applications and performance improvements such as increased bandwidth, reduced signal delay, improved power management, and smaller form-factors. There are many interdependent processing steps involved in the successful integration of TSVs. This article provides a tutorial style review of the following semiconductor fabrication process steps that are commonly used in forming TSVs: deep etching of silicon to form the via, thin film deposition to provide insulation, barrier, and seed layers, electroplating of copper for the conductive metal, and wafer thinning to reveal the TSVs. Recent work in copper electrochemical deposition is highlighted, analyzing the effect of accelerator and suppressor additives in the electrolyte to enable void-free bottom-up filling from a conformally lined seed metal.

42 ENGINEERING↗
DOE OSTI2020

Structural breakdown in high power GaN-on-GaN p-n diode devices stressed to failure

The morphology of GaN-on-GaN vertical p-i-n diode devices after reverse-bias electrical stressing to breakdown has been investigated. All failed devices had irreversible structural damage, showing large surface craters that were ∼15–35 μm deep with lengthy surface cracks. Cross-sectional electron micrographs of failed devices showed substantial concentrations of threading dislocations around the cracks and near the crater surfaces. Progressive ion-milling across damaged devices revealed high densities of threading dislocations and the presence of voids beneath the surface cracks; these features were not observed in any unstressed devices. These results should serve as a useful reference for future reliability studies of vertical high-power GaN devices.

Peri, Prudhvi (ORCID:000000022338441X)↗
DOE OSTI2021

Evoking ordered vacancies in metallic nanostructures toward a vacated Barlow packing for high-performance hydrogen evolution

Metallic nanostructures are commonly densely packed into a few packing variants with slightly different atomic packing factors. The structural aspects and physicochemical properties related with the vacancies in such nanostructures are rarely explored because of lack of an effective way to control the introduction of vacancy sites. Highly voided metallic nanostructures with ordered vacancies are however energetically high lying and very difficult to synthesize. Here, we report a chemical method for synthesis of hierarchical Rh nanostructures (Rh NSs) composed of ultrathin nanosheets, composed of hexagonal close-packed structure embedded with nanodomains that adopt a vacated Barlow packing with ordered vacancies. The obtained Rh NSs exhibit remarkably enhanced electrocatalytic activity and stability toward the hydrogen evolution reaction (HER) in alkaline media. Theoretical calculations reveal that the exceptional electrocatalytic performance of Rh NSs originates from their unique vacancy structures, which facilitate the adsorption and dissociation of H 2 O in the HER.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An interaction network in the polymerase active site is a prerequisite for Watson-Crick base pairing in Pol γ

The replication accuracy of DNA polymerase gamma (Pol γ) is essential for mitochondrial genome integrity. Mutation of human Pol γ arginine-853 has been linked to neurological diseases. Although not a catalytic residue, Pol γ arginine-853 mutants are void of polymerase activity. To identify the structural basis for the disease, we determined a crystal structure of the Pol γ mutant ternary complex with correct incoming nucleotide 2'-deoxycytidine 5'-triphosphate (dCTP). Opposite to the wild type that undergoes open-to-closed conformational changes when bound to a correct nucleotide that is essential for forming a catalytically competent active site, the mutant complex failed to undergo the conformational change, and the dCTP did not base pair with its Watson-Crick complementary templating residue. Our studies revealed that arginine-853 coordinates an interaction network that aligns the 3'-end of primer and dCTP with the catalytic residues. Disruption of the network precludes the formation of Watson-Crick base pairing and closing of the active site, resulting in an inactive polymerase.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Amphiphilic nanopores that condense undersaturated water vapor and exude water droplets

Condensation of water vapor in confined geometries, known as capillary condensation, is a fundamental phenomenon with far-reaching implications. While hydrophilic pores enable liquid formation from undersaturated vapor without energy input, the condensate typically remains confined, limiting practical utility. Here, we explore the use of amphiphilic nanoporous polymer-infiltrated nanoparticle films that condense and release liquid water under isothermal and undersaturated conditions. By tuning the polymer fraction and nanoparticle size, we optimize condensation and droplet formation. As vapor pressure increases, voids fill with condensate, which subsequently exudes onto the surface as microscopic droplets. This behavior, enabled by a balance of polymer hydrophobicity and capillarity, reveals how amphiphilic nanostructures can drive accessible water collection. Our findings provide design insights for materials supporting energy-efficient water harvesting and heat management without external input.

Science & Technology - Other Topics↗
DOE OSTI2025

Interface morphogenesis with a deformable secondary phase in solid-state lithium batteries

Here, the complex morphological evolution of lithium metal at the solid-state electrolyte interface limits performance of solid-state batteries, leading to inhomogeneous reactions and contact loss. Inspired by biological morphogenesis, we developed an interfacial self-regulation concept in which a deformable secondary phase dynamically aggregates at the interface in response to local electro-chemo-mechanical stimuli, enhancing contact. The stripping of a lithium electrode that contains 5 to 20 mole % electrochemically inactive sodium domains causes spontaneous sodium accumulation across the interface, with the sodium deforming to attain intimate electrical contact without blocking lithium transport. This process, characterized with operando x-ray tomography and electron microscopy, mitigates voiding and improves cycling at low stack pressures. The counterintuitive strategy of adding electrochemically inactive alkali metal to improve performance demonstrates the utility of interfacial self-regulation for solid-state batteries.

Yoon, Sun Geun [Georgia Institute of Technology, A↗
DOE OSTI2023

Inorganic sulfate-based signatures of chemosymbiosis in modern infaunal lucinids

Bivalves that host sulfur-oxidizing bacterial gill-hosted endosymbionts can inhabit low-diversity, sulfidic environmental niches. However, understanding the history of this life strategy is limited by the lack of a robust method that can be applied to fossils. Measurements of carbonate-associated sulfate S isotope ratios (CAS-$δ$ 34 S) in carbonate fossils could fill this void by fingerprinting symbiont-driven oxidation of environmental sulfide. We begin to evaluate this prediction using modern lucinid bivalves, a useful test case because: (1) all modern genera host symbionts and live in sulfidic sediments, and (2) morphological evidence suggests that this has been true since the earliest ancestral lucinids. We measured S speciation, abundance, and CAS-$δ$ 34 S values in the shells of a suite of modern infaunal lucinids, in addition to epifaunal bivalves with and without S-oxidizing symbionts as controls. For infaunal lucinids, CAS concentrations were at most one-third of those of non-symbiotic epifaunal bivalves, and CAS-$δ$ 34 S values were lower (9.2‰-18.5‰) than in modern seawater (21‰) or epifaunal bivalves (20.8‰-21‰). These observations indicate that lucinids with symbionts incorporate sulfide-derived sulfate into their shells as a direct consequence of their chemosymbiosis. In conclusion, we argue that both the concentration and the magnitude of 34 S depletion in infaunal lucinid CAS reflect environmental sulfide concentrations and could viably reveal chemosymbiosis in fossils.

58 GEOSCIENCES↗
DOE OSTI2024

Can the angular scale of cosmic homogeneity be used as a cosmological test?

Abstract In standard cosmology, the cosmic homogeneity scale is the transition scale above which the patterns arising from non-uniformities – such as groups and clusters of galaxies, voids, and filaments – become indistinguishable from a random distribution of sources. Recently, different groups have investigated the feasibility of using such a scale as a cosmological test and arrived at different conclusions. In this paper, we complement and extend these studies by exploring the evolution of the spatial ( $$R_{\textrm{H}}$$ R H ) and angular ( $$\theta _{\textrm{H}}$$ θ H ) homogeneity scales with redshift, assuming a spatially flat, $$\varLambda $$ Λ -Cold Dark Matter universe and linear cosmological perturbation theory. We confirm previous results concerning the non-monotonicity of $$R_{\textrm{H}}$$ R H with the matter density parameter $$\varOmega _{\textrm{m0}}$$ Ω m0 but also show that it exhibits a monotonical behavior with the Hubble constant $$H_{0}$$ H 0 within a large redshift interval. More importantly, we find that, for $$z \gtrsim 0.6$$ z ≳ 0.6 , $$\theta _{\textrm{H}}$$ θ H presents a monotonical behavior with $$\varOmega _{\textrm{m0}}$$ Ω m0 , as well as for $$H_0$$ H 0 the entire redshift interval analyzed. We find also that the angular homogeneity scale is sensitive to $$H_{0}$$ H 0 , especially at higher redshifts. Using the currently available $$\theta _{\textrm{H}}$$ θ H measurements, we illustrate the constraints on the $$\varOmega _{\textrm{m0}}$$ Ω m0 – $$H_{0}$$ H 0 plane through a MCMC analysis and show the feasibility of using the angular homogeneity scale as a new, model-independent way to constrain cosmological parameters.

Physics↗
DOE OSTI2020

Pore-Filled PEMs from Poly(Phenylene Sulfonic Acid)s and Electrospun Poly(Phenylene Sulfone) Fiber Mats

A novel, composite, non-PFSA-based fuel cell membrane has been fabricated using a pore filling technique. The membrane consists of a mechanically stabilizing skeleton from an electrospun poly(phenylene sulfone) (PPSU) fiber mat and a thermally crosslinkable poly(phenylene sulfonic acid) (cPPSA) proton conducting ionomer that fills the interfiber voids. cPPSA copolymer was synthesized using Ullmann coupling copolymerization of 4,4-dibromobiphenyl 3,3-disulfonic acid with 1,4-dibromobenzene-2,5-disulfonic, followed by grafting a certain fraction of backbone sulfonic acid groups with biphenyl linker. The PPSU fiber mat was electrospun from NMP/acetone solution. Pore-filling was carried out by pouring a solution of cPPSA in methanol over the mat, followed by heating at 70°C to evaporate solvent. The cPPSA was crosslinked by an additional heating step, in a vacuum oven at 210°C for 5 hours. Here the resultant membrane had excellent proton conductivity, 5 times greater than that of Nafion® 211 in the 40-90% RH range at 80°C.

25 ENERGY STORAGE↗
DOE OSTI2023

Degradation Effects at the Porous Transport Layer/Catalyst Layer Interface in Polymer Electrolyte Membrane Water Electrolyzer

The porous transport layer (PTL)/catalyst layer (CL) interface plays a crucial role in the achievement of high performance and efficiency in polymer electrolyte membrane water electrolyzers (PEMWEs). This study investigated the effects of the PTL/CL interface on the degradation of membrane electrode assemblies (MEAs) during a 4000 h test, comparing the MEAs assembled with uncoated and Ir-coated Ti PTLs. Our results show that compared to an uncoated PTL/CL interface, an optimized interface formed when using a platinum group metal (PGM) coating, i.e., an iridium layer at the PTL/CL interface, and reduced the degradation of the MEA. The agglomeration and formation of voids and cracks could be found for both MEAs after the long-term test, but the incorporation of an Ir coating on the PTL did not affect the morphology change or oxidation of IrO x in the catalyst layer. In addition, our studies suggest that the ionomer loss and restructuring of the anodic MEA can also be reduced by Ir coating of the PTL/CL interface. Optimization of the PTL/CL interface improves the performance and durability of a PEMWE.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Adverse Effects of Trace Non-polar Binder on Ion Transport in Free-standing Sulfide Solid Electrolyte Separators

Sulfide solid-state electrolyte (SE) possesses high room-temperature ionic conductivity. However, fabrication of the free-standing, sheet-type thin sulfide SE film electrolyte to enable all-solid-state batteries to deliver high energy and power density remains challenging. Herein we show that argyrodite sulfide (Li 6 PS 5 Cl) SE can be slurry cast to form free-standing films with low (≤5 wt%) loadings of poly(isobutylene) (PIB) binder. Two factors contribute to a lower areal specific resistance (ASR) of the thin film SEs benchmarked to the pristine powder pellet SSE counterparts: i) 1–2 orders reduced thickness and ii) reasonably comparable ionic conductivity at room temperature after the isostatic pressing process. Nevertheless, an increasing polymer binder loading inevitably introduced voids in the thin film SEs, compromising anode/electrolyte interfacial ion transport. Our findings highlight that electrolyte/electrode interfacial stability, as well as the selection of slurry components, including sulfide SE, binder, and solvent, play essential roles in thin film sulfide electrolyte development.

25 ENERGY STORAGE↗
DOE OSTI2020

Modeling Synergistic Fuel Cell Membrane Degradation with Mitigating Effects of Cerium

During operation, polymer-electrolyte-membrane (PEM) fuel cells undergo mechanical and chemical degradation mechanisms, which behave synergistically and lead to accelerated membrane degradation over time. This study builds upon previous modeling work on mechanical degradation as described by a pinhole in the membrane and the effects of cerium on chemical degradation.1 By combining these two models, analysis can be carried out on the coupled degradation methods and how the mitigation effects of cerium disrupt the degradation cycle. The mechanical model represents a pinhole in the membrane using an effective void fraction, which allows for increased gas crossover through the membrane and impacts the membrane transport and mechanical properties. A microkinetic model for the chemical degradation is included in the model, including attack of the membrane polymer by hydroxyl radicals as well as the mitigation reaction for quenching of hydroxyl radicals with cerium. A concentrated solution theory approach is used to model the transport of cerium ions throughout the cell.2 The model results show how the location of cerium in the cell can be used to prevent chemical degradation. In addition, the model shows how cerium slows down the rate of pinhole growth by reducing the gas crossover and membrane thinning rate. Finally, the model can be used to optimize the distribution of cerium in the membrane and catalyst layers by balancing trade-offs between lowering degradation rates and decreasing fuel cell performance.

25 ENERGY STORAGE↗
DOE OSTI2019

Secondary Pore Network Design Optimization Analytical Diffusion Model for Lithium Ion Battery

Fast ion transport along the electrode thickness is required for Lithium ion battery (LIB) to sustain continuous high-rate discharge or charge currents, which is a desired feature for the fast charging of electric vehicle batteries. Advance in LIB electrode manufacturing allows to control, to a certain extent, the electrode microstructure architecture in order to improve the macroscopic performances of these devices. For instance, several groups have experimentally tested architectures tailored specifically to increase the through plane ionic diffusion in regards for fast charge application by adding channels or groove-like large pores oriented along the electrode thickness. These voids do not replace the existing pores of the electrode microstructure but consist in a second, coarser, pore network, called the secondary pore network (SPN). The model quantifies the impact of SPN on ionic diffusion with a composite electrode through a simple analytical approach, considering various pore channel geometries and comparing to standard electrodes with identical gravimetric and identical volumetric specific theoretical capacity. The goal is to find optimal SPN design parameters according to three optimization objectives aiming to balance the improved overall through-plane, thanks to the coarse aligned channels, and the degraded in-plane diffusion, due to the porous matrix densification required to maintain gravimetric and volumetric specific theoretical capacity. The analytical model must be considered as a pre-screening tool to quickly investigate large design space, that can be refined later with more complex electrochemical CPU-expensive numerical models.

Usseglio Viretta, Francois↗
DOE OSTI2024

DualSPHysics-INL

Funded by the DOE's Bioenergy Technology Office through the Feedstock-Conversion Interface Consortium, INL researchers developed this code to model biomass freestock flow in various handling equipment, such as hoppers and augers. Built on top of an existing open-source code DualSPHysics (https://dual.sphysics.org/) , the enrichment includes modification of the mass conservation equation that switching tracking density to void ratio, adding a hypoplastic constitutive law to better capture the flow physics of this type of material and implementing a novel boundary condition that can handle the dynamic contact between material and equipment. All implementation were realized via Nvidia CUDA, so GPU accelaration can be leveraged to signifiantly speed up the computational process.

Jin, Wencheng [Idaho National Laboratory (INL), Id↗