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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Novel Ionomers and electrode structures for improved PEMFC electrode performance at low PGM loadings (Final Report)

In this project, the objective is to develop new ORR electrocatalysts on optimized supports which can exceed all of the Department of Energy (DOE) 2020 targets listed in DE-FOA-0001412 directly relevant to the subtopic. This project’s approach is to develop novel, electrode-specific ionomers, and integrate them with state-of-the-art NSTF electrocatalyst powder to develop a cathode electrode achieving >= 044 A/mg PGM mass activity, <=30% mass activity loss during metal cycling, and <=0.125 g PGM /kW performance under DOE testing protocols. Ionomer O 2 permeability and proton conductivity will be increased by up to 1.5X over the baseline 3M800 perfluorosulfonate (PFSA) ionomer to enhance cathode electrode performance. Integration of cathode NSTF powder into an ionomer-containing electrode will increase the surface enhancement factor (SEF) to >=40 cm 2 PGM /cm 2 GEO allowing NSTF containing cathodes to exceed DOE MEA robustness targets. This report summarizes this project’s progress towards meeting the stated objectives and includes a summary of significant findings, conclusions, and developments over the entire project period from Oct. 1 st 2016 – Jan. 31 st 2020. This work has overcome key operation robustness issues with classic NSTF electrodes, identified pathways to improved dispersed and dispersed NSTF cathode performance, developed novel ionomers with high bulk conductivity and oxygen permeability, demonstrated exceptional support-independent electrode activity, and significantly increased metal and support stability through ionomer development. At this point, Tufts, MTU and all 5 FCPAD national labs have been involved, and contributed to, the improvements, learning and achievements of this work. Over the course of this project, more than 50 grams of dispersed NSTF powder in 15 different configurations have been generated, paving the way for scaleup within 3M. These whiskers have been processed in multiple ways, including acid leaching, powder-annealed, and sonicated by various means. For Task 2, 27 different types of ionomers were tested, 19 of which were made for the first time during the course of this project. 377 electrode inks with both NSTF and metal-on-carbon catalysts with I/C ratios from 0.2 to 1.2 were generated and mostly coated on a 3M pilot manufacturing line resulting in more than 700 different electrode types.

08 HYDROGEN↗
DOE OSTI2020

Production of levulinic acid and biocarbon electrode material from corn stover through an integrated biorefinery process

To overcome the inefficient biomass conversion, waste generation, and lack of co-production in biorefineries, an integrated process was proposed for the conversion of corn stover into levulinic acid and biocarbon electrode material. Corn stover was pretreated through hydrothermal process using 0.45 wt% K 2 CO 3 which removed 76 wt% lignin and 85 wt% xylan while preserving 83 wt% glucan. This was followed by acid hydrolysis to produce levulinic acid at varying H 2 SO 4 concentrations and reaction time in a batch reactor at 190 °C. At a reaction time of 5 min in 2 wt% H 2 SO 4 , 35.8 wt% and 30 wt% glucan in raw and pretreated corn stover was converted to levulinic acid, respectively. The residue from acid hydrolysis was converted into biocarbon for supercapacitor electrodes via a two-step thermal activation process which showed a specific capacitance of 120 F g -1 . The proposed integrated biorefinery concept provides multiple value-added products for a greater financial and environmental sustainability.

09 BIOMASS FUELS↗
DOE OSTI2020

Thermodynamic properties of Ca–Pb electrodes determined by electromotive force measurements

Thermodynamic properties of Ca–Pb alloys are investigated by electromotive force (emf) measurements to determine equilibrium cell potentials and phase properties for their application in energy storage systems such as liquid metal batteries. Using the electrochemical cell Ca(s) | CaF 2 (s) | Ca(in Pb) at 700–1060 K, cell emf is measured for thirteen Ca–Pb alloys at mole fractions, x Ca = 0.06–0.80. At 873 K, the equilibrium potentials of liquid Ca–Pb alloys are 0.57–0.62 V versus Ca and the activity values are as low as a Ca = 6.2 × 10 -8 at x Ca = 0.06. In addition, the emf values as a function of temperature provide partial molar quantities (entropy and enthalpy) as well as phase transitions which are corroborated by determining transition temperatures and phase constituents using differential scanning calorimetry (DSC) and powder X-ray diffraction (XRD). This study establishes the fundamental data necessary for the design of Pb-containing liquid metal electrodes through the integration of electrochemical, thermal, and structural properties of Ca–Pb electrodes.

25 ENERGY STORAGE↗
NASA NTRS1991

I-BIEM calculations of the frequency dispersion and AC current distribution at disk and ring-disk electrodes

The Iterative Boundary Integral Equation Method (I-BIEM) has been applied to the problem of frequency dispersion at a disk electrode in a finite geometry. The I-BIEM permits the direct evaluation of the AC potential (a complex variable) using complex boundary conditions. The point spacing was made highly nonuniform, to give extremely high resolution in those regions where the variables change most rapidly, i.e., in the vicinity of the edge of the disk. Results are analyzed with respect to IR correction, equipotential surfaces, and reference electrode placement. The current distribution is also examined for a ring-disk configuration, with the ring and the disk at the same AC potential. It is shown that the apparent impedance of the disk is inductive at higher frequencies. The results are compared to analytic calculations from the literature, and usually agree to better than 0.001%.

Boris D Cahan↗
NASA NTRS1991

I-BIEM calculations of the frequency dispersion and ac current distribution at disk and ring-disk electrodes

The Iterative Boundary Integral Equation Method (I-BIEM) has been applied to the problem of frequency dispersion at a disk electrode in a finite geometry. The I-BIEM permits the direct evaluation of the AC potential (a complex variable) using complex boundary conditions. The point spacing was made highly nonuniform, to give extremely high resolution in those regions where the variables change most rapidly, i.e., in the vicinity of the edge of the disk. Results are analyzed with respect to IR correction, equipotential surfaces, and reference electrode placement. The current distribution is also examined for a ring-disk configuration, with the ring and the disk at the same AC potential. It is shown that the apparent impedance of the disk is inductive at higher frequencies. The results are compared to analytic calculations from the literature, and usually agree to better than 0.001 percent.

Cahan, Boris D.↗
DOE OSTI2025

Surface modification of cathode material enhances electrochemical performance in dry-processed Li-ion battery electrodes

The transition to electric vehicles (EVs) is pivotal for achieving energy security and integrating grid stability, with lithium-ion batteries (LIBs) playing a central role in this transformation. However, the conventional wet electrode manufacturing relying on N-methyl-2-pyrrolidone (NMP) solvent is energy intensive and costly. Dry processing (DP) has emerged as a promising alternative, eliminating solvents and using polytetrafluoroethylene (PTFE) binder for electrode fabrications. Despite its advantages, DP faces a critical challenge: poor interfacial adhesion between the hydrophobic PTFE binder and the hydrophilic cathode active material (CAM), particularly LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811), which undermines electrode performance. Here, to address this, we introduced a novel vapor-phase trimethoxymethylsilane (TMMS) coating to hydrophobize the CAM surface, enhancing compatibility with PTFE. This surface modification significantly enhances binder – CAM interactions, enabling uniform mixing and robust electrode integrity without damaging the CAM particles. Our findings advance the feasibility of environmentally sustainable and cost-effective dry processing, representing a significant step toward sustainable battery manufacturing.

Choi, Junbin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2021

Microfabricated ion trap chip with in situ radio-frequency sensing

A radio-frequency (RF) surface ion trap chip includes an RF electrode and an integrated capacitive voltage divider in which an intermediate voltage node is capacitively connected between the RF electrode and a ground. A sensor output trace is connected to the intermediate voltage node.

Maunz, Peter Lukas Wilhelm↗
NASA NTRS1983

Elastomeric binders for electrodes

The poor mechanical integrity of the cathode represents an important problem which affects the performance of ambient temperature secondary lithium cells. Repeated charge of a TiS2 cathode may give rise to stresses which disturb the electrode structure and can contribute to capacity loss. An investigation indicates that the use of an inelastic binder material, such as Teflon, aggravates the problem, and can lead to electrode disruption and poor TiS2 particle-particle contact. The feasibility of a use of elastomers as TiS2 binder materials has, therefore, been explored. It was found that elastomeric binders provide an effective approach for simplifying rechargeable cathode fabrication. A pronounced improvement in the mechanical integrity of the cathode structure contributes to a prolonged cycle life.

Yen, S. P. S.↗
DOE OSTI2022

Multi-electrode/multi-modal atmospheric pressure glow discharge plasma ionization device

Apparatus include an atmospheric pressure glow discharge (APGD) analyte electrode defining an analyte discharge axis into an APGD volume, and a plurality of APGD counter electrodes having respective electrical discharge ends directed to the APGD volume, wherein the APGD analyte electrode and the APGD counter electrodes are configured to produce an APGD plasma in the APGD volume with a voltage difference between the APGD analyte electrode and one or more of the AGPD counter electrodes. An electrode can be integrated into an ion inlet. Apparatus can be configured to perform auto-ignition and/or provide multi-modal operation through selectively powering electrodes. Electrode holder devices are disclosed. Related methods are disclosed.

Koppenaal, David W.↗
DOE OSTI2022

Topology optimization for the design of porous electrodes

Porous electrodes are an integral part of many electrochemical devices since they have high porosity to maximize electrochemical transport and high surface area to maximize activity. Traditional porous electrode materials are typically homogeneous, stochastic collections of small-scale particles and offer few opportunities to engineer higher performance. Fortunately, recent breakthroughs in advanced and additive manufacturing are yielding new methods to structure and pattern porous electrodes across length scales. These architected electrodes are emerging as a promising new technology to continue to drive improvement; however, it is still unclear which structures to employ and few tools are available to guide their design. Here we address this gap by applying topology optimization to the design of porous electrodes. We demonstrate our framework on two applications: a porous electrode driving a steady Faradaic reaction and a transiently operated electrode in a supercapacitor. We present computationally designed electrodes that minimize energy losses in a half-cell. For low-conductivity materials, the optimization algorithm creates electrode designs with a hierarchy of length scales. Further, the designed electrodes are found to outperform undesigned, homogeneous electrodes. Finally, we present three-dimensional porous electrode designs. We thus establish a topology optimization framework for designing porous electrodes.

25 ENERGY STORAGE↗
NASA NTRS2004

Split-resonator integrated-post MEMS gyroscope

A split-resonator integrated-post vibratory microgyroscope may be fabricated using micro electrical mechanical systems (MEMS) fabrication techniques. The microgyroscope may include two gyroscope sections bonded together, each gyroscope section including resonator petals, electrodes, and an integrated half post. The half posts are aligned and bonded to act as a single post.

Bae, Youngsam↗
DOE OSTI2023

Hierarchically Porous Carbons with Highly Curved Surfaces for Hosting Single Metal FeN 4 Sites as Outstanding Oxygen Reduction Catalysts

Iron–nitrogen–carbon (Fe₋N₋C) materials have emerged as a promising alternative to platinum-group metals for catalyzing the oxygen reduction reaction (ORR) in proton-exchange-membrane fuel cells. However, their low intrinsic activity and stability are major impediments. Herein, an Fe₋N–C electrocatalyst with dense FeN 4 sites on hierarchically porous carbons with highly curved surfaces (denoted as FeN 4 - hc C) is reported. The FeN 4 - hc C catalyst displays exceptional ORR activity in acidic media, with a high half-wave potential of 0.85 V (versus reversible hydrogen electrode) in 0.5 m H 2 SO 4 . When integrated into a membrane electrode assembly, the corresponding cathode displays a high maximum peak power density of 0.592 W cm -2 and demonstrates operating durability over 30 000 cycles under harsh H 2 /air conditions, outperforming previously reported Fe–N₋C electrocatalysts. These experimental and theoretical studies suggest that the curved carbon support fine-tunes the local coordination environment, lowers the energies of the Fe d-band centers, and inhibits the adsorption of oxygenated species, which can enhance the ORR activity and stability. This work provides new insight into the carbon nanostructure–activity correlation for ORR catalysis. It also offers a new approach to designing advanced single-metal-site catalysts for energy-conversion applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Impact of processing humidity on ionomer film structure and performance in hydroxide exchange membrane electrolyzers

Hydroxide exchange membrane electrolyzers (HEMELs) enable hydrogen production using low-cost, earth-abundant materials. Improving electrode fabrication is integral to enhancing device performance, and ionomer-responsible for transporting hydroxide and mechanically supporting the catalyst-is a major component. Here, we use experiments and computation to study the effects of relative humidity (RH) during the drying process of poly(aryl piperidinium) ionomer films on HEMEL electrodes. Broadly, the drying environments determine the physical structure and electrochemical traits of the ionomer network. High RH drying yields a highly porous network with excessive water uptake, structural defects, washout, and 64% reduction in hydroxide conductivity. Extremely low RH drying produces an overly compact pore network that hinders hydroxide mobility. In contrast, moderately low RH drying (9% RH) creates an ionomer film with well-balanced traits: excellent mechanical stability and connectivity needed for catalyst retention and hydroxide transport, which improves HEMEL performance by 40% at 1.8 V compared to suboptimal RHs. This research advances HEMEL manufacturing by providing a simple, scalable, and low-cost approach to optimize electrode ionomer films.

36 MATERIALS SCIENCE↗