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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 937 records · Page 52
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Organic Additive–derived Films on Cu Electrodes Promote Electrochemical CO 2 Reduction to C 2+ Products Under Strongly Acidic Conditions

Electrochemical CO 2 reduction (CO 2 R) at low pH is desired for high CO 2 utilization; the competing hydrogen evolution reaction (HER) remains a challenge. High alkali cation concentration at a high operating current density has recently been used to promote electrochemical CO 2 R at low pH. Herein we report an alternative approach to selective CO2R (>70 % Faradaic efficiency for C 2+ products, FE C2+ ) at low pH (pH 2; H 3 PO 4 /KH 2 PO 4 ) and low potassium concentration ([K + ]=0.1 M) using organic film-modified polycrystalline copper (Modified-Cu). Furthermore, such an electrode effectively mitigates HER due to attenuated proton transport. Modified-Cu still achieves high FE C2+ (45 % with Cu foil /55 % with Cu GDE) under 1.0 M H 3 PO 4 (pH≈1) at low [K + ] (0.1 M), even at low operating current, conditions where HER can otherwise dominate.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Influence of Potassium Metal-Support Interactions on Dendrite Growth

We report combined synchrotron X-ray nanotomography imaging, cryogenic electron microscopy (cryo-EM) and modeling elucidate how potassium (K) metal-support energetics influence electrodeposit microstructure. Three model supports are employed: O-functionalized carbon cloth (potassiophilic, fully-wetted), non-functionalized cloth and Cu foil (potassiophobic, nonwetted). Nanotomography and focused ion beam (cryo-FIB) cross-sections yield complementary three-dimensional (3D) maps of cycled electrodeposits. Electrodeposit on potassiophobic support is a triphasic sponge, with fibrous dendrites covered by solid electrolyte interphase (SEI) and interspersed with nanopores (sub-10 nm to 100 nm scale). Lage cracks and voids are also a key feature. On potassiophilic support, the deposit is dense and pore-free, with uniform surface and SEI morphology. Mesoscale modeling captures the critical role of substrate-metal interaction on K metal film nucleation and growth, as well as the associated stress state.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Catalytic Autoxidation for Depolymerization of Multilayer Plastic Films

Recycling multilayer plastic films is challenged by a diversity of polymers, prompting development of new recycling methods. For the depolymerization of mixed polymers like those in multilayer films, metal-catalyzed autoxidation offers a versatile chemical recycling method to deconstruct multiple polymers to useful oxygenates. Here, we demonstrate that catalytic autoxidation is effective for depolymerizing multilayer films across diverse chemistries. We investigated conditions for a model polyethylene substrate using a Co, Mn, and Br cocatalyst system, achieving full carbon closure with oxygenated small molecules contributing up to 48 mol% carbon. Subsequently, we characterized product distributions for several common polymers used in multilayer films using high-resolution mass spectrometry (HRMS) and developed analytical methods to quantify the resulting complex product streams. Optimized conditions for polyethylene were applied to 11 multilayer plastic films containing 10 different polymers, including films with nonpolymeric potential disrupters like aluminum foil and titanium dioxide, showing that catalytic autoxidation is effective across a broad range of polymer types and is resistant to disrupters and additives. The generation of CO 2 in these reactions overall suggests that both reaction engineering and modifications to the reaction conditions will be required to achieve higher yields of soluble oxygenated products.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme Fast-Charging Capability

Electric vehicles are pivotal in the global shift toward decarbonizing road transport, with lithium-ion batteries at the heart of this technological evolution. However, the pursuit of batteries capable of extremely fast charging that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion batteries technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, solar energy technologies, and vehicle light-eighting is driving these metals toward near-critical status in the medium term. This study introduces metalized polythylene terephthalate (mPET) polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate film—named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in lithium-ion batteries. We have fabricated current collectors that significantly reduce weight (by 73%), thickness (by 33%), and cost (by 85%) compared with traditional metal foil counterparts. These advancements have the potential to enhance energy density to 280 Wh kg -1 at the electrode level under 10-min charging at 6 C. Through testing, including a novel extremely fast charging protocol across various C-rates and long-term cycling (up to 1000 cycles) in different cell configurations, the superior performance of these metalized polymer films has been demonstrated. Notably, mPET/Cu and mPET/Al films exhibited comparable capacities to conventional cells under extremely fast charging, with the mPET cells showing a 27% improvement in energy density at 6 C and maintaining significant energy density after 1000 cycles. This study underscores the potential of mPET films to revolutionize the roll-to-roll battery manufacturing process and significantly advance the performance metrics of lithium-ion batteries in electric vehicles applications.

25 ENERGY STORAGE↗
DOE OSTI2025

Electron Microscopy Transfer System to Protect Atmosphere‐Sensitive Materials for Scanning Electron Microscopy Characterization

Atmosphere- and/or moisture-sensitive materials can be challenging to characterize using electron microscopy techniques due to sample preparation workflows that generally require exposure to ambient conditions. Here, we describe a novel preparation method that uses aluminum foil in combination with a commercial cryo-EM transfer system to circumvent undesired exposure to the atmosphere. First, hygroscopic MgCl 2 was used as a model material, and prepared samples (both protected and unprotected) were placed in a controlled-humidity environment (> 80% relative humidity) for various exposure lengths (circa seconds to hours). Following this, the effectiveness of the sample preparation method was determined by comparing qualitative photos and quantitative X-ray diffraction patterns between the two sample subsets. The combined results of these experiments suggest that the outlined preparation method effectively protects MgCl 2 from atmospheric contamination compared to MgCl 2 samples that had no protective measures taken. Finally, the preparation method was utilized to protect a highly hygroscopic crystalline BaO thin film for characterization via scanning electron microscopy, thereby demonstrating a functional application of the outlined preparation technique and an additional use for the commercial cryo-EM transfer system beyond its intended application.

atmosphere-sensitive materials↗
DOE OSTI2023

Susceptibility to polarization type potential induced degradation in commercial bifacial p-PERC PV modules

Potential induced degradation (PID) is a reliability issue affecting photovoltaic (PV) modules, mainly when PV strings operate under high voltages in hot/humid conditions. Polarization-type PID (PID-p) has been known to decrease module performance quickly. PID-p can be reduced or recovered under the light in some cases, but this effect, as expected, would be less pronounced on the rear side of bifacial PV modules receiving lower irradiance. As bifacial PV modules are projected to dominate the PV market within the next 10 years, it is crucial to understand the PID-p issue in bifacial modules better. In this study, we performed indoor PID testing to induce PID-p on 14 commercial bifacial p-PERC modules with three different module constructions from three manufacturers. Here, four rounds (+ve and –ve polarities for front and rear sides) of PID testing are done at 25°C, 54% relative humidity (RH) for 168 h using the aluminum foil method. Each module side (front cell side and back cell side) is tested individually under both negative and positive voltage bias. The results show that the highest degradation of 32% in maximum power (Pmax) at standard test conditions (1000 W/m 2 ) and 51% at low irradiance (200 W/m 2 ) has been observed in some cases. Recovery under sunlight is also done, and outcomes show a near-complete recovery in Pmax. This study presents an extensive experimental methodology and a detailed analysis to systematically and simultaneously/sequentially evaluate multiple construction types of bifacial modules to the PID-p susceptibility and recovery.

14 SOLAR ENERGY↗
DOE OSTI2024

Field‐representative evaluation of PID‐polarization in TOPCon PV modules by accelerated stress testing

Abstract Potential‐induced degradation‐polarization (PID‐p) can reduce module power, but how to project the extent to which PID‐p may occur in field conditions considering the factors of system voltage, condensed moisture, temperature, and illumination has not been clarified. Using tunnel oxide passivated contact (TOPCon) modules, this work demonstrates a method to test full‐size crystalline silicon PV modules for PID‐p to provide field‐representative results. In initial screening tests with positive or negative 1000 V electrical bias applied at 60°C for 96 h using Al foil electrodes on the glass surfaces, the module type exhibited reversible PID‐p only on the front face when the cell circuit was in negative voltage potential. No PID was detected on the rear after testing in either polarity. We then evaluated the PID‐p sensitivity on the front side under different UV irradiances while maintaining the glass surface wet to estimate real‐world susceptibility to PID‐p. The magnitude of the observed behavior was fit using a previously developed charge transfer and depletion by light model. Whereas power loss with −1000 V applied to the cell circuit at 60°C for 96 h in the dark was about 30%, testing the module front under 0.051 W·m −2 nm −1 at 340 nm UVA irradiation using fluorescent tubes, the mean degradation was only 3%. When the modules were tested in the dark for PID‐p with in situ dark current–voltage (I‐V) characterization, the thermal activation energy for degradation was 0.71 eV; for recovery in the dark, it was 0.58 eV. Whereas recovery from the degraded state at 60°C in the dark without voltage bias was 5% absolute in 38 h, rapid recovery of about 5% absolute was observed with 1000 W·s/m 2 exposure at 25°C using a flash tester.

14 SOLAR ENERGY↗
DOE OSTI2020

The Role of Pentaerythritol Tetranitrate (PETN) Aging in Determining Detonator Firing Characteristics

Pentaerythritol tetranitrate (PETN) is one of the most commonly used explosives for both military and mining applications. PETN is used in EBW (exploding bridge wire) and EFI (exploding foil initiator) detonator devices. Due the widespread usage of PETN, studies focusing on how the explosive changes with age, primarily its function in detonators has received particular interest. Aging studies have identified several factors that affect PETN detonator function over time, most notably the specific surface area of the explosive powder. Though small-scale studies have been performed on specific detonator systems with isolated batches of material, what is missing is a large statistically-significant study focusing on PETN aging characteristics - such as powder coarsening - and their influence on detonator performance. Herein we report the first large statistically viable PETN aging study focusing on four batches of PETN powder from the same stock of PETN using two stabilizers, polysaccharide and TriPEON. PETN was aged both as a free-flowing powder as well as in modified EBW RP-2 detonators, for one month at 75 °C. The PETN powder has been analyzed chemically using Fisher specific surface area analysis, SEM imaging and light scattering particle size analysis. Additionally the detonators were tested for performance through voltage-sweep threshold testing and function time measurements. Findings from the study indicate that aging at 75 °C for one month significantly changes the specific surface area and particle size of unstabilized PETN, leading to increases in detonator function time, but not detonator threshold values. Powders stabilized with TriPEON displayed less significant increases in function time, while powder stabilized with polysaccharide exhibited no aging effects, despite the high temperature aging.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

Alloying Interlayers for Anode‐Less Lithium‐Metal Polymer Batteries

Anode‐less lithium‐metal batteries potentially offer further increased energy densities. However, the Coulombic efficiency (CE) of lithium plating and stripping, as a classical measure of Li inventory reversibility, is commonly still insufficient for achieving long‐lasting rechargeable batteries. Herein, the potential benefits of employing thin (20 nm) metal interlayers of Ag, Pt, and Au on Cu to alloy with Li in Cu||Li half‐cells and induce homogeneous Li plating with poly(ethylene oxide)‐based electrolytes are investigated. Interestingly, not all alloying interlayers enable a higher CE compared to neat Cu foil with 84%—specifically Ag@Cu with only 81%, while the best performing one, Au@Cu, provides a substantially increased CE of 91%. While generally the formation of “dead lithium” is found to be the major source of CE, this appears to be less pronounced in the case of Au@Cu, indeed. Further improvement can be achieved by carefully adjusting the cell voltage to a region in which the continuous de‐/alloying is suppressed, yielding a further enhanced CE of 94%, thus highlighting the need for a comprehensive approach to design suitable electrode chemistries and designs beyond a “simple” material improvement.

anode-less battery↗
DOE OSTI2022

Extraction of gold, mercury, and lead with TEVA resin from HCl and HNO 3

The extraction behavior of 212 Pb, 197m Hg, and 194 Au on TEVA resin in HCl and HNO 3 solutions was studied with batch uptake, kinetics, and column studies. The uptake of mercury and gold was extremely high from HCl solutions, with maximum k’ >80,000 for both elements. The uptake of mercury was lower in HNO3 than HCl with a maximum k’ of ~ 8,000 in 0.02 M HNO 3 and decreasing uptake at higher concentrations of HNO3, which agrees well with previous work. The batch uptake of gold in HNO 3 was not measured, as it had been reported previously. The uptake of lead on TEVA resin in HCl was low with a maximum k’ of only ~ 90 in 1 M HCl. The uptake of lead in HNO 3 was negligible. The uptake kinetics of gold and mercury were characterized in HCl and HNO 3 solutions and high uptake was seen after ~ 60 s for both elements. Column separations of 212 Pb, 197m Hg, and 194 Au on TEVA resin from HCl and HNO 3 solutions are reported with high yields of mercury and lead, but with high losses of gold, which is retained on the resin. A rapid, high yield separation of 197m Hg from irradiated gold foils is presented with yields of ~ 100% for both elements and a total separation time of < 2 h.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

Fission neutron activations of stainless steel and its corresponding elemental components

Characterizing neutron activation of stainless steel is a critical task for many applications, and yet little activation data is available for this alloy. To address the need, a series of neutron activation experiments have been performed using the Flattop critical assembly at the National Criticality Experiments Research Center. Several experimental conditions were probed for complete understanding of the neutron environment, including foil composition and position within the assembly. The experimental results reported here will aid in the production of stainless steel benchmarks for a range of nuclear data applications including those used in nuclear forensics analysis.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Simple separation of technetium from molybdenum for tracer isotope production

A procedure for the separation of technetium isotopes from bulk molybdenum was developed in nitric acid media. After irradiation of nat Mo foils, and dissolution in H 2 O 2 , the solution is acidified to 2 M HNO 3 , and anion exchange resin is used to separate technetium from molybdenum. The procedure is simple, requiring only basic laboratory equipment and, with a two-column separation, the technetium yield is high (~ 85%) with extremely high purity (< 0.1 ppm nat Mo). In conclusion, this is ideally suited for laboratory production of technetium tracer isotopes, particularly 95m Tc.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2026

Measurement of low energy characteristic X-rays emitted present in U-10Mo HALEU alloy fuel

Advance high density monolithic alloy HALEU fuels have been scanned with a silicon drift detector scanning system to measure low-energy characteristic X-rays emitted by uranium daughters, as well as zirconium present as a foil diffusion barrier. Four peaks were measured across the surfaces of three plates, and are consistent with other thorium and protactinium peaks present in depleted uranium samples that are induced by the decay of 235 U and 238 U. Of the four peaks detected, three are dominated by the decay of 235 U, and one peak at 15.70 keV covers two characteristic X-rays from the zirconium diffusion barrier (Kα 1 ) and from a 231 Th 15.62 keV X-ray induced by 235 U α-decay. The low energies of these lines suggest that they are mostly emitted from the fuel meat surface, and the poor counting statistics caused by strong self-attenuation make these data a poor candidate for 235 U/ 238 U ratio analysis. We suggest, then, that these X-rays could be used for passive measurement of variations in the cladding thickness of these fuels to complement manual thickness measurement methods.

HALEU↗
DOE OSTI2022

Residual Stress Measurements in Extreme Environments for Hazardous, Layered Specimens

In nuclear fuel plates of low-enriched U-10Mo (LEU) clad with aluminum by hot isostatic pressing (HIP), post-irradiation stresses arising during reactor shutdown are a major concern for safe reactor operations. Measurement of those residual stresses has not previously been possible because the high radioactivity of the plates requires handling only by remote manipulation in a hot cell. The incremental slitting method for measuring through-thickness stress profiles was modified, and a system for automated, remote operation was built and tested. Experimental modifications consisted of replacing electric-discharge machining (EDM) with a small end mill and strain-gauge measurements with cantilever displacement measurements. The inverse method used to calculate stresses was the pulse-regularization method modified to allow discontinuities across material interfaces. The new system was validated by comparing with conventional slitting on a depleted U-10Mo (DU) fuel plate. The new system was applied to two measurements each on six as-fabricated (pre-irradiation) LEU miniature fuel plates. Variations between the measurements at two locations in the same plate were strongly correlated with measured geometrical heterogeneity in the plate—a tilt in the fuel foil. Compressive stresses in the U-10Mo were shown to increase from 20 to 250 MPa as the ratio of aluminum thickness to U-10Mo thickness increased causing increased constraint during cooling. Faster cooling rates during processing also increased stress magnitudes. The measurements trends agreed with data in the literature from similar plates made with DU, which further validates the method. Because other methods are impractical in a hot cell, the modified slitting method is now poised for the first measurements of post-irradiation stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compatibility of Alumina-Forming Austenitic Steels in Static and Flowing Pb

Alumina-forming austenitic (AFA) steels were evaluated for the lead fast reactor application in static and flowing high-purity Pb. Two AFA composition ranges with different Ni, Mn, Al, Cr and Nb contents were targeted, and Zr foil was used in an attempt to getter O in some capsules. Based on two rounds of capsule testing at 500–800°C, two AFA compositions were selected for evaluation in flowing Pb with a peak temperature of 650°C in a thermal convection loop made of pre-oxidized FeCrAlMo tubing. After exposure for 1000 h, the mass losses for both AFA alloys were generally low, suggesting good compatibility under these conditions without preoxidation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Lessons learned from the design and operation of a small-scale cross-flow tidal turbine

In 2023, a first-generation prototype of a small-scale marine current turbine was operated in Sequim Bay, Washington (USA) for 141 days. The system, referred to as the Turbine Lander, was the product of a laboratory-to-field effort to develop a system that enables enhanced ocean sensing or vehicle recharge in remote, energetic settings. The turbine consists of a vertical-axis, cantilevered rotor (1.19 m x 0.85 m) with four foils installed on a gravity foundation. A broader range of constraints including the deployment strategy, site characteristics, and estimated loads, drove the system’s design. This work presents the design, characterization, operation, and post-recovery engineering assessment of the Turbine Lander. Pre-deployment characterization efforts yielded a peak power coefficient of approximately 0.3 for the rotor, although system losses resulted in much lower water-to-wire efficiencies under most operating conditions. The results demonstrate the importance of co-design among key components of the powertrain and control systems to achieve acceptable system efficiency across operating conditions.

Co-design↗
DOE OSTI2022

The annihilation of antiphase boundary tubes and their effect on strengthening in Ni 3 Al

The temperature at which antiphase boundary (APB) tubes anneal out of lightly-strained Ni-rich Ni 3 Al thin foils has been measured via in-situ heating in a transmission electron microscope to be ~530 °C. Given this new information, the wealth of literature on the mechanical properties of Ni 3 Al across the entire temperature regime of the yield stress anomaly, ~25–800 °C, is re-evaluated to consider the impact of APB tubes. Contrary to previous theoretical predications, APB tubes do not appear to affect the strength of Ni 3 Al.

36 MATERIALS SCIENCE↗
DOE OSTI2023

In-situ TEM investigation of void swelling in nickel under irradiation with analysis aided by computer vision

Understanding the stability of irradiation-induced voids in materials is important for engineering material's swelling behavior under irradiation. In-situ TEM offers a spatial and temporal resolution that is suitable for investigating the evolution of voids under irradiation. However, the in-situ videos have often been too large to be analyzed manually, leaving the valuable data underutilized. For this work, we developed a deep learning-based semantic segmentation model to consistently study the growth and shrinkage of voids in nickel under 1 MeV krypton ion irradiation at various temperatures from 525 °C to 650 °C. With a foil thickness near 100 nm and ion flux of 6.3 × 10 11 ions∙ cm –2 ∙s –1 , the pre-existing voids, which were created beforehand by irradiation at 600 °C to 0.5 dpa, shrank at low temperatures and grew at high temperatures under irradiation, where the transition occurred at 575 °C (~0.5 T M ). The observed stability transition provided new insight for the shrinkage mechanism of voids under irradiation. In addition, an annealing experiment on nickel, previously irradiated at 600 °C to 3 dpa, was performed sequentially at 650 °C to 720 °C to reveal the shrinkage rate of void as a function of temperature and void size. The advantage of combining computer vision and in-situ TEM to obtain comprehensive void evolution was demonstrated.

36 MATERIALS SCIENCE↗