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At least 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fe–N–C Boosts the Stability of Supported Platinum Nanoparticles for Fuel Cells

The poor durability of Pt-based nanoparticles dispersed on carbon black is the challenge for the application of long-life polymer electrolyte fuel cells. Recent work suggests that Fe- and N-codoped carbon (Fe-N-C) might be a better support than conventional high-surface-area carbon. In this work, we find that the electrochemical surface area retention of Pt/Fe-N-C is much better than that of commercial Pt/C during potential cycling in both acidic and basic media. In situ inductively coupled plasma mass spectrometry studies indicate that the Pt dissolution rate of Pt/Fe-N-C is 3 times smaller than that of Pt/C during cycling. Density functional theory calculations further illustrate that the Fe-N-C substrate can provide strong and stable support to the Pt nanoparticles and alleviate the oxide formation by adjusting the electronic structure. The strong metal-substrate interaction, together with a lower metal dissolution rate and highly stable support, may be the reason for the significantly enhanced stability of Pt/Fe-N-C. In conclusion, this finding highlights the importance of carbon support selection to achieve a more durable Pt-based electrocatalyst for fuel cells.

25 ENERGY STORAGE↗
DOE OSTI2022

Novel Functional Thermal Energy Storage Materials for Buildings Applications

The leakage of solid-liquid phase change materials (PCMs) tremendously limits their long-term application in thermal energy storage (TES). In this work, we present durable and form-stable shape-stabilized PCMs (ss-PCMs) for TES in building envelopes. These ss-PCMs are fabricated by encapsulating polyethylene glycol (PEG) consisting of different molecular weights within mesoporous magnesium oxide and silica dioxide. For the first time, the phase transition temperature (Tt) of ss-PCMs has been fine-tuned synthetically to be comfortable to building occupants by utilizing PEG blends with molecular weights of 600 and 800 g/mol. Several parameters, including surface hydrophilicity/hydrophobicity, surface area, and PCM loading percentage, have been studied to maximize the latent heat enthalpy for high energy efficiency and maintain form stability. The best ss-PCM candidate with suitable Tt and appreciable latent heat enthalpy exhibits a repeatable phase change behavior for up to 1,000 thermal cycles without leakage, which provides a promising solution for durable TES in buildings. The Tt tunability extends its application over a wider temperature range beyond buildings.

building envelope↗
DOE OSTI2020

Probing Membrane Degradation with Varying Catalyst Layer Thickness and Carbon Support

Understanding membrane degradation continues to be of significant importance when studying fuel cell durability. Fuel cell performance and durability depends heavily on the membrane's chemical and mechanical integrity. In Nafion® membranes, hydroxyl radicals are the primary cause of chemical membrane degradation as they attack the membrane's polymer structure. Radical formation can ensue via peroxide decomposition at the cathode or gases reacting on Pt particles within the membrane. Here, a previous research effort on membrane degradation as a function of ultra-low Pt loadings (≤ 0.1 mgPt cm -2 ) showed the degradation rate increases with Pt loading. This is most likely due to more heterogenous sites for radical formation. Manufacturing MEAs with ultra-low Pt loadings can yield thin, non-uniform catalyst layers. In this research effort we studied membrane degradation with ultra-low Pt loadings while varying catalyst layer thickness, I/C ratio, and types of carbon support.

25 ENERGY STORAGE↗
DOE OSTI2021

Stability of Atomically Dispersed Fe–N–C ORR Catalyst in Polymer Electrolyte Fuel Cell Environment

We have investigated the durability of a platinum group metal (PGM-)free Fe–N–C catalyst in which the Fe sites are atomically dispersed (AD), and found it to be quite stable in standard accelerated stress test (AST) cycles normally used for low-PGM catalysts: a square wave with 0.6 V lower potential limit (LPL)—0.95 V upper potential limit (UPL) with 3-s holds at UPL and LPL in H 2 /N 2 , at 1.5 atm, 80 °C and 100% RH. Considering the metrics normally employed to characterize the durability of the low-PGM catalysts after 30,000 AST cycles, this PGM-free catalyst lost <50% catalyst activity, <50% H 2 /air performance at 0.8 V, and 40 mV at 1.5 A cm -2 . However, it is less stable in H 2 /air, losing ~50% catalyst activity after just 7.5 h of polarization measurements (load cycles). In combined cycles, the majority of the loss in catalyst activity occurred during the load cycles in H 2 /air rather than AST cycles in H 2 /N 2 . We have concluded that, unlike low-PGM catalysts that lose electrochemically active surface area (ECSA) through potential cycling-induced processes, (AD)Fe–N–C catalysts degrade by processes associated with the presence of oxygen.

25 ENERGY STORAGE↗
DOE OSTI2025

Reversible Losses in Proton Exchange Membrane Water Electrolysis

Lower anode catalyst loadings and higher current densities are essential to lowering the levelized cost of H 2 production via proton exchange membrane water electrolysis (PEMWE). However, these approaches can induce significant durability challenges. Here, we show that cell degradation can include large reversible voltage losses across a variety of conditions, including low loadings and high currents. Although there is limited published discussion of reversible voltage losses in PEMWE, we demonstrate that they are an important consideration in cell efficiency and durability. Understanding the mechanisms of reversible losses and developing mitigation strategies is therefore a key priority for enabling low-cost PEMWE.

08 HYDROGEN↗
DOE OSTI2026

An Acid-Free, Temperature-Based Cation Contamination Removal Strategy for PEM Water Electrolysis

It is widely understood that the durability and reliability of polymer electrolyte membrane (PEM) water electrolyzers are heavily dependent on feedwater purity, with cation contaminants that originate from incomplete water purification and balance of plant materials significantly harming electrolyzer performance. However, contamination remains a challenge and a common cause of failure at the stack level, indicating the need for strategies to recover the performance of contaminated cells. In this study, we investigate the effects of temperature on the uptake, electrochemical impacts, and removal of contaminant calcium and iron cations. Lower operating temperatures increase the sensitivity of the cell performance to contaminant cations, while also decreasing cation uptake and promoting contaminant removal. Computational charge transfer modelling shows that lower temperature increases the concentration of contaminant at the cathode and facilitates their removal from the cell. By testing single cells under scenarios designed to mimic stack temperature dynamics, we investigate low-temperature operation as an approach to stack-relevant contaminant recovery. Together, these results demonstrate that the low-temperature recovery approach is a promising approach for acid-free contamination recovery for PEM water electrolysis to promote stack reliability and durability.

08 HYDROGEN↗
DOE OSTI2026

Quantifying Sources of Long-Term Voltage Decay for Rutile Iridium Oxide Anodes in Proton Exchange Membrane Water Electrolysis

To achieve aggressive hydrogen cost targets for proton exchange membrane water electrolysis (PEMWE), it is necessary to develop catalyst systems that reduce precious metal loadings while maintaining performance over extended operation. While amorphous iridium (Ir) -based catalysts exhibit high initial activity, their long-term stability remains a key limitation. In this study, the behavior of a rutile IrO2 catalyst is investigated over 4000 h of durability testing and compared to past efforts evaluating a more amorphous material. This study finds that rutile IrO2 results in a smaller decay rate (4.9 ..mu..V h-1) than an amorphous catalyst (28 ..mu..V h-1); additionally, the rutile IrO2 results in a smaller degree of Ir migration (20% to the membrane and cathode) than an amorphous catalyst (35%). This research emphasizes rutile IrO2 as a promising avenue for the development of durable, low-iridium anodes that can meet lifetime and cost targets for next-generation electrolyzer systems.

08 HYDROGEN↗
DOE OSTI2022

Conduct Performance Validation of the Electrodynamic Shield (EDS) Induced Cleaning Under Realistic Environmental Soiling Conditions: CRADA Number CRD-21-17861 (Cooperative Research and Development Final Report)

NREL will work with the Participant to perform accelerated long-term durability and other standard durability tests for prototypes to help demonstrate the reliability of the technology for PV applications. NREL will test commercially relevant-sized prototypes under realistic environmental soiling conditions to correlate dust removal efficacy for improving the PV output under standard solar conditions. Measurements will include voltage-current characterization in solar simulators before and after dust cleaning.

14 SOLAR ENERGY↗
DOE OSTI2022

Nepheline Crystallization Studies and the Structural Integrity of the Residual (SIR) - FY 2022 Study Glasses

In FY22 a set of 367 HLW glasses with compositions representative of the Waste Treatment and Immobilization Plant (WTP) processing region were aggregated and analyzed with the Structural Integrity of the Residual (SIR) model developed by the Savannah River National Laboratory (SRNL). An additional 12 glasses targeting 27 – 37 wt % alumina (in glass) and at waste loadings up to ~70 wt % were fabricated and added to the database. Collectively, this data set was analyzed with regression statistics and partitioning functions to reveal correlations between boron release and the chemical composition. FY22 results indicate that the SIR theoretical alkali-silicate precipitation term, Al 2 O 3 and B 2 O 3 concentration, and SIR computed non-bridging oxygen are significant predictors of chemical durability. A statistical model using the SIR parameters was shown to have greater overall accuracy than the nepheline discriminator model while maintaining false predictions of pour durability below 1%. In FY23, we will continue this work to focus on refining the SIR with glass compositions that challenge the SIR correlation terms, namely the theoretical crystalline precipitation and non-bridging oxygen terms.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]

Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Advanced Diagnosis and Accelerated Testing of Balance of System Components for Utility Scale PV Installations: October 1, 2022-September 30, 2024

A study of the durability of PV Balance of System components was performed. Specifically, wire cable jackets and cable connectors were examined within the direct current (DC) PV Power Transmission Chain (PTC). Degraded and failed samples have been obtained from utility PV installations to provide feedback on the degradation modes and the related damage-enabling considerations in today's PV systems. An industry interface group (including system owners, system inspectors, component manufacturers, and test labs) was used to help identify and obtain field-failed samples, for feedback (including samples and experimental design), and to facilitate the subsequent dissemination of the results of this study. Samples were empirically studied using accelerated stress testing with steady-state conditions (cable jackets) in addition to combined-accelerated stress testing (cable jackets, connectors and uncapped connectors). Steady-state accelerated testing has been performed using at least one applied stressor (e.g. UV light) to aid understanding of jacket durability relative to its application. Component- and material-focused failure analysis was conducted to develop an understanding and advise the PV industry. In-depth characterization will be applied selectively to field- and artificially aged-samples, to gain scientific understanding of the structural, chemical, electrical, mechanical, and thermal properties enabling degradation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

The User Guide for the ComPro Database

An extensive database of glass composition and durability data has been compiled at Savannah River National Laboratory to support the development of nuclear waste glasses. This database is referred to as the Glass Composition-Properties Database (ComPro). The ComPro Database, Revision 3, contains 14,134 total rows of data and 125 columns of composition, durability, as defined by the Product Consistency Test, and other fabrication and characterization information, if available, for each glass. Of the 14,134 total rows, 8,484 rows have been classified as “Model” data and 5,650 rows have been classified as “Non-Model” data. An integral supplement to the ComPro database is the User Guide. The User Guide was developed as a tool to aid the End User in a more effective use of the ComPro database. The User Guide provides a road-map of the specific datasets that comprise the ComPro database (both “Model” and “Non-Model” data) as well as a technical basis for the terminology and definitions the End User will encounter. In this report, a general description of the format and information contained in the User Guide is provided. In addition, specific terminology used in the User Guide is also discussed.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Solvari SR, Simplifying Residential Solar to 1 SKU, with Extended Testing

Accelerated weathering and material compatibility testing for polymeric and asphaltic materials. NLR will be testing the durability of the polymeric materials proposed for use in the supporting structures designed by TESCI solar. This will include the bare materials and coupons attached to asphalt shingles. The exposure will be in damp heat and separately heat, humidity and UV light, all followed by mechanical evaluation. Modification 1 is an extension of the first round of testing with both a continuation of some of the same testing and addition of new testing methods and materials. The testing of materials in the condition of A3 looking at mechanical durability will be continued looking at the materials used in the mounting brackets. We will be adding in testing of the silicone adhesive to the module and of the module itself. For the mounting brackets, testing will also be conducted at multiple temperatures and humidity levels to allow for extrapolation to the field.

14 SOLAR ENERGY↗
DOE OSTI2026

NLR CSP Optical Facilities: Illuminating the Path Forward Through Innovation and Impact: Agreement 38490

This initiative is a multi-faceted project at the National Laboratory of the Rockies (NLR) aimed at strengthening its Concentrating Solar Power (CSP) Optical Facilities to advance the development of low-cost, high-performance materials for solar and other applications. The project's strategy is built on three pillars: strategic stakeholder engagement, diligent facility maintenance and utilization, and the development of new research capabilities. The overarching goal is to ensure the facilities remain state-of-the-art resources for industry and academia, thereby accelerating the conversion of concentrated sunlight into energy. A key driver of the project is an international Advisory Board, which provides critical guidance on research priorities and industry needs, leading to new collaborations and secured funding. This external engagement, combined with proactive outreach to industry partners, ensures the lab's work remains aligned with real-world challenges, including materials durability and performance certification. Significant efforts in facility maintenance have addressed challenges with aging infrastructure. Notable achievements include the complete refurbishment of the hail-damaged Ultra-Accelerated Weathering System (UAWS) and the successful replacement of a failing 15-year-old Lambda 1050 spectrophotometer with a new-generation model, substantially upgrading material characterization capabilities. These maintenance activities were complemented by achieving a prestigious ISO 9001:2015 certification for the Advanced Optical Materials Labs, formally recognizing the quality and reliability of NLR's measurement capabilities. Despite these successes, challenges remain, including high demand for the High Flux Solar Furnace (HFSF) and intermittent failures of other key instruments. The project has delivered major advancements in research techniques and capabilities. At the Flatirons campus, a new indoor laboratory, was established to house advanced deflectometry and photogrammetry systems for heliostat characterization. For on-sun testing, a novel, actively cooled turning mirror was developed for the HFSF, enabling more realistic testing of particle receivers and components. A collaboration with Virginia Tech successfully demonstrated the high-temperature durability of a new solar absorber coating through extensive cyclic testing. Concurrently, new modeling took place to better predict material degradation on rough, fractal surfaces. In summary, this project has systematically enhanced NLR's CSP Optical Facilities through strategic upgrades, rigorous maintenance, and stakeholder-guided research. By overcoming equipment failures, budgetary constraints, and logistical hurdles, the project has reinforced NLR's role as a central hub for CSP innovation and materials testing. Future work will focus on securing diverse funding, expanding collaborations, and continuing to provide the critical infrastructure needed to accelerate the development and deployment of next-generation technologies.

14 SOLAR ENERGY↗
NASA NTRS2016

Development and Property Evaluation of Selected HfO2-Silicon and Rare Earth-Silicon Based Bond Coats and Environmental Barrier Coating Systems for SiC/SiC Ceramic Matrix Composites

Ceramic environmental barrier coatings (EBC) and SiC/SiC ceramic matrix composites (CMCs) will play a crucial role in future aircraft propulsion systems because of their ability to significantly increase engine operating temperatures, improve component durability, reduce engine weight and cooling requirements. Advanced EBC systems for SiC/SiC CMC turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant material development challenges for the high temperature CMC components is to develop prime-reliant, high strength and high temperature capable environmental barrier coating bond coat systems, since the current silicon bond coat cannot meet the advanced EBC-CMC temperature and stability requirements. In this paper, advanced NASA HfO2-Si and rare earth Si based EBC bond coat EBC systems for SiC/SiC CMC combustor and turbine airfoil applications are investigated. High temperature properties of the advanced EBC systems, including the strength, fracture toughness, creep and oxidation resistance have been studied and summarized. The advanced NASA EBC systems showed some promise to achieve 1500C temperature capability, helping enable next generation turbine engines with significantly improved engine component temperature capability and durability.

Oxidation and cyclic durability↗
NASA NTRS2017

Development of Advanced Environmental Barrier Coatings for SiC/SiC Ceramic Matrix Composites: Path Toward 2700 F Temperature Capability and Beyond

Advanced environmental barrier coating systems for SiC-SiC Ceramic Matrix Composite (CMC) turbine and combustor hot section components are currently being developed to meet future turbine engine emission and performance goals. One of the significant coating development challenges is to achieve prime-reliant environmental barrier coating systems to meet the future 2700F EBC-CMC temperature stability and environmental durability requirements. This presentation will emphasize recent NASA environmental barrier coating system testing and down-selects, particularly the development path and properties towards 2700-3000F durability goals by using NASA hafnium-hafnia-rare earth-silicon-silicate composition EBC systems for the SiC-SiC CMC turbine component applications. Advanced hafnium-based compositions for enabling next generation EBC and CMCs capabilities towards ultra-high temperature ceramic coating systems will also be briefly mentioned.

Ceramic Matrix Composite↗
DOE OSTI2024

Redesigning Photoelectrodes So They Can Work in the Light and Dark

Unassisted photoelectrochemical (PEC) reactions, such as H2 generation and CO2 reduction, are limited by the durability of the immersed photoelectrode. Small band gap semiconductors, like Si, are efficient at utilizing a large portion of the solar spectrum but are not stable in aqueous environments without protection. While great strides have been made to improve stability under constant illumination, dark stability remains relatively unexamined and presents great challenges for durable PEC systems. Cathodic protection is an established electrochemical method for preventing metal electrode degradation in harsh conditions. Similar protection strategies cannot be applied to traditional two-terminal (2T) semiconductor photoelectrodes because of their inability to pass reverse bias current in the dark. New, three-terminal (3T) photovoltaic (PV) architectures introduce additional degrees of freedom in traditional 2T PEC operations by adding an extra electrical contact for an alternative low resistance path to protect the photoelectrode and drive electrochemical reactions, even in the dark. Here, we investigate bare 3T Si PV devices operating as photocathodes in aqueous methyl viologen electrolyte. The 3T architecture provides additional capabilities to PEC systems such as cathodic protection, the ability to drive reactions with or without illumination, and in situ switching between different operational modes. We show that 3T-based Si photocathodes maintain PEC activity after several hours of light/dark cycling. This work helps advance PEC use in real-world conditions where variable illumination must be considered.

cathodic protection↗
DOE OSTI2021

Enhancing Oxygen Reduction Activity and Cr Tolerance of Solid Oxide Fuel Cell Cathodes by a Multiphase Catalyst Coating

Intermediate temperature solid oxide fuel cells (IT-SOFCs) are cost-effective and efficient energy conversion systems. Here, the sluggish oxygen reduction reaction (ORR) and the degradation of cathodes are critical challenges to the commercialization of IT-SOFCs. Here, a highly efficient multiphase (MP) catalyst coating, consisting of Ba 1–x Co 0.7 Fe 0.2 Nb 0.1 O 3–δ (BCFN) and BaCO 3 , to enhance the ORR activity and durability of the state-of-the-art lanthanum strontium cobalt ferrite (La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3–δ , LSCF) cathode is reported. The conformal MP catalyst-coated LSCF cathode shows a polarization resistance (R p ) of 0.048 Ω cm 2 at 650 °C, about one order of magnitude smaller than that of the bare LSCF. In an accelerated Cr-poisoning test, the degradation rate of the catalyst-coated LSCF electrode is 10 –3 Ω cm 2 h –1 (0.59% h –1 ) over 200 h, only one fifth of the degradation rate of the bare LSCF electrode at 750 °C. In addition, anode-supported single cells with the MP catalyst-coated LSCF cathode show a dramatically enhanced peak power density (1.4 W cm –2 vs 0.67 W cm –2 at 750 °C) and increased durability against Cr and H 2 O. Both experimental results and density functional theory-based calculations indicate that the BCFN phase improves the ORR activity while the BaCO 3 phase enhances the stability of the LSCF cathode.

solid oxide fuel cells↗