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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Predicting oxidation damage in ultra high-temperature borides: A machine learning approach

Ultra-high temperature (UHT) borides are ceramics materials with melting points above 3000 °C for structural applications in extreme environments. However, at temperatures exceeding 1600 °C and under oxidizing conditions, the material suffers from detrimental degradation. Optimized design and performance of diboride materials under such extreme conditions requires filling the missing composition-microstructure-oxidation gap. This study proposes a computational data-driven framework to connect the processing and microstructure of Ultra-high temperature borides with the oxidation damage. Random Forest Regressor (RFR) model is adopted to forecast the oxide scale thickness developed after oxidation testing based on processing variables and microstructural features. The model trained on a dataset consisting of 107 samples of experimental data extracted from the literature aims to predict oxidation damage. With proper data manipulation and fine model tuning, the predictor could forecast the oxide scale thickness of UHT diborides with a Mean Absolute Error of 37.45 μm and an R-square of 0.83. This model could be used as a high-throughput scheme to design and test new UHT diborides materials computationally. Furthermore, a model with larger composition capabilities could also be developed in the future as more experimental data become available.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Studying the Durability of Molybdenum Carbide Aerogel as an Electrocatalyst Support for Proton Exchange Membrane Fuel Cells

Carbon-supported platinum nanoparticles (Pt/C) are currently the state-of-the-art catalyst in proton exchange membrane fuel cells (PEMFCs). Unfortunately, the carbon support lacks the ability to stabilize the metal catalyst, as platinum tends to dissolve and agglomerate, significantly compromising the durability. Herein, we synthesized a ceramic material, molybdenum carbide aerogel (MCAG), and utilized it as a Pt support for PEMFCs, as an alternative for conventional carbon supports. N 2 adsorption and XRD analysis showed that the MCAG possesses a combination of high porosity and a well-defined ceramic crystalline structure. The Pt/MCAG system was studied for its electrocatalytic activity toward ORR in a half-cell and demonstrated satisfactory reaction kinetics and electrochemical active surface area, comparable to the commercial Pt/C. For durability examination, an accelerated stress test (AST) in a single cell was conducted with the Pt/MCAG catalyst at the cathode, following the U.S. DOE electrocatalyst AST protocol. Intermediate polarization curves and cyclic voltammograms were recorded over the course of the AST to monitor the aging process. The results indicated that the MCAG support exhibited superior durability in long-term fuel cell operation compared to a carbon support. The Pt/MCAG system demonstrated stable behavior during the progressive stages of the AST, retaining more than 50% of its initial performance by the end of the test, whereas carbon-supported Pt preserved only 30%.

25 ENERGY STORAGE↗
DOE OSTI2020

Toward Higher Voltage Solid-State Batteries by Metastability and Kinetic Stability Design

The energy density of battery systems is limited largely by the electrochemical window of the electrolyte. Here, the combined thermodynamic and kinetic effects of mechanically induced metastability are shown to greatly widen the operational voltage window of solid-state batteries based on ceramic-sulfide electrolytes. Solid electrolyte voltage stability up to 10 V is achieved with minimal degradation, far beyond the capability of organic liquid electrolytes. Furthermore, combined experiment, ab initio computation, and theoretical modeling identify the nature of mechanically constrained Li 10 GeP 2 S 12 decomposition both within the bulk and at interfaces with cathode materials at very high voltages. Previously unclear kinetic processes are identified that, when properly implemented, can potentially allow solid-state full cells with remarkably high operational voltages.

25 ENERGY STORAGE↗
DOE OSTI2023

A room temperature rechargeable Li 2 O-based lithium-air battery enabled by a solid electrolyte

Lithium-air batteries have scope to compete with gasoline in terms of energy density. However, in most systems, the reaction pathways either involve one- or two-electron transfer, leading to lithium peroxide (Li 2 O 2 ) or lithium superoxide (LiO 2 ), respectively. Kondori et al. investigated a lithium-air battery that uses a ceramic-polyethylene oxide–based composite solid electrolyte and found that it can undergo a four-electron redox reaction through lithium oxide (Li 2 O) formation and decomposition (see the Perspective by Dong and Lu). The composite electrolyte embedded with Li 10 GeP 2 S 12 nanoparticles shows high ionic conductivity and stability and high cycle stability through a four-electron transfer process.

25 ENERGY STORAGE↗
DOE OSTI2025

Destructive Analysis of TRISO Particles: Crush/Burn/Leach Followed by Davies-Gray Titration and IDMS

The accurate accounting of nuclear materials is a cornerstone of international nuclear safeguards. One emerging challenge in this domain is the fabrication of TRIstructural ISOtropic (TRISO) particle fuels. Although these innovative fuel forms are critical for advanced reactor applications, their robust refractory ceramics and coating compositions present significant obstacles to destructive analysis (DA) methods. Ensuring full and quantitative recovery from these particles is essential for accurate mass accountancy. The current study was initiated to address these challenges, first by validating a previously established destructive method developed by Oak Ridge National Laboratory (ORNL) for the quantitative recovery of uranium from TRISO particles and then following that process with uranium content determination through isotope dilution mass spectrometry (IDMS) and Davies-Gray titration. This study expands on the scope of a digestive method that was developed under the Advanced Gas Reactor Fuel Development and Qualification program and is currently implemented in both the Coated Particle Fuel Development Laboratory and Irradiated Fuels Examination Laboratory at ORNL. The success of the previous Advanced Gas Reactor work relied on developing a DA method to evaluate the fabrication process and reactor experiments. The methodology described in this report was designed to rigorously investigate the efficacy of the crush/burn/leach sample preparation of TRISO particles; it aims to quantify uranium recovery while also assessing the effects of TRISO constituents (e.g., silicon and zirconium) on analytical precision and accuracy. By comparing the results from the titration method and IDMS, we sought to determine whether existing analytical procedures accepted by the International Atomic Energy Agency (IAEA) could be effectively translated to TRISO fuel forms. The team employed an approach that involved processing replicate TRISO samples, optimizing the milling (i.e., crushing) step and performing serial leaches. The elemental composition of the analytical samples was examined to prepare for interference studies in the second year of this project. The integration of gamma spectrometry to verify residual uranium activity further strengthened the validation. Statistical methods were applied to the collected data to evaluate the uncertainties arising from sampling, sample preparation and uranium quantification. These uncertainties were then compared to the IAEA’s international target values (ITVs). Additional data collected in upcoming project work will strengthen the uncertainty estimates. Ultimately, it is hoped that this project will contribute materially to the body of work related to characterization of TRISO based fuels for the purpose of material accountancy and its applications to international safeguards.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

A reduced-order modeling of a tubular solar reactor for long duration thermochemical energy storage

The storage of solar energy in a solid form, referred to as a “solar fuel”, can be achieved through a process known as endothermic solar thermochemistry. This process transforms the absorbed solar energy into a stable and retrievable form that can be stored for extended periods of time. This paper presents a low–order heat transfer model of a counter–current tubular falling bed reactor designed to produce thermally reduced magnesium manganese oxide pellets for long duration thermochemical energy storage. The energy required for the endothermic reduction was supplied by concentrated solar energy or renewable electricity via indirect heating of the gas and solid reactants flowing in a ceramic tube. The counter-current gas flow enhances the mixing of the solid particles with the heat recuperation zone, allowing the gas and particles to enter and exit the tubular reactor close to room temperature. Further, the reactor was vertically oriented and was heated circumferentially by an adjustable level heat flux along a finite segment of its length. The temperature distribution of the reactor in response to transient changes along the tube was modeled by considering conduction, convection, and radiation heat transfer. Governing equations for the heat transfer model were solved by discretizing the reactor tube into a finite number of control volumes and using an energy balance for the heat exchange between the reactor wall, gas, and particles within the control volume. The energy absorbed during this endothermic reaction was modeled numerically by fitting the data of the chemical conversion rate with the corresponding temperature of particles in the heating zone. The numerical model has been experimentally validated using a reactor prototype made of a 121.92 cm alumina tube heated by a 7kW electric tube–furnace. The alumina tube receives magnesium manganese oxide pellets of 3.66±0.516 mm in diameter from the top, and a counter–current gas flow from the bottom. The reactor wall temperature was monitored by six thermocouples installed along the reactor tube length. The experimental procedure was numerically simulated, and the temperature variation along the reactor tube was compared with a matrix of experimental runs for a range of particles mass flowrates (0.75–1.25g/s) and corresponding gas flowrates (36–65 SLPM). The reactor system was heated gradually from room temperature to a steady state temperature of 1673K, and then cooled down to room temperature. The heating and cooling processes were simulated, and the numerical and experimental results were compared throughout processes. The numerical model showed similar trends to the experimental results, with an error of 0.69 to 7.9% for the particle inlet and 0.7 to 7.9% for the gas inlet during steady-state operation. The proposed numerical model can be implemented as a simplified physical model to design a feedback control system to regulate reactor temperature.

14 SOLAR ENERGY↗
DOE OSTI2013

Relaxor nature in lead-free Sr{sub 5}LaTi{sub 3}Nb{sub 7}O{sub 30} tetragonal tungsten bronze ceramics

Lead-free tetragonal tungsten bronze Sr{sub 5}LaTi{sub 3}Nb{sub 7}O{sub 30} ceramics were prepared and the correlation of the relaxor nature and crystal structure was studied using dielectric spectroscopy and powder X-ray diffraction. Three dielectric relaxations were observed below the deviation temperature T{sub D}∼ 330 K. Relaxation I and II followed the Vogel-Fulcher law with the freezing temperatures of 189 K and ∼90 K. Low temperature relaxation III, which was first observed in filled tungsten bronze, followed well the Arrhenius law. Dielectric response becomes static below 50 K. Polarization-field (P-E) hysteresis loops were evaluated from 183 K to 298 K. P{sub r} value of 0.41μC/cm{sup 2} was observed at 183 K. Deviation of lattice parameter c from the linear contraction and increasing of tetragonality (c/a ratio) were observed below T{sub D}, reflecting the structure change during the formation of polar nanoregions and the following freezing process. Opposite tendency was observed below 100 K for all the lattice parameters, corresponding to relaxation III. Generally, the main dielectric relaxation I and II were attributed to flipping and breathing of polar nanoregions along c axis, while the concerted rotations of the oxygen octahedra in the ab plane were suggested as the origin of relaxation III.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Preliminary hyperspectral neutron radiography of binder jet 3D printed and melt infiltrated Si–SiC

The preliminary results of hyperspectral neutron radiography of Si–SiC made with binder jet additive manufacturing, subsequent carbon addition, and silicon melt infiltration are presented. The samples were measured in the processing states before and after the melt infiltration to determine if neutrons would help characterize the microstructure to better understand the melt infiltration process. Theoretical Bragg edges were calculated for comparison with the radiographic results. The changes in the Bragg edges from pre- to post-infiltrated reaction-bonded SiC were evident, that could be used to address the differences in microstructures. In conclusion, the preliminary results presented in this study demonstrated that neutron Bragg-edge imaging is possible with Si–SiC reaction-bonded ceramics and can help determine the microstructure of melt infiltrated samples.

SiC↗
DOE OSTI2015

Highly Textured BaTiO 3 via Templated Grain Growth and Resulting Polarization Reversal Dynamics

Samples of bulk textured polycrystalline BaTiO 3 ceramics were fabricated using a templated grain growth ( TGG ) approach in order to investigate effects of polycrystallinity and texture related to ferroelectric domain reversal under high‐power drive conditions. Barium titanate platelets were formed via two‐step topochemical conversion of bismuth titanate platelets grown via molten salt synthesis, then aligned via tape casting within a matrix of fine BaTiO 3 powder. The coarse‐grained parts showed a high degree of crystallographic texture after sintering. Combined with ceramics of similar density and polycrystallinity, but random orientation and commercial single‐crystal specimens, this sample set enabled direct isolation of crystallographic texture and polycrystallinity as the primary variables for high‐power polarization reversal studies. These studies have also demonstrated a link between grain size and polarization reversal time that strongly suggests that grain boundaries serve effectively as nucleation sites during the ferroelectric switching process.

Meier, William↗
DOE OSTI2025

SPC-70804 Rev 1 Zircar ZAL-45 Alumina Standoff Plates for Use in MARVEL

Idaho National Laboratory (INL) is developing a microreactor to produce electrical power utilizing a small nuclear core and Stirling engines under the Microreactor Application Research Validation and Evaluation (MARVEL) program. This procurement specification defines the requirements for fabrication of the MARVEL ZAL-45 standoff plates manufactured by Zircar. The design requires eight (8) ceramic standoff plates; however, the requested quantity shall be twelve to account for required testing after receipt of materials. Any conflict between this specification and referenced Codes and Standards, or any supplementary specifications in the procurement documents requires written clarification from the Contractor prior to proceeding with any work. Any deviation from the procurement documents requires approval by the Contractor with the change request process.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2026

Task Sharing of Proton Incorporation in Vertically Aligned Nanocomposite Triple Conductors: Growth, Structure, and Surface Exchange Kinetics

As protonic ceramic electrolysis cells emerge for efficient H 2 production, there is a need to develop air electrode materials enabling fast, durable steam splitting and proton incorporation. Single-phase triple conductors may fail to satisfy the myriad performance/stability requirements, and their critical charge-carriers (holes, oxygen vacancies, and protons) are in competition, limiting their concentrations. Instead, we propose task-sharing, vertically aligned nanocomposites (VANs), comprising a proton conductor (BaZr 0.9 Y 0.1 O 3-δ ) and a redox-active mixed ionic electronic conductor (Ce 0.9 Pr 0.1 O 2-δ ), that may enable rapid proton surface exchange at the solid–gas interface and transport along the solid–solid heterointerfaces. We grew VANs by pulsed laser deposition and investigated the interplay between their processing conditions, structure, and proton and oxygen surface exchange kinetics. We varied the substrate temperature, laser repetition rate, laser fluence, and processing oxygen pressure. The crystallinity and phases were characterized by grazing-incidence X-ray diffraction, and the strain and structural order as a function of depth were evaluated by angle-dependent synchrotron X-ray pair distribution function analysis. To evaluate the potential for interdiffusion, the formation energies of substitutional defects were simulated with density functional theory. Corresponding structural analysis and elemental mapping were performed by scanning/transmission electron microscopy, energy-dispersive X-ray spectroscopy, and electron energy-loss spectroscopy, indicating distinct nanoscale compositional regions with a hierarchical structure embedded in individual VANs columns and minimal interdiffusion across a bilayer film. Proton and oxygen surface exchange coefficients (k H , k O ) and polarization resistances were evaluated by electrical and optical relaxations and impedance spectroscopy of VAN-incorporated protonic ceramic electrochemical cells, respectively, at 400–500 °C, demonstrating values comparable to some of the best-known triple and mixed conductors.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Molten Salt Reactors and Electrochemical Reprocessing: Synthesis and Chemical Durability of Potential Waste Forms for Metal and Salt Waste Streams

The molten salt reactor (MSR) is one of the leading advanced nuclear reactor candidates to replace current nuclear reactor technologies in the U.S. Besides having more economical and reliable designs, MSRs have are amenable to a closed fuel cycle, in which electrochemical reprocessing can be performed to recycle the used nuclear fuel. This review intends to provide information about potential waste forms for metal and salt waste streams from these salt-based nuclear processes. Metal waste streams arise from reactor components and structural materials. Salt waste streams are generated during reactor operations as fission products build up in salt-fueled systems. Waste forms that have the highest waste loading and/or have shown the most commercial promise are discussed with an emphasis on the current state of efforts to understand the synthesis and chemical durability of metal and ceramic waste forms.

molten salt reactors, electrochemical reprocessing↗
DOE OSTI2019

Thermodynamic Stabilities of Perfect and Vacancy-Defected Li 2 TiO 3 (001) Surfaces From First-Principles Analyses

Lithium titanate (Li 2 TiO 3 ) is an attractive ceramic material for various industrial applications, particularly as one of the most promising breeder blanket materials in future nuclear-fusion reactors. Previously reported studies mainly focus on sintered polycrystalline samples of Li 2 TiO 3 . Surface structure of the single-crystal form is rarely reported, although the information of surface structures and stabilities can be critical for further understanding the surface-associated processes. In this work, we perform extensive first-principles density-functional-theory (DFT) calculations to obtain the surface energies of Li 2 TiO 3 (001) with different surface terminations. For four perfect (defect-free) Li-, O-, or LiTi-terminated (001) surfaces, Li- or O-terminated (001) surfaces can be most stable in limited chemical-potential ranges corresponding to certain experimental conditions, while a LiTi-terminated (001) surface is always unfavorable relative to Li or O terminations. By calculating the total energies of various possible configurations with surface vacancies, we determine the energetically most favorable vacancy-defected surface terminations. From the corresponding ternary phase diagram, we analyze the stability of a specific surface termination with vacancies as well as the possible formation of oxides. Here, our stability analysis together with DFT-simulated STM images reveals that a 1/3-monolayer-Li-terminated surface most likely corresponds to the ordered hexagonal-like pattern observed previously in STM experiments. For a 1/2-monolayer-Li-terminated surface, the most stable surface structure from our DFT calculations contrasts with previous results from an empirical-potential model.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Two-dimensional heteronuclear single quantum coherence (HSQC) NMR spectra of lignin isolated from Populus trichocarpa residues after CELF pretreatment and CBP fermentation

Here we present a curated dataset of a series of two-dimensional heteronuclear single quantum coherence (HSQC) nuclear magnetic resonance (NMR) spectra of lignin isolated from a woody energy crop (Populus trichocarpa) residues after co-solvent enhanced lignocellulosic fractionation (CELF) pretreatment and consolidated bioprocessing (CBP) process. The natural poplar variant GW-9947 from the Center for Bioenergy Innovation (CBI) was used. The poplar was knife milled and passed through a 1 mm sieve. The CELF pretreatment was performed in a Parr autoclave reactor with 7.5 wt % solids loading, 0.5 wt% H2SO4 as catalyst at 150°C with 15, 25 and 30 minutes, respectively. Tetrahydrofuran was added in a 1:1 mass ratio with water as the pretreatment solvent. The residues from CELF pretreatment were then subjected to CBP using the bacterium C. thermocellum DSM 1313. CBP fermentations were performed at 60 °C in a shaker at 50 grams/L solids loadings. Lignin was isolated from the pretreated samples after ball-milling in a porcelain jar with ceramic balls via Retsch PM 200 at 580 rpm for 2.5 h followed by enzymatic hydrolysis in acetate buffer (pH 4.8, 50 °C) for 48 h. The lignin samples were characterized using 13C–1H HSQC experiments which were performed in a Bruker Avance III HD 500 MHz NMR spectrometer operating at a frequency of 125.12 MHz for the 13C nucleus. A standard Bruker pulse sequence was used on a Prodigy platform cryoprobe. The dry lignin samples were dissolved in deuterated dimethylsulfoxide for HSQC experiments. The spectra were acquired under the following acquisition conditions: 210 ppm spectral width in F1 (13C) dimension with 256 data points and 11 ppm spectral width in F2 (1H) dimension with 1024 data points, a 90° pulse, a one bond C–H coupling constant of 145 Hz, a 1.0 s pulse delay, and 64 scans. All the data was processed using the TopSpin 3.6 software (Bruker BioSpin). The NMR spectra provides structural characteristics information about lignin remaining in solids after CELF (150 °C with 15, 25 and 30 minutes) process and C. thermocellum CBP.

Lignin structure, HSQC, poplar, CELF, CBP, CBI↗
DOE OSTI2024

Electrolyzer Integrated Modular Nano-Array Monolithic Catalytic Reactors

The project objective is to design and develop a new class of electrolyzer-integrated, modular, nanostructure array (nano-array) monolithic catalytic reactors for high-flux, robust and selective methanol synthesis. The modular reactor features metal oxide nano-array grown on an additively-manufactured channeled honeycomb monolith made of ceramic or metals; this low-pressure carbon dioxide hydrogenation reactor is fueled with hydrogen from a low-temperature water electrolyzer having reduced platinum group metal (PGM) content. Through these nanostructured monolithic reactors, methanol synthesis is enabled with cost-effective hydrogenation reactions under low-temperature (<200°C) and low-pressure (<10 atm) conditions, thus significantly reducing the energy demand of the entire process.

08 HYDROGEN↗
DOE OSTI2015

Turbine repair process, repaired coating, and repaired turbine component

A turbine repair process, a repaired coating, and a repaired turbine component are disclosed. The turbine repair process includes providing a turbine component having a higher-pressure region and a lower-pressure region, introducing particles into the higher-pressure region, and at least partially repairing an opening between the higher-pressure region and the lower-pressure region with at least one of the particles to form a repaired turbine component. The repaired coating includes a silicon material, a ceramic matrix composite material, and a repaired region having the silicon material deposited on and surrounded by the ceramic matrix composite material. The repaired turbine component a ceramic matrix composite layer and a repaired region having silicon material deposited on and surrounded by the ceramic matrix composite material.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Influence of Ba Substitutions on Microstructure and Magnetic Properties of La–Ca–Co System Permanent Ferrite

La{sub 0.6}Ca{sub 0.4−x}Ba{sub x}O⋅n/2(Fe{sub 1−y}Co{sub y}){sub 2}O{sub 3}(x = 0, 0.05, 0.1, 0.15 and 0.2) permanent ferrite materials were prepared by ceramic technique. The topography and the structure were characterized by scanning electron microscopy (SEM) and x-ray diffraction (XRD), respectively. The magnetic properties were measured using vibrating sample magnetometer (VSM) and digital magnetometer. Single M-phase and flake-like grains were obtained for samples without Ba substitution(x = 0), and the magnetic properties of the pre-sintering La–Ca–Co ferrite were as follows: B{sub r} = 440 mT, H{sub cb} = 296 kA/m, H{sub cj} = 426 kA/m, (BH){sub max} = 36.6 kJ/m{sup 3} and H{sub k}/H{sub cj} = 0.83. When Ca was substituted by Ba, pre-sintered powder presents single M-phase structure and close three-dimensional size of grains, resulting in an improved rectangle ratio of sintered magnet. The rectangle ratio of sintered magnet reaches a maximum of 0.93 when x = 0.1. By optimizing process parameters, M-type La–Ca–Ba–Co sintered magnet was prepared with B{sub r} = 445 mT, H{sub cb} = 337 kA/m, H{sub cj} = 420 kA/m, (BH){sub max} = 38.6 kJ/m{sup 3} and H{sub k}/H{sub cj} = 0.95.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2013

Recovery Act: High-Temperature Circuit Boards for use in Geothermal Well Monitoring Applications

The U.S. Department of Energy is leading the development of alternative energy sources that will ensure the long-term energy independence of our nation. One of the key renewable resources currently being advanced is geothermal energy. To tap into the large potential offered by generating power from the heat of the earth, and for geothermal energy to be more widely used, it will be necessary to drill deeper wells to reach the hot, dry rock located up to 10 km beneath the earth’s surface. In this instance, water will be introduced into the well to create a geothermal reservoir. A geothermal well produced in this manner is referred to as an enhanced geothermal system (EGS). EGS reservoirs are typically at depths of 3 to 10 km, and the temperatures at these depths have become a limiting factor in the application of existing downhole technologies. These high temperatures are especially problematic for electronic systems such as downhole data-logging tools, which are used to map and characterize the fractures and high-permeability regions in underground formations. Information provided by these tools is assessed so that underground formations capable of providing geothermal energy can be identified, and the subsequent drilling operations can be accurately directed to those locations. The mapping of geothermal resources involves the design and fabrication of sensor packages, including the electronic control modules, to quantify downhole conditions (300°C temperature, high pressure, seismic activity, etc.). Because of the extreme depths at which these measurements are performed, it is most desirable to perform the sensor signal processing downhole and then transmit the information to the surface. This approach necessitates the use of high-temperature electronics that can operate in the downhole environment. Downhole signal processing in EGS wells will require the development and demonstration of circuit boards that can withstand the elevated temperatures found at these depths. At present, the highest-temperature commercially available circuit boards are based on polyimide materials, and those have maximum use temperatures of 200 to 250°C. In addition to thermal stability, downhole electronics must also be fabricated into high-aspect-ratio packages. For example, the multilayer assemblies produced at SNL were approximately 2.5 cm wide and 50 cm long. Because of this very high form factor, glass-fiber-reinforced polymers are much more desirable than multilayer ceramic modules (MCM). MCMs have many advantages for some applications, but are susceptible to damage induced by the mechanical and vibrational loads commonly experienced by data-logging tools. Thus, as EGS technology continues to advance, there is a strong need for multilayer electronics that can provide the necessary thermal performance while also being compatible with high-form-factor circuit designs. This project involved the design and development of high-temperature circuit materials, as well as the fabrication and testing of circuit components. The material development included the evaluation of various polymer/fiberglass composites, whereas the circuit components were tested using conventional microelectronic evaluation techniques. This effort targeted development of a new class of high-temperature multilayer circuit boards for use in downhole data-logging applications where temperatures are on the order of 300°C. This is consistent with DOE’s multiyear plan for advancing technologies for use in enhanced geothermal systems. Organic and inorganic polymer systems, both with glass reinforcements, were considered to provide the following performance at elevated temperatures: • Mechanical strength and durability • High dielectric strength and electrical resistivity • Thermal stability • Strong adhesion to copper to ensure the reliability of the multilayer assemblies • Processing characteristics that are consistent with state-of-the-art multilayer circuit board manufacturing practices

15 GEOTHERMAL ENERGY↗