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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

Engineering↗
DOE OSTI2024

The Prompt Fission Uranium Neutron Spectrum (PFUNS) Experiment: Critical Configurations and Irradiations

The objective of the Prompt Fission Uranium Neutron Spectrum (PFUNS) experiment is to reduce the uncertainty of the Prompt Fission Neutron Spectrum (PFNS) of 235 U above 8 MeV. The experiment was performed at the DOE National Criticality Experiments Research Center (NCERC) at the Nevada National Security Site. To meet the experiment objective, activation foils were placed in a central void region of a critical configuration consisting of concentric highly enriched uranium (HEU) metal hemishells. The set of activation foils were chosen based on threshold reactions to neutron energies across the fission spectrum, but especially those in the high energy tail of the fission spectrum. PFUNS was performed on the Planet critical assembly machine at NCERC and uses the Rocky Flats (RF) HEU hemishells. PFUNS has similarities to the Measurement of Uranium Subcritical and Critical (MUSiC) experiment conducted at NCERC in 2021, which also used RF hemishells, but contains a large central cavity to allow for a sample plate to be inserted. This large void means that much more HEU is needed to achieve a critical configuration (108 kg for PFUNS versus 59 kg for MUSiC). This work describes the 2024 experiment execution of four critical configurations and two irradiations for the PFUNS project.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Processing iridium foil targets for the production of radioplatinum isotopes

Dissolving noble metals remains challenging because of their high reduction potentials and tendency to passivate as oxides. This barrier is acute for iridium metal targets used to produce platinum radioisotopes, where post-irradiation processing is costly and hazardous with conventional routes. Here, we report a rapid alkali-fusion method that converts Ir metal directly into chloride media compatible with downstream separations. In the process, an Ir foil is fused with Na 2 O 2 and KCl at temperatures above the KCl melting point; the molten salt enhances heat transfer and facilitates O 2− /Na + transport to the Ir surface, overcoming Ir's oxidation resistance. The fused cake is then cooled and leached in 10 M HCl, yielding Ir in solution without specialized microwave digestion or HF. Pt separation from bulk Ir was evaluated using extraction-chromatography resins. A newly formulated ionic-liquid resin containing Cyphos IL 104 (E104) was compared with two commercial resins (TrisKem TK200 and TK201). All resins achieved >90 % Ir recovery. Pt co-recovery depended on resin chemistry: TK200 recovered 85.9 % Pt, TK201 recovered 54.1 % Pt, and E104 recovered 72.9 % Pt. This study introduces a fast, scalable dissolution route for solid Ir targets and demonstrates resin choices that tune Ir/Pt separation, lowering the barrier to routine production and purification of Pt radioisotopes.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2023

Single‐Step Deformation Processing of Ultrathin Lithium Foil and Strip

Abstract Next‐generation, high‐efficiency energy storage and conversion systems require development of lithium metal batteries. But the high cost of production and constraints on thickness of lithium (anode) foils continue to limit adoption for integration into battery cell architectures. Here, a novel lithium anode manufacturing solution is demonstrated – single‐step production of ultrathin gauge foil formats directly from solid ingot. Hybrid cutting‐based deformation processes, involving large plastic strains and strain rates, produce foil to sub‐10 µm thickness, with surface quality even superior to present Li anode processing routes. Energy analysis shows the single‐stage processing is ≈50% more efficient than conventional processing by extrusion‐rolling. Through in situ force measurements and high‐speed imaging of the cutting it also characterize – for the first time – the flow stress of Li to strain rates of 800 sec −1 , revealing a power‐law relationship. The results present a paradigm shift in manufacturing and integration of solid lithium anodes for energy applications.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

A low-cost, fluorine-free electrolyte for improved sodium batteries

Sodium batteries are an attractive alternative to lithium-ion technologies due to sodium’s lower cost and natural abundance—over 1,000 times greater than lithium, comprising approximately 2.4% of the Earth’s crust. However, most current electrolytes rely on fluorine-containing components, which raise economic and environmental concerns. This study explores fluorine-free, borate-based electrolytes that offer improved cycling stability and significant cost and sustainability benefits. We demonstrate stable sodium metal stripping and plating on aluminum foil, enabling anode-free cell configurations with over 50% capacity retention after 700 cycles. Spectroscopic and electrochemical analyses reveal the effects of solvents and salt composition on solvation, ionic conductivity, and oxidative stability. In full-cell configurations, the fluorine-free electrolyte maintains more than 98% capacity retention after 400 cycles. Furthermore, these findings represent a critical step toward the development of cost-effective, environmentally friendly, and high-performance sodium battery systems suitable for future electrification.

anode-free sodium batteries↗
DOE OSTI2020

Mechanical rolling formation of interpenetrated lithium metal/lithium tin alloy foil for ultrahigh-rate battery anode

To achieve good rate capability of lithium metal anodes for high-energy-density batteries, one fundamental challenge is the slow lithium diffusion at the interface. Here we report an interpenetrated, three-dimensional lithium metal/lithium tin alloy nanocomposite foil realized by a simple calendering and folding process of lithium and tin foils, and spontaneous alloying reactions. The strong affinity between the metallic lithium and lithium tin alloy as mixed electronic and ionic conducting networks, and their abundant interfaces enable ultrafast charger diffusion across the entire electrode. Furthermore, we demonstrate that a lithium/lithium tin alloy foil electrode sustains stable lithium stripping/plating under 30 mA cm -2 and 5 mAh cm -2 with a very low overpotential of 20 mV for 200 cycles in a commercial carbonate electrolyte. Cycled under 6 C (6.6 mA cm -2 ), a 1.0 mAh cm -2 LiNi 0.6 Co 0.2 Mn 0.2 O 2 electrode maintains a substantial 74% of its capacity by pairing with such anode.

25 ENERGY STORAGE↗
DOE OSTI2020

Revealing and Elucidating ALD-Derived Control of Lithium Plating Microstructure

The practical implementation of Li metal batteries is hindered by difficulties in controlling the Li metal plating microstructure. While previous atomic layer deposition (ALD) studies have focused on directly coating Li metal with thin films for the passivation of the electrode–electrolyte interface, a different approach is adopted, situating the ALD film beneath Li metal and directly on the copper current collector. Here, a mechanistic explanation for this simple strategy of controlling the Li metal plating microstructure using TiO 2 grown on copper foil by ALD is presented. In contrast to previous studies where ALD-grown layers act as artificial interphases, this TiO 2 layer resides at the copper–Li metal interface, acting as a nucleation layer to improve the Li metal plating morphology. Upon lithiation of TiO 2 , a Li x TiO 2 complex forms; this alloy provides a lithiophilic surface layer that enables uniform and reversible Li plating. The reversibility of lithium deposition is evident from the champion cell (5 nm TiO 2 ), which displays an average Coulombic efficiency (CE) of 96% after 150 cycles at a moderate current density of 1 mA cm –2 . This simple approach provides the first account of the mechanism of ALD-derived Li nucleation control and suggests new possibilities for future ALD-synthesized nucleation layers.

25 ENERGY STORAGE↗
DOE OSTI2020

Design of Experiments Involving Molybdenum in SNL SPRF/CX Facility

This report is part of the collaboration with the Nuclear Criticality Safety Program and constitutes the “CED-2 report” of the experiments proposed in the SPRF/CX facility of SANDIA National Laboratories to contribute to the validation of Molybdenum in thermal energy spectrum. It supplements the study carried out in the CED-1 report by providing a more precise design of the proposed experiments and presents a complete evaluation of the experimental uncertainties. In the CED-1 report, corresponding to the preliminary design of the experiments, IRSN identified several promising configurations that could be implemented in the SPRF/CX facility of SNL. They use metallic molybdenum either in the form of foils between the UO 2 pellets inside BUCCX rods, or in the form of sleeves surrounding 7uPCX rods. In this CED-2 report, a new design using molybdenum sleeves surrounding BUCCX rods is also analyzed and the experimental uncertainties of all the proposed configurations are estimated. Given the constraints to carry out the experiments and the costs associated with the manufacturing of the foils, the experiments using molybdenum foils are discarded. Similarly, the design using molybdenum sleeves around BUCCX rods leads to significant manufacturing costs which could certainly be partially offset by use of existing grids but which would lead to slightly lower values of the integral sensitivities to the cross sections of molybdenum. Consequently, the design using molybdenum sleeves around 7uPCX rods is favored insofar as it presents higher $k_{eff}$ sensitivities to the molybdenum cross sections and that there is still possibility to reduce the number of sleeves to reduce the cost of experiments. Regarding feedback on nuclear data in support of criticality safety assessment, one of the advantages of the work described here is that the proposed experiments are not correlated with the MIRTE and FP experiments using molybdenum. In addition, they lead to higher sensitivity values in the thermal energy range than the existing experiments and partly “cover” the first resonance of the 95 Mo, which is a real advantage for improving knowledge on molybdenum cross sections.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Selective determination of grain size in the electrodeposition of nanocrystalline nickel foils

There are many synthesis methods through phase space to produce nanostructures in metals. Condensation methods with rapid solidification are extensively explored from the gas or liquid phase. In particular, electrodeposition using pulsed currents favors continuous nucleation in the processing of structures to produce free-standing sheets as well as protective coatings for surfaces. An analysis approach used to develop the method for refining the structure and surface finish for nanocrystalline gold-copper alloy coatings relates the energy in each deposition pulse to the constituent grain size that forms during growth. Application is now pursued to evaluate a select determination of the grain size for nanocrystalline nickel foils synthesized by pulsed electrodeposition. The mechanical behaviors of hardness and rate-sensitivity of strength are assessed as function of grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fast-Charging and Ultrahigh-Capacity Lithium Metal Anode Enabled by Surface Alloying

Li metal anodes are going through a great revival but they still encounter grand challenges. One often neglected issue is that most reported Li metal anodes are only cyclable under relatively low current density (<5 mA cm -2 ) and small areal capacity (<5 mAh cm -2 ), which essentially limits their high-power applications and results in ineffective Li utilization (<1%). Herein, it is reported that surface alloyed Li metal anodes can enable reversible cycling with ultrafast rate and ultralarge areal capacity. Low-cost Si wafers are used and are chemically etched down to 20-30 mu m membranes. Simply laminating a Si membrane onto Li foil results in the formation of LixSi alloy film fused onto Li metal with mechanical robustness and high Li-ion conductivity. Symmetric cell measurements show that the surface alloyed Li anode has excellent cycling stability, even under high current density up to 25 mA cm -2 and unprecedented areal capacity up to 100 mAh cm -2 . Furthermore, the surface alloyed Li anode is paired with amorphous MoS 3 cathode and achieves remarkable full-cell performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Sweeping potential regulated structural and chemical evolution of solid-electrolyte interphase on Cu and Li as revealed by cryo-TEM

A fundamental understanding of solid-electrolyte interphase (SEI) is paramount importance for controlling the cycling performance of rechargeable lithium metal batteries. The structural and chemical evolution of SEI with respect to electrochemical operating condition remains barely established. Here we develop a unique method for imaging the evolution of SEI formed on the Cu foil under sweeping electrochemical potential. By using cryogenic TEM imaging combined with energy dispersive X-ray spectroscopy and X-ray photoelectron spectroscopy electronic structure analyses, we reveal that, for the vinylene carbonate (VC)-free electrolyte, the SEI formed at 1.0 V is a monolithic amorphous structure, which evolves to amorphous matrix embedded with Li 2 O particles as the voltage decreases to 0 V. In the case of VC-containing electrolyte, the SEI is featured by an amorphous matrix with Li 2 O particles from 1.0 V to 0 V. The thickness of SEI formed on Cu foil increases with decreasing voltage. Associated with the localized charge modulation by the surface topographic feature and defects in the Cu foil, the SEI layer shows direct spatial correlation with these structural defects in the Cu. In addition, upon Li deposition, the SEI formed on the Li metal has similar thickness with, but different composition from the SEI formed on the Cu foil at 0 V. Furthermore, those results provide insight toward SEI engineering for enhanced cycling stability of Li metal.

25 ENERGY STORAGE↗
DOE OSTI2024

Li Stripping Behavior of Anode‐Free Solid‐State Batteries Under Intermittent‐Current Discharge Conditions

Anode‐free manufacturing holds promise to enable high energy densities and lower Lithium (Li)‐metal solid‐state batteries (LMSSBs). Nevertheless, in contrast to thick Li foil (>50 µm), the stripping capacity of in situ‐formed Li (10–30 µm) is limited due to diminished creep flow, resulting in reduced accessible capacity. This study explores the correlation between stripping capacity and surface roughness of garnet Li 7 La 3 Zr 2 O 12 (LLZO) solid electrolyte. The results reveal that stripping capacity can be enhanced through the surface modification of solid electrolytes. Additionally, this study scrutinizes the stripping behavior of in situ Li under intermittent‐current discharge conditions, which are more relevant to the operational conditions of electric vehicles (EVs). It is demonstrated that, when compared to constant‐current stripping, intermittent‐current stripping effectively suppresses void formation and enhances the stripping capacity of in situ Li by 40%. It is considered that the intermittent current inhibits the accumulation of Li vacancies, thereby delaying the void formation. These findings provide valuable insights into the development of high‐performance anode‐free LMSSBs for EVs.

25 ENERGY STORAGE↗
DOE OSTI2025

Ex-situ Heat Treatment of TEM Foils in a Custom Titanium Fixture: A Case Study on Ni-based Superalloy

The advancement of microstructural characterization at the nanoscale is critical to understanding the microstructural evolution and performance of engineering materials. Transmission electron microscopy (TEM) plays a vital role in such investigations, particularly when coupled with controlled ex- and in-situ experiments. In this study, we introduce a novel method for ex-situ heat treatment (HT) of TEM foils using a custom-designed fixture, made from pure titanium, and vacuum furnace to inhibit oxidation. This approach ensures precise temperature control and minimal sample contamination during HT, critical for substructural characterization and analysis of metallic materials. The fixture consists of a titanium base with three slits, for three sample foils, and a titanium cap for closure. The entire assembly is placed in a vacuum heat treatment furnace with high vacuum capability to prevent oxidation. To validate the effectiveness of the setup, precipitation behavior and microstructural changes were studied in an IN725 variant heat-treated at 500°C for 1 hour and 282 variant heat-treated at 700°C for 1 hour, as case studies.

electron microscopy↗
DOE OSTI2020

Aluminum Metal–Organic Framework Triggers Carbon Dioxide Reduction Activity

Confinement of metal centers is a powerful tool to manipulate reactivity and tune selectivity in chemical transformations. While aluminum as a foil is inactive for carbon dioxide reduction and shows high selectivity for the hydrogen evolution reaction, here we show that aluminum confined in a metal-organic framework (MOF), MIL-53(Al), suppresses hydrogen evolution reaction activity and enhances carbon dioxide reduction. This aluminum MOF can produce up to 40% faradaic efficiency for carbon monoxide and formic acid. Here, this study demonstrates that the unique reaction environment created by the MOF enables changes in reaction selectivity and can impart atypical catalytic capabilities to metals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Production of C 2 /C 3 Oxygenates from Planar Copper Nitride-Derived Mesoporous Copper via Electrochemical Reduction of CO 2

Electrochemical reduction of CO 2 provides an opportunity to produce fuels and chemicals in a carbon-neutral manner, assuming that CO 2 can be captured from the atmosphere. To do so requires efficient, selective, and stable catalysts. In this study, we report a highly mesoporous metallic Cu catalyst prepared by electrochemical reduction of thermally nitrided Cu foil. Under aqueous saturated CO 2 reduction conditions, the Cu 3 N-derived Cu electrocatalyst produces virtually no CH 4 , very little CO, and exhibits a faradaic efficiency of 68% in C 2+ products (C 2 H 4 , C 2 H 5 OH, and C 3 H 7 OH) at a current density of ~18.5 mA cm –2 and a cathode potential of -1.0 V versus the reversible hydrogen electrode. Under these conditions, the catalyst produces more oxygenated products than hydrocarbons. We show that surface roughness is a good descriptor of catalytic performance. The roughest surface reached 98% CO utilization efficiency for C 2+ product formation from CO 2 reduction and the ratio of oxygenated to hydrocarbon products correlates with the degree of surface roughness. These effects of surface roughness are attributed to the high population of undercoordinated sites as well as a high pH environment within the mesopores and adjacent to the surface of the catalyst.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Three-Dimensional Polymeric-Scaffold-Based Current Collector for a Lithium Metal Anode toward High-Energy-Density Batteries

Here, the practical applications of high-energy-density rechargeable lithium (Li) metal batteries (LMBs) have been impeded by the intrinsic issues of the Li metal anode (LMA) including high reactivity with electrolyte and dendritic formation. Conventional LMAs, which have the "hostless" feature consisting of a Li layer on a two-dimensional copper (Cu) foil as a current collector, led to additional loss in specific energy density, since Cu is a nonfaradaic heavy metal, bringing formidable areal capacity loss. To address these problems, a heat-treated three-dimensional-structured Cu-coated polyimide (HT-Cu@PI) membrane is designed and fabricated as a current collector. Benefiting from this unique material/structure, it enables not only better electrochemically deposited Li by a uniform/continuous Li-ion transport pathway but also a significant increase in the gravimetric/volumetric energy densities of LMBs by allowing more Li deposition in a fixed weight/volume. Therefore, this new LMA structure will accelerate the practical application of high-energy-density LMBs.

25 ENERGY STORAGE↗