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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Understanding rate-dependent textured growth in zinc electrodeposition via high-throughput in situ x-ray diffraction

Zn-ion batteries with aqueous electrolytes are promising for large-scale energy storage as they are low-cost, environment-friendly and safe. The commercialization of Zn-ion batteries is hindered by several challenges such as the formation of detrimental Zn dendrites. High current density is previously thought to stimulate the dendritic growth of metals such as Li in electrodeposition. However, our study finds that for metallic Zn negative electrode in Zn-ion batteries, high-current deposition results in a dense and flat Zn layer with a (002) texture, which extends the cycling life. Low-current deposition, on the other hand, leads to a porous and dendritic morphology and a short cycling life. Using a synchrotron-based high-throughput in situ X-ray diffraction method we recently developed, Zn deposition under different conditions is systematically investigated, and a texture formation mechanism is proposed. Based on these findings, we suggest guidelines for designing cycling protocols that enable long-lasting Zn-ion batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Polymer Inhibitors Enable >900 cm2 Dynamic Windows Based on Reversible Metal Electrodeposition with High Solar Modulation

Dynamic windows with adjustable tint give users control over the flow of light and heat to decrease the carbon footprint of buildings and improve the occupants’ comfort. Despite the benefits of dynamic windows, they are rarely deployed in buildings because the existing technology cannot achieve fast and colour-neutral tinting at an agreeable cost. Reversible metal electrodeposition is a promising approach to solve these problems. Here, we demonstrate the use of polymer inhibitors to reversibly deposit metal films with controlled morphology in dynamic windows. The windows that employ the polymer inhibitor can readily tint to below 0.001% visible transmittance in less than 3 min and exhibit high infrared reflectance (>70%), colour-neutral transmittance (C*<5) and an ultrawide range of optical and solar modulation (..delta..Tvis=0.76 and ..delta..SHGC=0.56). The polymer inhibitors also increase the efficiency and improve the durability of the windows and enable construction of >900 cm2 dynamic windows with fast response and excellent uniformity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Quantized electronic transitions in electrodeposited copper indium selenide nanocrystalline homojunctions

Pairing semiconductors with electrochemical processing offers an untapped opportunity to create novel nanostructures for practical devices. Here we report the results of one such pairing: the in-situ formation of highly-doped, interface-matched, sharp nanocrystalline homojunctions (NHJs) with single step electrodeposition of two copper-indium-selenide (CISe) compounds on flexible foil. It produces a homogenous film, comprising inherently ordered, 3-dimensional interconnected network of pn -CISe NHJs. These CISe NHJs exhibit surprising non-linear emissions, quantized transitions, large carrier mobility, low trap-state-density, long carrier lifetime and possible up-conversion. They facilitate efficient separation of minority carriers, reduce recombination and essentially function like quantum materials. This approach mitigates the material issues and complex fabrication of incumbent nanoscale heterojunctions; it also overcomes the flexibility and scale-up challenges of conventional planar pn junctions. The self-stabilized CISe NHJ film can be roll-to-roll processed in ambient atmosphere, thus providing a promising platform for a range of optoelectronic technologies. This concept exemplified by CISe compounds can be adapted to create nano-scale pn junctions with other inorganic semiconductors.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Mixed-anion electrolytes: from bulk speciation to interfacial dynamics in divalent metal electrodeposition

Mixing anions is emerging as a promising strategy for multivalent electrolyte design, allowing for adjustment of the solvation structure of bulk cations and enhancing the efficiency of electrochemical processes (e.g. metal deposition for batteries and catalysis). Further progress in electrolyte development requires a fundamental understanding of how tailored electrolyte speciation in mixed anion systems can modify the dynamic electrochemical interface during metal cycling. In this study, we present an anode-focused mechanistic study of exemplar Mg electrolytes containing three different secondary anions, correlating electrochemical behavior with bulk speciation and operando interfacial dynamics. Electrospray Ionization-Mass Spectrometry (ESI-MS) results reveal a general trend of forming mixed anion contact ion pairs (CIPs) across various anions, with the extent of ion pairing influenced by the association strength of the secondary anion. Operando multiharmonic electrochemical quartz crystal microbalance with dissipation (EQCM-D) reveals how these bulk species influence interfacial mass uptake, viscoelasticity, and solvent-coupled hydrodynamic behavior during deposition and stripping. The results indicate that Mg-containing ion pairs and solvated complexes shape adsorption, nucleation, and deposit growth, leading to distinct anion-dependent interphases ranging from more permeable, solvent-coupled layers to relatively compact and rigid deposits. This work establishes a quantitative link between bulk speciation and interfacial dynamics in divalent metal electrodeposition and provides mechanistic guidance for electrolyte design.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Void-free Copper Electrodeposition in High Aspect Ratio, Full Wafer Thickness Through-Silicon Vias with Endpoint Detection

High density interconnects are required for increased input/output for microelectronics applications, incentivizing the development of Cu electrochemical deposition (ECD) processes for high aspect ratio through-silicon vias (TSVs). This work outlines Cu ECD processes for 62.5 μ m diameter TSVs, etched into a 625 μ m thick silicon substrate, a 10:1 aspect ratio. Cu ECD in high aspect ratio features relies on a delicate balance of electrolyte composition, solution replenishment, and applied voltage. Implementing a CuSO 4 -H 2 SO 4 electrolyte, which contains suppressor and a low chloride concentration, allows for a tunable relationship between applied voltage and localized deposition in the vias. A stepped potential waveform was applied to move the Cu growth front from the bottom of the via to the top. Sample characterization was performed through mechanical cross-sections and X-ray computed tomography (CT) scans. The CT scans revealed small seam voids in the Cu electrodeposit, and process parameters were tuned accordingly to produce void-free Cu features. During the voltage-controlled experiments, measured current data showed a characteristic current minimum, which was identified as an endpoint detection method for Cu deposition in these vias. We believe this is the first report of this novel endpoint detection method for TSV filling.

42 ENGINEERING↗
DOE OSTI2020

Novel Membrane and Electrodeposition-Based Separation and Recovery of Rare Earth Elements from Coal Combustion Residues (Final Report)

This project developed a hydrometallurgical-based technology to extract and concentrate rare earth elements (REEs) from a representative group of coal combustion residuals (CCRs) from major coal sources in the United States. The approach for REE recovery comprises two general components: (1) Leaching of REEs from CCRs and (2) Separation of REEs from other major ions in the CCR leachate. The leaching step entails acid leaching with nitric or hydrochloric acid, and in some cases, pretreatment of CCRs with alkaline roasting prior to acid leaching. The follow-up REE recovery steps involve a series of membrane-based methods to separate and concentrate rare earth ions from other major ions in acid leachates of CCRs. These methods include liquid emulsion membranes, supported liquid membranes and electrodeposition with carbon nanotube electrochemical filters. The advantage of these separation approaches (relative to conventional approaches such as solvent extraction) is a reduction in the usage of solvents and other costly chemicals and a reduction of hazardous waste products that are challenges in conventional REE separation methods. In the testing of our process, we selected a representative set of CCR samples from our collection and performed a suite of characterization measurements (total REE content and major mineralogy). The major results of this work demonstrated that heated acid leaching could efficiently extract REEs from PRB-based coal fly ashes while the Appalachian and Illinois Basin CCRs required alkaline roasting with NaOH prior to acid leaching at room temperature. The supported liquid membrane (SLM) configuration and electrochemical deposition (ED) system yielded the most promising methods of REE recovery from the acid leachates of fly ash. Our most concentrated product to date comprised 1 wt.% (dry basis) REEs produced from an Appalachian-based fly ash leached and purified by SLM. The SLM separation process was more selective for heavy REEs over the light REEs. When SLM was combined with ED, preliminary results demonstrated that a final product of >2 wt.% REEs was possible.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Electrodeposition for Low-Cost, Water-Based Electrode Manufacturing. Research Performance Progress Report, Jan. 1, 2016 - Dec. 31, 2019

The viability of electrocoat to fabricate battery electrodes at commercially relevant formulations has been demonstrated using both bench-scale equipment and a small pilot-scale roll-to-roll system (mini-coater). Through this, we show that an electrodeposited lithium-ion battery electrode coating system and manufacturing process is capable of reducing cell costs. Specifically, >60% decrease in capital costs is expected when transitioning from slot-die to electrocoat-based coating systems due to the removal of a solvent recovery system. In addition, a 50% reduction in operating costs in also expected as we enable 2-coat/2-cure processing of cathode electrodes.

25 ENERGY STORAGE↗
DOE OSTI2022

Electrodeposition method development for Californium Rare Isotope Breeder Upgrade (CARIBU) Source

Electrodeposition is one of the most widely utilized techniques for thin-film production with high yields. Although it is used extensively, this technique still presents several issues limiting its usefulness, including excess thickness and frequent cracking of deposited films. Efforts to improve thin-film production recently undertaken at Oak Ridge Laboratory by the authors have included studying operating conditions and applied electrolytes. Samarium was used as a surrogate material for californium, and yield was compared with different deposition condition. The final procedure from the optimized condition will be applied during production of the californium-252 source for the Californium Rare Isotope Breeder Upgrade (CARIBU) project, and the fission fragment will be analyzed.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2025

Elucidating the Morphological Instability Mechanisms During Electrodeposition of Active Metals

The primary aim of this investigation is to elucidate the mechanisms by which a group of metals pertinent to battery technology exhibit unstable growth morphology during electrodeposition, which are crucial for the operational efficacy of batteries. The metals under consideration include alkali metals alongside zinc, all of which are characterized by high atomic mobility and reactivity with the electrolytes employed in battery systems. These materials represent promising electrode candidates for next-generation rechargeable batteries that are anticipated to deliver significantly enhanced energy density at a reduced cost. Nevertheless, the widespread occurrence of distinctly non-uniform morphologies, exemplified by the emergence of filamentous and moss-like structures, constitutes a significant impediment to their effective utilization, as it leads to accelerated capacity degradation and potential internal short circuits. This study addresses a critical question that has thus far garnered limited attention: Does the residual stress induced by the plating process play an instrumental role in inducing the morphological instability? Utilizing zinc as the primary model system, this project will be executed through three interconnected tasks: (1) the quantification of the relationship between plating stress and electroplating morphologies, (2) the three-dimensional imaging of the microstructure of the mossy structure at the nanoscale, and (3) the development of a mesoscale electroplating model to interpret empirical findings and generate additional predictive insights.

25 ENERGY STORAGE↗
DOE OSTI2026

Low Temperature Tantalum Electrodeposition: Enabling Next Generation Coatings

This project aimed to identify the ligand and solvation conditions necessary for the electrodeposition of refractory metals from low-temperature organic electrolytes. Tantalum (Ta) was chosen as a specific exemplar for programmatic purposes. It was hoped that a deeper understanding of these relationships could facilitate the innovative application of refractory metal coatings on thermally sensitive and geometrically intricate components used in extreme environments related to energy generation and storage, nuclear deterrence, aerospace, defense, and beyond.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Electrodeposition of Aluminum in the 1-Ethyl-3-Methylimidazolium Tetrachloroaluminate Ionic Liquid

The electrodeposition of Al was investigated in an ionic liquid (IL), with 1-ethyl-3-methylimidazolium tetrachloroaluminate ([EMIm]AlCl4) as the electrolyte with AlCl3 precursor. The [EMIm]AlCl4 electrolyte exhibited a wide and stable electrochemical window from 3.2 to 2.3 V on a glassy carbon electrode when temperature was increased from 30 °C to 110 °C. The addition of AlCl3 into [EMIm]AlCl4 generated significant well-developed nucleation growth loops, and new coupled reduction and oxidation peaks in cyclic voltammograms corresponding to the Al deposition and dissolution, respectively. A calculation model was proposed predicting compositions of anions in AlCl3/[EMIm]AlCl4 system, and [Al2Cl7]− was found to be the active species for Al deposition. In AlCl3/[EMIm]AlCl4 (1:5), the reduction rate constants were 1.18 × 10−5 cm s−1 and 3.37 × 10−4 cm s−1 at 30 °C and 110 °C, respectively. Scanning electron microscope (SEM), energy dispersive spectroscope (EDS), and X-ray diffraction (XRD) microscope results showed that the metallic Al film had been successfully deposited on glassy carbon electrodes through constant-potential cathodic reductions. The [EMIm]AlCl4 was a promising electrolyte directly used for Al deposition.

Shi, Meng↗
NASA NTRS1970

Electrodeposited inorganic separators for alkaline batteries

Coating electrodes of silver-cadmium cells with thermostable electrodeposits of calcium hydroxide or magnesium hydroxide reduces silver migration and increases cell life. Absence of organic matter enables assembled cells to be sterilized without oxidation of the material of the separators.

Carson, W. N., Jr.↗
NASA NTRS1977

Relation of morphology of electrodeposited zinc to ion concentration profile

The morphology of electrodeposited zinc was studied with special attention to the ion concentration profile. The initial concentrations were 9M hydroxide ion and 1.21M zincate. Current densities were 6.4 to 64 mA/sq cm. Experiments were run with a horizontal cathode which was observed in situ using a microscope. The morphology of the zinc deposit was found to be a function of time as well as current density; roughly, the log of the transition time from mossy to large crystalline type deposit is inversely proportional to current density. Probe electrodes indicated that the electrolyte in the cathode chamber was mixed by self inducted convection. However, relatively large concentration gradients of the involved species existed across the boundary layer of the cathode. Analysis of the data suggests that the morphology converts from mossy to large crystalline when the hydroxide activity on the cathode surface exceeds about 12 M. Other experiments show that the pulse discharge technique had no effect on the morphology in the system where the bulk concentration of the electrolyte was kept homogeneous via self induced convection.

May, C. E.↗