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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 OSTI2023

Computational design of isotropic and anisotropic ultralow thermal conductivity polymer foams

Current state-of-the-art commercial polymer thermal insulation foam exhibits a thermal conductivity of 24 mW·m -1 ·K -1 (equivalently thermal resistivity of R-6/in.), similar to that of static air. To further optimize building energy efficiency, achieving even lower thermal conductivity is needed, which is, however, highly challenging. This paper presents computational evidence that demonstrates the feasibility of achieving an ultra-low thermal conductivity of less than 14.4 mW·m -1 ·K -1 (equivalently R-10/in.) using isotropic and anisotropic foam cell designs. For the isotropic design, we have identified analytical effective medium approximation (EMA) models within the accuracy of ±5% as finite element analysis (FEA) in predicting the effective thermal conductivity of foams with various porosities and filler gases. For the anisotropic design, we have developed and validated new EMA models against FEA in predicting the effective thermal conductivity of general anisotropic cuboids and Voronoi foams. For both isotropic and anisotropic designs, the design spaces for 18, 16, and 14.4 mW·m -1 ·K -1 (equivalently R-8, R-9 and R-10/in.) using various filler gases are obtained. It is found that polymer foams can be improved to achieve ultralow thermal conductivity by reducing CO 2 concentration, reducing radiation, increasing porosity, and using anisotropic pore geometry. In conclusion, these findings contribute to the development of highly efficient thermal insulation materials, enhancing building energy efficiency and promoting sustainable construction practices.

42 ENGINEERING↗
DOE OSTI2021

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Progress on the evolution of the pilot scale manufacturing plant and initial results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Synergistic enhancement of nanocellulose foam with dual in situ mineralization and crosslinking reaction

Cellulose nanocrystals (CNCs) foams have recently gained research interests because they are renewable, abundant, biodegradable and exhibit high surface area. However, the application of CNCs-based foams is still challenging, which is attributed to its lack of effective entanglements between the CNCs particles, thus lowering foam properties. In this study, a synergistic enhancement strategy was proposed, based on the in situ mineralization with hydroxyapatite (HAP) layer onto the CNCs surface, followed by a chemical crosslinking reaction. The physical and chemical structures of the composites were analyzed with SEM, STEM, XRD, FTIR, and TGA. By controlling the amount of coated HAP and the crosslinker, it is possible to manufacture a series of CNCs-based foams that are lightweight (50–75 mg/cm 3 ), highly porous (~90%) with high water absorption (>1300%) and outstanding mechanical strength properties (as high as 1.37 MPa). Moreover, our study further indicated that these CNCs/HAP materials could increase the proliferation of rat osteoblast cells. The method developed in this study presents a novel approach to design improved networked CNCs foam, which has the potential to be used in thermal-retardant material, wastewater treatment, tissue engineering, and personal care applications.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Investigation of oxygen evolution reaction with Ni foam and stainless-steel mesh electrodes in alkaline seawater electrolysis

We report alkaline seawater electrolysis is a promising method for hydrogen production; however, little progress has been made in investigating the substrates for oxygen evolution reaction (OER) electrocatalysts. Ni foam and stainless-steel mesh (SS mesh) were investigated systematically for OER in alkaline seawater electrolysis in this work. The overpotentials and Tafel slopes with SS meshes are smaller than Ni foams, and it also exhibits excellent stability. Interestingly, the performance of the SS mesh even outperforms various non-noble metal electrocatalysts and is comparable to commercial RuO2 and IrO2. The corrosion conditions of Ni foam and SS mesh electrodes were studied and revealed. Furthermore, the electrochemically active surface area (ECSA) of Ni foam is 12 times higher than SS mesh in the same geometric area, indicating the electrochemical activity of SS mesh is much superior to Ni foam. This work expands on promising substrates for alkaline seawater electrolysis, with cost and performance advantages.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Viscosity of transient glass-forming melt and its relation to foaming during batch-to-glass conversion

Primary foam, which affects the heat transfer into the glass batch and the final glass quality, occurs when a sufficient quantity of transient glass-forming melt evolves with viscosity low enough to close the open porosity of the reacting glass batch. To better understand how the fraction of transient melt and its viscosity affect the primary foam temperature range, we determined, with x-ray diffraction, the fraction and composition of the transient glass-forming melt in a heated waste glass melter feed as a function of temperature. Then we prepared a set of transient melts that occurred within the foaming temperature interval and measured their viscosities with spindle and falling sphere viscometers. Further, the results agree with the Adam-Gibbs and VFT viscosity-composition models, even for transient melt compositions outside of the models compositional validity range. As silica and other refractory particles dissolved in the predominantly borate transient melt while temperature increased, viscosity increased from the initial value of ~500 Pa s at the onset of foaming (~650°C) to a maximum of ~770 Pa s when silica dissolution was almost complete (~700°C). As temperature increased further, transient melt viscosity decreased to ~220 Pa s (~850°C) when the primary foam collapsed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Fully Additively Manufactured Wetted Foam Capsules for Inertial Confinement Fusion

In the pursuit of realizing reliable clean energy generation via inertial confinement fusion (ICF), wetted foam (WF) capsule targets have long been coveted due to their potential to simplify the target fielding process and suppress hydrodynamic instabilities and material mixing that limit achievable energy output, yet producing and deploying a WF target has proven challenging. Here, in this work, we demonstrate the design, fabrication, metrology, and testing of fully additively manufactured (AM) foam-lined capsules using two-photon polymerization (2PP) for ICF. We successfully fielded an AM polymeric foam capsule with a 3-mm outer diameter, a nominally 15-µm-thick solid outer layer, a 120-µm-thick inner foam layer, and a 250-µm outer diameter copper fill tube on the National Ignition Facility for a polar direct-drive shot, and we showcase deuterium wetting of the capsule foam layer inside an ignition target proofing station. Our exploration showed that 2PP can produce fieldable targets with complex geometries and potentially shorten the design iteration turnaround time and the overall target fabrication time.

Target↗
DOE OSTI2025

Secondary electron emission for reticulated carbon foam surfaces using direct measurements and spectroscopic analysis

This study investigates secondary electron emission (SEE) characteristics of reticulated foams using direct measurements and analytical modeling. Total SEE was quantified, revealing suppression of up to 44% in carbon foam structures compared to planar graphite surfaces. An optimal geometric configuration was identified and supported by analytical models. SEE angular dependence experiments showed diverse behaviors: fiber-like behavior and directional dependence for pore and ligaments on the mm scale, with fuzz-like characteristics when the foam features are between 10–100 µm. Electron energy analyzer measurements showed that carbon foams preferentially suppress inelastic backscattered electrons (BSEs) more so than true secondary electrons (SEs). The analysis indicated a larger fraction of low-energy SE generation in foams compared to flat surfaces due to increased emission from curved fiber ligaments and tertiary SEs from high-energy BSEs. These findings have implications for design and optimization of materials with tailored electron emission properties for applications like plasma-facing components, spacecraft materials, and accelerator surfaces.

Auger↗
DOE OSTI2022

Manufacture of Carbon Foam in Continuous Process at Atmospheric Pressure

CFOAM LLC has been manufacturing vitreous carbon foam from coal in panel form for several years. The process is currently set up in batch mode as two steps, where the first step is conducted at very high pressure. In order to reduce cost and increase capacity, a new process for making carbon foam is being developed that can be performed at atmospheric pressure. This advance in turn would enable the development of a continuous manufacturing process, which is also being pursued. Both carbon foam panels and light weight aggregates are being investigate. Construction of the pilot scale manufacturing plant has been completed and results of processing, microstructure, properties and performance of carbon foam products made using this new process will be discussed. This project is being supported by a cooperative agreement with the Department of Energy – National Energy Technology Laboratory (DE-FOA-0002185, Area of Interest 4: Coal-Derived Carbon Foam Produced via a Continuous Process, award number DE-FE-0031992).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Preparation of Mechanically Robust, Macroscopic Low-Density Gold Foams by Highly Efficient Electroless Gold Plating

Mechanically robust, macroscopic-sized low-density gold foams with unique morphology of hollow gold shells were prepared by the synthesis of gold-coated polystyrene coreshell particles followed by thermal removal of the polymer core. Here, we reported a simple, highly efficient electroless gold plating procedure to form ultrathin, conformal gold coatings on the surface of polystyrene particles. A modified, scalable casting approach to form uniform, large monoliths (up to 1 cm diameter) and a baking condition to minimize undesirable densification of final foams were also developed. To demonstrate the mechanical stability and integrity of the Au foams, a representative monolithic sample (~0.9 g/ cm3 ) was successfully cut and shaped into a gold foam “washer” by a series of precision machining and processing. A depth-sensing indentation test (nanoindentation) as well as characterizations on other useful properties such as surface areas and electrical conductivity of the Au foams were carried out to understand the mechanical behavior and potential applicability.

Electroless Gold Plating↗
DOE OSTI2020

Advancement of Commercial Intumescent Expanding Foams for Deactivation and Decommissioning in the Nuclear Sector - 20198

Florida International University (FIU), in collaboration with The Department of Energy's Office of Environmental Management (DOE-EM), Savannah River National Laboratory (SRNL), and sites across the Savannah River complex, have identified an operational requirement for a fixative technology that is intended to immobilize and/or isolate residual contamination within a 3-dimensional space. Fixation of radiological contamination can reduce worker risk and mitigate potentially hazardous conditions, however nearly every marketed contamination fixative has been found to be flammable; a significant concern in radiological facilities. Coupled with this, industry fixatives are normally used as a thin coating which can present problems when attempting to stabilize irregular geometry or areas that are difficult to access whilst ensuring full coverage. The technical evaluation and advancement of commercial-off-the-shelf (COTS) polyurethane foams has yielded a down-selected candidate that shows potential in meeting the requirements to support deactivation and decommissioning activities. Several performance criteria have been established and tested to progress the technology readiness level towards an active field demonstration (TRL-7). Such criteria include: mechanical failure limits, adhesive and cohesive properties, thermal/fire resilience, determining thermal behavior, ability to immobilize contamination, and a means of non-destructive evaluation of applications. The test scenario examined was targeted towards an application for decommissioning nuclear pipework, in which the down-selected polyurethane foam would act as a barrier to segregate pipework and mitigate the potential for release during cutting, packaging, and storage operations. Testing carried out at SRNL included: mechanical evaluation of tensile, compressive, and adhesion strength by dynamic mechanical analysis (DMA), as well as thermogravimetric analysis (TGA). FIU examined the foam's fixative properties by utilizing phosphorescent europium-dysprosium doped strontium aluminate powder to investigating the extent to which contamination can be immobilized. FIU has also exploited previous successes in the field of intumescent technologies to assess the down-selected foam's tolerance to an extreme fire scenario, while maintaining the ability to effectively mitigate a contamination release. Parallel to this, extensive thermal investigations were carried out to determine the upper boundary of anticipated heat generation during the curing process as heat generation has the potential to compromise rubber parts of contaminated enclosures. These investigations subsequently yielded a promising method for a non-destructive application evaluation by means of infrared thermography. Utilizing the high sensitivity of modern IR cameras, coupled with the heat generated during the curing process of the polyurethane foam, FIU has been exploring the concept of monitoring the external pipe surface for indications of an irregular or abnormal application, thus informing operational decision making. The testing carried out utilized several current 'best fit' ASTM standards, which serve as helpful guidelines for testing, however, a precise definition of the operational parameters and requirements is still necessary. With continued collaboration with SRNL, FIU aims refine said definitions and develop new standards by which this, and other decommissioning technologies, can be accredited by relevant standards based testing. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Numerical Evaluation of Effective Thermal Conductivity of PCM with Metal Foam Incorporating Buoyancy Effects for Thermal Energy Storage

The thermal energy storage (TES) system has the capability to efficiently preserve thermal energy directly derived from the energy source, minimizing any conversion losses. Especially latent heat storage offers distinct advantages, including a substantial increase in energy storage density and minimization of temperature fluctuations within the plants. However, the phase change material (PCM) employed in latent heat storage has low thermal conductivity. Consequently, various studies are being conducted to enhance heat transfer. One approach to enhance heat transfer involves utilizing metal foam to maximize the heat transfer area. However, modeling metal foam with its intricate structure is a challenging task in numerical analysis. For this reason, ongoing research focuses on simplifying the modeling of metal foam. Nevertheless, fully encompassing all the characteristics of actual metal foam proves to be a challenging task for the simplified analytical model. The objective of this paper is to interpret the simple lattice metal foam analysis model from the perspective of behavior induced by buoyancy. When comparing the analysis results of solid PCM and liquid PCM with the same thermal conductivity under changes in porosity and gravity direction, we conducted an analysis to discern the trends in effective thermal conductivity that are overestimated due to convection. In the analysis, a constant heat flux of 10 kW and a constant surface boundary condition of 350 K were applied, and a sensitivity study regarding the mesh was conducted. The results indicate that, from the perspective of gravity in the simple lattice model, the solid analysis yields an effective thermal conductivity 29-47% higher compared to the liquid analysis. Additionally, as porosity increases, there is an observed increase of 24-33% in effective thermal conductivity.

25 ENERGY STORAGE↗
DOE OSTI2025

Bioinspired Dry‐Steam Superinsulation Straw Foam

Abstract Cellulosic materials offer sustainable advantages for building energy conservation. However, their development has been hindered by reduced thermal performance, often caused by structural collapse during the transition from solution to solid. Inspired by natural goose down, a bio‐based, lightweight insulation foam derived from agricultural waste straw is presented. Through in situ synthesis, bio‐silica fibers with branched structures capable of supporting hollow silica microspheres are fabricated. After steam‐mediated processing, the resulting foam exhibit low density (95 mg cm − 3 ), high porosity (95.5%), low thermal conductivity (0.03 ± 0.003 W mK −1 ), and a cyclic compressive strength of 90 kPa at 50% strain. Owing to the synergistic microstructure formed by branched bio‐fibers and hollow silica spheres, the bio‐silica foam exhibit outstanding thermal insulation performance relative to other bio‐based foams prepared by ambient drying. A passivated insulation panel is further developed by incorporating this material as the core component, achieving a thermal conductivity of 0.0275 W mk −1 and flexural strength of 6.85 MPa. The panel demonstrated durability with stable thermal performance throughout a 60‐day outdoor test. Moreover, the bio‐silica foam shows a carbon footprint of 7.50 kgCO₂ kg −1 at 70.2 wt.% silica, highlighting its promise as a sustainable insulation solution for green buildings.

Chemistry↗
DOE OSTI2025

Properties and performance of lignin-based polyurethane foams from lignin and castor oil as synergistic bio-polyols

Lignin and castor oil with intrinsic hydroxyl groups are attractive green resources for polyurethane (PU) applications. However, lignin's heterogeneous and highly crosslinked structure, poor processability, as well as the feedstock variability, lead to inconsistent and poor performance of the final foam products. Castor oil-based polyurethane foam (PUF) has a relatively high price and density, which are big hurdles to its practical applications. Here, in this study, we hypothesized that synergistic bio-polyol mixtures composed of lignin and castor oil could balance the drawbacks from individual component. Castor oil could improve the dispersity of lignin, while lignin simultaneously addressed the issues caused by PUF prepared with castor oil, such as its high density and low thermal stability. For a comprehensive understanding of the effects of structural properties of lignin on its PUF processing and applications, various lignin fractions were isolated by co-solvent enhanced lignocellulosic fractionation (CELF) from different species, including hardwood, softwood, and herbaceous plants, and the processed lignins with different molecular weights were applied with castor oil. The lignin fractions with lower molecular weight showed good dispersity in castor oil with a high lignin content (up to 50 wt%) and completely replaced petroleum-based polyols. The produced foam with 50 wt% low-molecular-weight lignin fractions from woody biomass showed comparable/higher compressive strength (up to 20 psi) and thermal insulation performance (up to 5.69 R-value in −1 for 50 % L-Pine foam). In addition, this study revealed the relationship between lignin's structural properties and foam performance, providing insights for practical applications of lignin-based PUF.

Jeong, Soyeon [State Univ. of New York (SUNY), Syr↗
DOE OSTI2025

Nature-inspired lotus-shaped fins combined with hybrid nanoparticles and metal foam for high-performance latent heat thermal energy storage

Latent heat thermal energy storage (LHTES) systems play a critical role in renewable energy integration by providing high energy density and nearly isothermal operation during phase transitions. However, their performance is often limited by slow melting/charging rates, which motivates the search for enhanced heat transfer designs. This study investigates the melting behavior of RT-82 phase change material (PCM) using novel lotus-shaped fins combined with copper metal foam and conductive graphene nanoparticles and carbon nanotubes. A two-dimensional enthalpy-porosity model in ANSYS Fluent was developed to simulate the charging/melting process, capturing non-thermal equilibrium between the foam and PCM/nano-PCM. In this study, effects of fin geometry, nanoparticle concentration, and foam porosity on melting dynamics and cost-performance trade-offs were investigated. Results showed that natural convection accelerated melting by ~12% compared to conduction-only scenarios. Optimized lotus-shaped fins with higher fin density (T3F4 and T3F10) achieved up to 63% faster melting relative to sparse configurations. Graphene nanoparticles improved thermal conductivity, with a 6% volume fraction, by reducing melting time by ~6.9%, while their combination with 75% porosity foam achieved a maximum reduction in the melting time of ~51% compared to pure PCM. Cost-performance analysis identified T3F4 as the most balanced design, offering rapid thermal response without excessive material costs, while moderate-density designs like T3S6 provided economical alternatives with acceptable performance. These results highlight the performance enhancement that can be achieved by integrating bio-inspired fins, nanoparticles, and foams, into compact and efficient LHTES for solar heating, building thermal management, and industrial waste-heat recovery applications.

25 ENERGY STORAGE↗
DOE OSTI2022

Nickel foam supported porous copper oxide catalysts with noble metal-like activity for aqueous phase reactions

Contiguous metal foams offer a multitude of advantages over conventional powders as supports for nanostructured heterogeneous catalysts; most critically a preformed 3-D porous framework ensuring full directional coverage of supported catalyst, and intrinsic ease of handling and recyclability. Nonetheless, metal foams remain comparatively underused in thermal catalysis compared to more conventional supports such as amorphous carbon, metal oxides, zeolites and more recently MOFs. Herein, we demonstrate a facile preparation of highly-reactive, robust, and easy to handle Ni foam-supported Cu-based metal catalysts. The highly sustainable synthesis requires no specialized equipment, no surfactants or additive redox reagents, uses water as solvent, and CuCl 2 (H 2 O) 2 as precursor. The resulting material seeds as well-separated micro-crystalline Cu 2 (OH) 3 Cl evenly covering the Ni foam. Calcination above 400 °C transforms the Cu 2 (OH) 3 Cl to highly porous CuO. All materials display promising activity towards the reduction of 4-nitrophenol and methyl orange. Notably, our leading CuO-based material displays 4-nitrophenol reduction activity comparable with very reactive precious-metal based systems. Furthermore, recyclability studies highlight the intrinsic ease of handling for the Ni foam support, and our results point to a very robust, highly recyclable catalyst system.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Shock propagation in aerogel and TPP foams for inertial fusion energy target design

Achieving practical inertial fusion energy (IFE) requires the development of target designs with well-characterized microstructure and compression response. We measured shock dynamics in low-density (17.5–500 mg/cm 3 ) aerogel and two-photon polymerization (TPP) foams using x-ray phase contrast imaging (XPCI) methods and the Velocity Interferometer System for Any Reflector. By analyzing shock front evolution, we examined how target type and density influence shock propagation and energy dissipation. Talbot-XPCI shows that aerogels support a smooth, bowed shock front due to their homogeneous nanometer-scale pore network. In contrast, TPP foams exhibit irregular, stepwise propagation driven by interactions with their periodic micrometer-scale lattice. Shock velocity follows a power-law relation: aerogels deviate from classical ρ −1/2 scaling due to pore-collapse dissipation, while TPP foams follow the trend with larger uncertainties from density variations. Comparisons with xRAGE simulations reveal systematic underestimation of shock speeds. These results provide the first experimental constraints on shock propagation in TPP foams over a wide density range and highlight the influence of internal structure on anisotropic shock behavior. Our findings support improved benchmarking of EOS and hydrodynamic models and inform the design of foam architectures that promote implosion symmetry in IFE capsules.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Experimental and Numerical Investigation of Flow Boiling in Additive Manufactured Foam Structures With Vapor Pathways

Abstract The unique properties of metal foams make them potential candidates for a range of applications, including microsystem thermal management. Using additive manufacturing to create foam-type structures can improve upon prior thermal solutions by eliminating thermal interface materials and allowing for customization/local control of parameters. In the present investigation, flow boiling in additive-manufactured metal foams is investigated both experimentally and numerically. Two test samples, one with uniform structure and the other with pathways for vapor removal, are compared both experimentally and numerically. A conjugate computational fluid dynamics and heat transfer (CFD-HT) model utilizing a three-dimensional volume of fluid (VOF) model with accompanying evaporation/condensation model provided in-depth visualization of the boiling flow phenomena. The experiments generated the thermohydraulic performance over a range of heat fluxes, demonstrating that the sample incorporating dedicated vapor pathways performed better in both pressure and heat transfer performance metrics compared to the uniform foam. Additionally, negative system-level effects (i.e., hydraulic oscillations) were shown to be abated using the vapor removal structures. The numerical model yielded further insight into the factors contributing to the improved performance. Results indicated the pathways functioned as vapor removal channels, allowing the generated vapor to vent from the foam structure into the lanes. Further computational investigations demonstrated changes in flow regimes, where the addition of vapor channels caused the flow to change from churn to annular. Bubble behavior unique to the vapor pathway structure was studied, showing stagnant regions that eject vapor into the channel.

Engineering↗