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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 1,297 records · Page 72
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Heat Exchanger Intensification Through Powder Processing and Enhanced Design (HIPPED)

High intensity, supercritical CO 2 heat exchangers capable of operating at temperatures between 800 and 1100 ˚C and pressures greater than 80 bar are considered a critical component for high efficiency power generation and a range of next-generation industrial processes. A novel heat exchanger concept was proposed in this project. The proposed concept involved a plate-type architecture with three-dimensional fins, called twisted s-shaped fins, that capitalize on additive manufacturing. Four manufacturing processes were studied to realize the complex envisioned design: press and sinter of metallic powders, directed energy deposition, laser powder bed fusion, and a novel powder bed process involving a photoreactive polymer called SEAM (scalable expeditious additive manufacturing), that later was developed at MSU. The team was able to manufacture subscale heat exchangers using laser powder bed fusion (LPBF) and SEAM. The team settled on using SEAM as a final manufacturing approach due to its very low cost. The SEAM-manufactured heat exchanger, however, when tested under pressure, exhibited leaks and the process still requires further development beyond the timeline of the project. To support the heat exchanger design and testing, the team developed a new high temperature flow loop allowing testing under high temperature and pressure. Computational modeling of the heat exchanger was also performed for the twisted s-shaped fins and the computations were validated with experimental data. The new twisted fins resulted in enhanced heat transfer and reduced pressure drop. To further minimize pressure drop in the plate heat exchanger, the team also developed a simplified model for flow maldistribution in the manifolds, providing a new tool for designers that eliminates the need for complex CFD calculations. A technoeconomic analysis was also developed to contrast SEAM with LPBF, this tool indicated that SEAM is several times less costly and offer significant promises as a rapid low cost additive manufacturing process for metallic systems.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

The K2 M67 Study: Precise Mass for a Turnoff Star in the Old Open Cluster M67

We present a study of the bright detached eclipsing main-sequence binary WOCS 11028 (Sanders 617) in the open cluster M67. Although the binary has only one eclipse per orbital cycle, we show that the masses of the stars can be derived very precisely thanks to a strong constraint on the orbital inclination: M {sub A} = 1.222 ± 0.006M {sub ⊙} and M {sub B} = 0.909 ± 0.004M {sub ⊙}. We use a spectral energy distribution fitting method to derive characteristics of the component stars in lieu of the precise radii that would normally be derived from a doubly eclipsing binary. The deconvolution of the SEDs reveals that the brighter component of the binary is at the faint turnoff point for the cluster—a distinct evolutionary point that occurs after the convective core has been established and while the star is in the middle of its movement toward lower surface temperatures, before the so-called hook at the end of the main sequence. The measurements are in distinct disagreement with evolution models at solar metallicity: higher metal abundances are needed to reproduce the characteristics of WOCS 11028 A. We discuss the changes to model physics that are likely to be needed to address the discrepancies. The clearest conclusions are that diffusion is probably necessary to reconcile spectroscopic abundances of M67 stars with the need for higher metallicity models and that reduced strength convective overshooting is occurring for stars at the turnoff. At super-solar bulk metallicity, various indicators agree on a cluster age between about 3.5 and 4.0 Gyr.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The R -process Alliance: Enrichment of r -process Elements in a Simulated Milky Way–like Galaxy

We study the formation of stars with varying amounts of heavy elements synthesized by the rapid neutron-capture process (r-process) based on our detailed cosmological zoom-in simulation of a Milky Way–like galaxy with an N-body/smoothed particle hydrodynamics code, asura. Most stars with no overabundance in r-process elements, as well as the strongly r-process-enhanced (RPE) r-II stars ([Eu/Fe] > +0.7), are formed in dwarf galaxies accreted by the Milky Way within the 6 Gyr after the Big Bang. In contrast, over half of the moderately enhanced r-I stars (+0.3 < [Eu/Fe] ≤ +0.7) are formed in the main in situ disk after 6 Gyr. Our results suggest that the fraction of r-I and r-II stars formed in disrupted dwarf galaxies is larger the higher their [Eu/Fe] is. Accordingly, the most strongly enhanced r-III stars ([Eu/Fe] > +2.0) are formed in accreted components. These results suggest that non-r-process-enhanced stars and r-II stars are mainly formed in low-mass dwarf galaxies that hosted either none or a single neutron star merger, while the r-I stars tend to form in the well-mixed in situ disk. We compare our findings with high-resolution spectroscopic observations of RPE metal-poor stars in the halo and dwarf galaxies, including those collected by the R-Process Alliance. We conclude that observed [Eu/Fe] and [Eu/Mg] ratios can be employed in chemical tagging of the Milky Way’s accretion history.

Chemical enrichment↗
DOE OSTI2019

Development of Multicomponent EAM Potential for Ni-Based Superalloy

We initiated the development of multi-component EAM potentials for Aluminides and Carbides, key phases in Ni-based Superalloys. The goal is to utilize the MD simulation to understand the deformation dynamics that contribute to the formation of voids and creep initiation. For this purpose, we constructed the raw data from ab-initio (molecular dynamics) MD simulations fed into the potential development code and used Nickel as the base metal with the addition of a number of various elements including Aluminum, Chromium, Tungsten. We then developed the EAM potentials for the aluminide and carbide phases using the force-fitting code MEAMfit. Our generated potential reproduces the fundamental properties of the Ni3Al and Mo23C6 phases. We verified further the EAM potential through the thermal stability test at different temperatures and by reproducing the elastic constants consistent with the experimental values.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE neams program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework. This report summarizes recent advances in developing an integrated system- and engineering-scale modeling capability for the msr concept, which has gained significant interest in recent years. A consistent framework was established by coupling Pronghorn and SAM through the Saline interface, with thermophysical properties provided by the Molten Salt Thermal Property Database (MSTDB-TP). Further improvements were made to the coupling schemes and domain-overlapping strategies, enhancing the stability and robustness of multi-code simulations. Verification and validation efforts demonstrate the accuracy of this integration across a range of benchmark problems, including one-dimensional heated pipe flows, three-dimensional natural convection loops with evolving isotopic compositions, and \gls{msre} demonstration cases. Within Pronghorn, new capabilities were introduced to model corrosion and noble-metal plating phenomena, supported by an extended thermal-hydraulics framework and refined turbulence treatments. To capture two-phase flow behavior, a multiphase Euler–Euler model was implemented in Pronghorn, including advanced closure relations, high-resolution advection techniques, and capillary force reconstruction. Preliminary verification cases confirm the fidelity of the approach, while planned validation efforts target canonical multiphase benchmarks and application to msr components such as the msre pump bowl. Finally, updates to SAM’s msr mass transfer modeling were extended to consider noble gas migration into porous structures like graphite. The point kinetics model was updated to include reactivity feedback contributions from any defined species, such as xenon. The gas transport model was expanded for applicability to gas mixtures, bubble efflux phenomena, and species transport between liquid and gas phases. A selection of multi-scale Sherwood number correlations from MOSCATO/NekRS and multi-phase correlations from literature have been added for improved accuracy in calculating mass transfer coefficients. A companion effort on developing system-level redox corrosion has also been incorporated into SAM. Collectively, these enhancements strengthen the predictive capability of SAM and Pronghorn for simulating MSR thermal-hydraulics, corrosion, multiphase behavior, and fission-product transport, providing a more complete toolset for design, safety analysis, and licensing support of next-generation \gls{msr}s.

42 - ENGINEERING↗
DOE OSTI2021

Determine Oxidation State of Transition Metals in Molten Salt Corrosion using Electron Energy Loss Spectroscopy

This work utilizes electron energy loss spectroscopy (EELS) to identify oxidation state of alloying elements in Ni-based alloys after exposure to molten chloride salt systems. Pure Ni and Ni 20Cr model alloy were corroded in molten ZnCl2 and KCl-MgCl2 under argon atmosphere at various temperatures. Oxidation states of Cr (Cr3+) and Ni (Ni2+) in the molten salt after corrosion were determined by monitoring changes in the L2,3 edges of corresponding EELS spectra. Oxidation state mapping technique using principal component analysis and multiple linear least squares fitting in HyperSpy Python package was developed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization

This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.

03 NATURAL GAS↗
DOE OSTI2022

Proton-Coupled Electron Transfer in a Ruthenium(II) Bipyrimidine Complex in Its Ground and Excited Electronic States

In this work, proton-coupled electron transfer (PCET) was studied for the ground and excited electronic states of a [Ru(terpy)(bpm)(OH 2 )(PF 6 ) 2 ] complex, Ru-bpm. Cyclic voltammetry measurements show that the Ru(II)-aqua moiety undergoes PCET to form a Ru(IV)-oxo moiety in the anodic region, while the bpm ligand undergoes PCET to form bpmH 2 in the cathodic region. The photophysical behavior of Ru-bpm was studied using steady-state and femtosecond transient UV–vis absorption spectroscopy, coupled with density functional theory (DFT) calculations. The lowest-lying excited state of Ru-bpm is described as a (Ru → bpm) metal-to-ligand charge-transfer (MLCT) state, while the metal-centered (MC) excited state was found computationally to be close in energy to the lowest-energy bright MLCT state (MC state was 0.16 eV above the MLCT state). The excited-state kinetics of Ru-bpm were found via transient absorption spectroscopy to be short-lived and were fit well to a biexponential function with lifetimes $τ_1$ = 4 ps and $τ_2$ = 65 ps in aqueous solution. Kinetic isotope effects of 1.75 ($τ_1$) and 1.61 ($τ_2$) were observed for both decay components, indicating that the solvent plays an important role in the excited-state dynamics of Ru-bpm. Based on the pH-dependent studies and the results from prior studies of similar Ru-complexes, we hypothesize that the 3 MLCT state forms an excited-state hydrogen-bond adduct with the solvent molecules and that this process occurs with a 4 ps lifetime. The formation of such a hydrogen-bond complex is consistent with the electronic density accumulation at the peripheral N atoms of the bpm moiety in the 3 MLCT state. The hydrogen-bonded state 3 MLCT decays to the ground state with a 65 ps lifetime. Such a short lifetime is likely associated with the efficient vibrational energy transfer from the 3 MLCT state to the solvent.

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

Significant H i and Metal Differences around the z = 0.83 Lens Galaxy toward the Doubly Lensed Quasar SBS 0909+532

We report a large difference in neutral hydrogen (H i) and metal column densities between the two sight lines probing opposite sides of the lensing galaxy at z {sub lens} = 0.83 toward the doubly lensed quasar SBS 0909+532. Using archival HST-STIS and Keck HIRES spectra of the lensed quasar images, we measure log N {sub H I} = 18.77 ± 0.12 cm{sup −2} toward the brighter image (A) at an impact parameter of r {sub A} = 3.15 kpc and log N {sub H I} = 20.38 ± 0.20 cm{sup −2} toward the fainter image (B) at an impact parameter of r {sub B} = 5.74 kpc. This difference by a factor of ∼41 is the highest difference between sight lines for a lens galaxy in which H i has been measured, suggesting patchiness and/or anisotropy on these scales. We estimate an average Fe abundance gradient between the sight lines to be ≥+0.35 dex kpc{sup −1}. The N {sub Fe II}/N {sub Mg II} ratios for the individual components detected in the Keck HIRES spectra have supersolar values for all components in sight line A and for 11 out of 18 components in sight line B, suggesting that Type Ia supernovae may have contributed to the chemical enrichment of the galaxy’s environment. Additionally, these observations provide complementary information to detections of cold gas in early-type galaxies and the tension between these and some models of cloud survival.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Physical Background, Computations and Practical Issues of the Magnetohydrodynamic Pressure Drop in a Fusion Liquid Metal Blanket

In blankets of a fusion power reactor, liquid metal (LM) breeders, such as pure lithium or lead-lithium alloy, circulate in complex shape blanket conduits for power conversion and tritium breeding in the presence of a strong plasma-confining magnetic field. The interaction of the magnetic field with induced electric currents in the breeder results in various magnetohydrodynamic (MHD) effects on the flow. Of them, high MHD pressure losses in the LM breeder flows is one of the most important feasibility issues. To design new feasible LM breeding blankets or to improve the existing blanket concepts and designs, one needs to identify and characterize sources of high MHD pressure drop, to understand the underlying physics of MHD flows and to eventually define ways of mitigating high MHD pressure drop in the entire blanket and its sub-components. This article is a comprehensive review of earlier and recent studies of MHD pressure drop in LM blankets with a special focus on: (1) physics of LM MHD flows in typical blanket configurations, (2) development and testing of computational tools for LM MHD flows, (3) practical aspects associated with pumping of a conducting liquid breeder through a strong magnetic field, and (4) approaches to mitigation of the MHD pressure drop in a LM blanket.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Design Principles for Efficient and Stable Water Splitting Photoelectrocatalysts

Photoelectrochemical water splitting is a promising avenue for sustainable production of hydrogen used in the chemical industry and hydrogen fuel cells. The basic components of most photoelectrochemical water splitting systems are semiconductor light absorbers coupled to electrocatalysts, which perform the desired chemical reactions. A critical challenge for the design of these systems is the lack of stability for the majority of desired semiconductors under operating water splitting conditions. One strategy to address this issue is to protect the semiconductor by covering it with a stabilizing insulator layer, creating a metal–insulator–semiconductor (MIS) architecture, which has demonstrated improved stability. In addition to enhanced stability, the insulator layer may significantly affect the electron and hole transfer, which governs the recombination rates. Furthermore, the insertion of an insulator layer leads to the introduction of additional insulator/electrocatalyst and insulator/semiconductor interfaces. These interfaces can impact the system’s performance significantly, and they need to be carefully engineered to optimize the efficiencies of MIS systems. In this Account, we describe our recent progress in shedding light on the critical role of the insulator and the interfaces on the performance of MIS systems. We discuss our findings by focusing on the concrete example of planar n-type Si protected by a HfO 2 insulator layer and coupled to a Ni or Ir electrocatalyst that performs the oxygen evolution reaction, one of the water splitting half-reactions. To improve our fundamental understanding of the insulator layer, we precisely control the HfO 2 insulator thickness using atomic layer deposition (ALD), and we perform a series of rigorous electrochemical experiments coupled with theory and modeling. We demonstrate that by tuning the insulator thickness, we can control the flux and recombination of photogenerated electrons and holes to optimize the generated photovoltage. Despite optimizing the thickness, we find that the maximum generated photovoltage in MIS systems is often significantly lower than the upper performance limit, i.e., there are additional losses in the system that could not be addressed by optimizing the insulator thickness. We identify the sources of these losses and describe strategies to minimize them by a combination of improving the semiconductor light absorption, removing nonidealities associated with interfacial defects, and finding alternative insulators with improved charge carrier selectivity. Finally, we quantify the improvements that can be obtained by implementing these specific strategies. Our collective work outlines strategies to analyze MIS systems, identify the sources of efficiency losses, and optimize the design to approach the fundamental performance limits. Furthermore, these general approaches are broadly applicable to photoelectrochemical materials that utilize sunlight to produce value-added chemicals.

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

Bioactivity Profiling of Chemical Mixtures for Hazard Characterization

Abstract The assessment and regulation of chemical toxicity to protect human health and the environment are done one chemical at a time and seldom at environmentally relevant concentrations. However, chemicals are found in the environment as mixtures, and their toxicity is largely unknown. Understanding the hazard posed by chemicals within the mixture is critical to enforce protective measures. Here, we demonstrate the application of bioactivity profiling of environmental water samples using the sentinel and ecotoxicology model species Daphnia to reveal the biomolecular response induced by exposure to real-world mixtures. We exposed a Daphnia strain to 30 sampled waters of the Chaobai River and measured the gene expression response profiles. Using a multiblock correlation analysis, we establish correlations between chemical mixtures identified in 30 water samples with gene expression patterns induced by these chemical mixtures. We identified 80 metabolic pathways putatively activated by mixtures of inorganic ions, heavy metals, polycyclic aromatic hydrocarbons, industrial chemicals, and a set of biocides, pesticides, and pharmacologically active substances. Our data-driven approach discovered both known bioactivity signatures with previously described modes of action and new pathways linked to undiscovered potential hazards. This study demonstrates the feasibility of reducing the complexity of real-world mixture toxicity to characterize the biomolecular effects of a defined number of chemical components based on gene expression monitoring of the sentinel species Daphnia.

Engineering↗
DOE OSTI2021

Spin and Orbital Effects on Asymmetric Exchange Interaction in Polar Magnets: M(IO 3 ) 2 (M = Cu and Mn)

We report magnetic polar materials feature an astonishing range of physical properties, such as magnetoelectric coupling, chiral spin textures, and related new spin topology physics. This is primarily attributable to their lack of space inversion symmetry in conjunction with unpaired electrons, potentially facilitating an asymmetric Dzyaloshinskii–Moriya (DM) exchange interaction supported by spin–orbital and electron–lattice coupling. However, engineering the appropriate ensemble of coupled degrees of freedom necessary for enhanced DM exchange has remained elusive for polar magnets. Here, we study how spin and orbital components influence the capability of promoting the magnetic interaction by studying two magnetic polar materials, α-Cu(IO 3 ) 2 ( 2 D) and Mn(IO 3 ) 2 ( 6 S), and connecting their electronic and magnetic properties with their structures. The chemically controlled low-temperature synthesis of these complexes resulted in pure polycrystalline samples, providing a viable pathway to prepare bulk forms of transition-metal iodates. Rietveld refinements of the powder synchrotron X-ray diffraction data reveal that these materials exhibit different crystal structures but crystallize in the same polar and chiral P2 1 space group, giving rise to an electric polarization along the b-axis direction. The presence and absence of an evident phase transition to a possible topologically distinct state observed in α-Cu(IO 3 ) 2 and Mn(IO 3 ) 2 , respectively, imply the important role of spin–orbit coupling. Neutron diffraction experiments reveal helpful insights into the magnetic ground state of these materials. While the long-wavelength incommensurability of α-Cu(IO 3 ) 2 is in harmony with sizable asymmetric DM interaction and low dimensionality of the electronic structure, the commensurate stripe AFM ground state of Mn(IO 3 ) 2 is attributed to negligible DM exchange and isotropic orbital overlapping. The work demonstrates connections between combined spin and orbital effects, magnetic coupling dimensionality, and DM exchange, providing a worthwhile approach for tuning asymmetric interaction, which promotes evolution of topologically distinct spin phases.

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

Sustainable layered cathode with suppressed phase transition for long-life sodium-ion batteries

Sodium-ion batteries are among the most promising alternatives to lithium-based technologies for grid and other energy storage applications due to their cost benefits and sustainable resource supply. For the cathode—the component that largely determines the energy density of a sodium-ion battery cell—one major category of materials is P2-type layered oxides. Unfortunately, at high state-of-charge, such materials tend to undergo a phase transition with a very large volume change and consequent structural degradation during long-term cycling. Here we address this issue by introducing vacancies into the transition metal layer of P2-Na$_{0.7}$Fe$_{0.1}$Mn$_{0.75\square}$$_{0.15}$O2 (‘$_{\square}$’ represents a vacancy). The transition metal vacancy serves to suppress migration of neighbouring Na ions and therefore maintain structural and thermal stability in Na-depleted states. Moreover, the specific Na-O-$_{\square}$ configuration triggers a reversible anionic redox reaction and boosts the energy density. As a result, the cathode design here enables pouch cells with energy densities of 170 Wh kg -1 and 120 Wh kg -1 that can operate for over 600 and 1,000 cycles, respectively. In conclusion, our work not only suggests a feasible strategy for cathode design but also confirms the possibility of developing a battery chemistry that features a reduced need for critical raw materials.

25 ENERGY STORAGE↗
DOE OSTI2022

Revisiting W–ZrC interfaces: A first principles study

We investigate W–ZrC interfaces using first-principles calculations based on the density functional theory. There have been theoretical and experimental studies exploring W–ZrC interfaces, however, the debate regarding the most stable interface continues to persist. In this study, we systematically simulated various W–ZrC interfaces merging W and ZrC surfaces with different orientations. Subsequently, we evaluated their stabilities and explained the corresponding stabilities in terms of the nature of bonding and charge-transfer processes at the interface. We find ZrC(111)–W(110) is the most stable interface with higher adhesive energy than the other interfaces. The additional stability associated with the ZrC(111)–W(110) results from significant interface reconstruction. Three layers of W and ZrC adjacent to the interface are involved in the charge-transfer process leading to stronger ionic bonds in ZrC(111)–W(110) as compared to the other potential candidate: ZrC(100)–W(100). The C and W atoms are found to be displaced from their symmetric position during the reconstruction process at the interface to facilitate stronger bonds with shorter W–C and W–Zr bonds in ZrC(111)–W(110) as compared to ZrC(100)–W(100). This leads to stronger covalent bonds in ZrC(111)–W(110) than that in ZrC(100)–W(100). Therefore, we conclude that the stronger covalent and ionic forces in ZrC(111)–W(110) than those in ZrC(100)–W(100) are responsible for making ZrC(111)–W(110) to be the most stable interface. In conclusion, this study addresses the long-standing question of the most stable W–ZrC interface and derives a number of implications for other W-transition metal carbide interfaces which are potential candidates for improving the mechanical properties of plasma facing materials.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗
DOE OSTI2020

σ‐Aromaticity‐Induced Stabilization of Heterometallic Supertetrahedral Clusters [Zn 6 Ge 16 ] 4− and [Cd 6 Ge 16 ] 4−

Abstract In this work, the largest heterometallic supertetrahedral clusters, [Zn 6 Ge 16 ] 4− and [Cd 6 Ge 16 ] 4− , were directly self‐assembled through highly‐charged [Ge 4 ] 4− units and transition metal cations, in which 3‐center–2‐electron σ bonding in Ge 2 Zn or Ge 2 Cd triangles plays a vital role in the stabilization of the whole structure. The cluster structures have an open framework with a large central cavity of diameter 4.6 Å for Zn and 5.0 Å for Cd, respectively. Time‐dependent HRESI‐MS spectra show that the larger clusters grow from smaller components with a single [Ge 4 ] 4− and ZnMes 2 units. Calculations performed at the DFT level indicate a very large HOMO–LUMO energy gap in [M 6 Ge 16 ] 4− (2.22 eV), suggesting high kinetic stability that may offer opportunities in materials science. These observations offer a new strategy for the assembly of heterometallic clusters with high symmetry.

Xu, Hong‐Lei↗
DOE OSTI2025

Selectively extracting lithium from single and mixed cathode materials

With the burgeoning reliance on lithium-ion batteries for sustainable energy solutions and electric transportation, the environmental and resource management associated with battery disposal are increasingly critical. Addressing these challenges necessitates innovative recycling techniques that recover valuable battery components, particularly lithium. This research introduces a universal, eco-friendly approach tailored for the efficient selective extraction of lithium from both single and mixed cathode materials, achieving impressive selective leaching efficiencies of lithium (99.51 % for LFP, 90 % for NMC, and 97.24 % for mixed cathode). Surprisingly, leaching efficiency of lithium from NMC can be significantly improved by introducing LFP since LFP can remove the dense transition-metal salts on the surface of NMC. The extracted lithium is recovered as lithium carbonate with battery-grade purity. This study also highlights the reuse of formic acid and the adoption of oxygen as an oxidizing agent to prevent wastewater production. Therefore, this method provides a robust foundation for sustainable lithium battery recycling.

economically and environmentally feasible↗