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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 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Microstructure–Property Correlation in a Laser Powder Bed Fusion Processed High-Strength AF-9628 Steel

Laser powder bed fusion additive manufacturing (LPBF-AM) of a low-alloy, high-performance AF-9628 steel results in exceptionally high strength and good ductility. The reasons for such mechanical properties are investigated through detailed microscopy performed at several length scales. Thus, the characterization of melt pool, porosity, grain morphology, phases, and dislocations is performed in the as-printed material. The as-printed material consists of only 0.004 vol% of uniformly distributed porosity, single-phase martensitic laths with an average lath size of ≈2.5 μm, the absence of carbides indicating interstitial trapping of C atom, and high dislocation density in the martensitic laths. Experimental data through microscopy are then fed in analytical models for calculating strengthening contributions from various strengthening mechanisms. Calculated yield strength agrees well with experimentally determined value, and therefore, activation of various strengthening mechanisms is established in as-printed AF-9628.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Fracture‐Resistant and Thermally Insulating Ultrahigh‐Temperature Carbide Foams

Dense ultrahigh‐temperature ceramics (UHTCs) carbides are recognized as potential materials for thermal protection systems (TPS) owing to properties beyond existing structural materials’ capabilities. Recent advances in UHTCs have enabled the development of multiscale porous microstructures. Herein, it is highlighted that the porosity in UHTCs are no longer treated as a defect but as a functional property specifically tailored for thermal insulation. It is a promising solution to design and fabricate bulk UHTC foams via a freeze‐drying (FD) approach followed by calibrated pressureless spark plasma sintering. Herein, monolithic TaC and HfC UHTC foams and their composite show the partial solid–solution formation of (Ta, Hf)C with porosity ≥50%. TaC–HfC foam (≈80–92 N) shows an intermediate load‐bearing capability compared to monolithic TaC (≈120–135 N) and HfC (≈28–35 N) foams, with no evident cracking on the sample surface. The thermal conductivity of partial solid‐solution TaC–HfC foam increases up to fivefold compared to parent UHTC foams. In the results, solid solutions’ efficacy and pores’ unidirectionality in providing thermal insulation to TaC–HfC while maintaining its high‐load bearing capability are illustrated. In conclusion, the developed technique establishes a new paradigm shift in UHTCs, expanding their potential for TPS in extreme environments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Controlled In Situ Foaming for Mechanical Responsiveness of Architected Foams

Addition of chemical blowing agents to polysiloxane resins produces foams with closed–cell morphology. Combining this chemistry with the 3D–printing technique direct ink writing (DIW) permits the creation of architected foams with controllable, hierarchical tiers of porosity. Here, using a two–component foaming ink, the extent of foaming can be controlled by incorporating an active mixing printhead as part of the fabrication process. Changes in the mixing speed allows for in situ control of the foaming reaction where the mixing speed is directly correlated with the resulting foaming that occurs upon extrusion. These architected foams display tunable mechanical responses, porosities, and open–to–closed cell ratios. While chemically blown polysiloxane foam is a well–established material, utilizing DIW as fabrication technique presents a novel approach for creating tailored, architected foams that require minimal post–processing.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Aerobijels: Ultralight Carbon Monoliths from Cocontinuous Emulsions

In this work, bijels are used to develop a new class of ultralight hierarchically porous aerogels exhibiting multimodal porosity across multiple length scales. Through in situ functionalization of a particle-laden liquid interface wherein binary liquid pairs are kinetically trapped out of equilibrium through interfacial jamming, monolithic and freestanding carbon electrodes are produced with prescribed bulk densities down to ≈2 mg cm -3 . Exemplary electrokinetic experiments indicate that the bicontinuity of the pore structure is essential for enhancing transport to and from the active electrode surfaces, demonstrating that these materials possess a superior ability to accumulate and transport charge when compared to analogous systems with restricted pore connectivity and fluid throughput. This approach offers a new synthetic route to bicontinuous and hierarchical aerogel materials with nested multimodal porosities. Furthermore, the flexibility of this scheme can address critical issues related to transport-limited behaviors that arise in many technological fields, ranging from energy and catalysis research to remediation and sensing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Efficient Mercury Capture Using Functionalized Porous Organic Polymer

The primary challenge in materials design and synthesis is achieving the balance between performance and economy for real-world application. Here, this issue is addressed by creating a thiol functionalized porous organic polymer (POP) using simple free radical polymerization techniques to prepare a cost-effective material with a high density of chelating sites designed for mercury capture and therefore environmental remediation. The resulting POP is able to remove aqueous and airborne mercury with uptake capacities of 1216 and 630 mg g -1 , respectively. The material demonstrates rapid kinetics, capable of dropping the mercury concentration from 5 ppm to 1 ppb, lower than the US Environmental Protection Agency's drinking water limit (2 ppb), within 10 min. Furthermore, the material has the added benefits of recyclability, stability in a broad pH range, and selectivity for toxic metals. These results are attributed to the material's physical properties, which include hierarchical porosity, a high density of chelating sites, and the material's robustness, which improve the thiol availability to bind with mercury as determined by X-ray photoelectron spectroscopy and X-ray absorption fine structure studies. Finally, the work provides promising results for POPs as an economical material for multiple environmental remediation applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Functionalized Porous Aromatic Frameworks as High‐Performance Adsorbents for the Rapid Removal of Boric Acid from Water

Abstract This study demonstrates that functionalized, highly porous polymers are promising for the adsorptive capture of boric acid, a neutral contaminant that is difficult to remove from seawater using conventional reverse osmosis membranes. Appending N ‐methyl‐d‐glucamine (NMDG) to the pore walls of high‐surface‐area porous aromatic frameworks (PAFs) yields the adsorbents PAF‐1‐NMDG and P2‐NMDG in a simple two‐step synthesis. The boron‐selective PAFs demonstrate adsorption capacities that are up to 70% higher than those of a commercial boron‐selective resin, Amberlite IRA743, and markedly faster adsorption rates, owing to their higher NMDG loadings and greater porosities relative to the resin. Remarkably, PAF‐1‐NMDG is able to reduce the boron concentration in synthetic seawater from 2.91 to <0.5 ppm in less than 3 min at an adsorbent loading of only 0.3 mg mL −1 . The boron adsorption rate constants of both frameworks, determined via a pseudo‐second‐order rate model, represent the highest values reported in the literature—in most cases orders of magnitude higher than those of other boron‐selective adsorbents. The frameworks can also be readily regenerated via mild acid/base treatment and maintain constant boron adsorption capacities for at least 10 regeneration cycles. These results highlight the numerous advantages of PAFs over traditional porous polymers in water treatment applications.

Kamcev, Jovan↗
DOE OSTI2016

Water‐Based Assembly of Polymer–Metal Organic Framework (MOF) Functional Coatings

Metal organic frameworks (MOFs) have gained attention for their porosity, size selectivity, and structural diversity. There is a need for MOF‐based coatings, particularly in applications such as separations, electronics, and energy; yet forming thin, functional, conformal coatings is prohibitive because MOFs exist as a powder. Layer‐by‐layer assembly, a versatile thin film coating approach, offers a unique solution to this problem, but this approach requires MOFs that are water‐dispersible and bear a surface charge. Here, these issues are addressed by examining water‐based dispersions of MIL‐101(Cr) that facilitate the formation of robust polymer–MOF hybrid coatings. Specifically, the substrate to be coated is alternately exposed to an aqueous solution of poly(styrene sulfonate) and nano MIL‐101(Cr) dispersion, yielding linear film growth and coatings with a MOF content as high as 77 wt%. This approach is surface‐agnostic, in which the coating is successfully applied to silicon, glass, flexible plastic, and even cotton fabric, conformally coating individual fibers. By contrast, prior attempts at forming MOF‐coatings are severely limited to a handful of surfaces, require harsh chemical treatment, and are not conformal. The approach presented here unambiguously confirms that MOFs can be conformally coated onto complex and unusual surfaces, opening the door for a wide variety of applications.

De, Souvik↗
DOE OSTI2026

Durable Thin‐Film Porous Transport Electrodes for High Current Density PEM Water Electrolysis

Proton exchange membrane water electrolyzers rely on relatively expensive Ir-based catalysts for efficient and durable hydrogen production. To reduce system costs, Ir loadings can be reduced if performance and durability are maintained. Sputter deposition is a readily scalable method to synthesize uniform, low-loading catalyst layers with controlled composition. A catalyst applied directly to the porous transport layer can have advantages for performance, manufacturing simplicity, and catalyst recovery. Suitable porous transport layer porosity can minimize activity losses when reducing loadings. Here, methods are presented to deposit metallic Ir as well as amorphous and rutile Ir oxides. The activity and durability of these materials in the porous transport electrode architecture is evaluated. The metallic and amorphous forms have better initial activity, however, operation at 3 A cm −2 with 0.1 mg Ir cm −2 shows that only rutile IrO 2 maintains performance beyond 100 h with a 50 mV improvement after 700 h. A >10x reduced dissolution rate is shown for rutile IrO 2 . With a low-porosity transport layer and 0.4 mg Ir cm −2 , a steady-state voltage decay rate of 6 µV h −1 is achieved. The results demonstrate that sputter-deposited rutile IrO 2 porous transport electrodes with low Ir loading can be operated at high current density to reduce hydrogen production costs.

08 HYDROGEN↗
DOE OSTI2026

Passivation‐Induced Species Dynamics and Microstructural Evolution in Solid‐State Lithium–Sulfur Cathodes

Solid-state lithium–sulfur (SSLS) batteries offer high theoretical energy density, yet their practical viability is hindered by poor sulfur utilization and limited rechargeability. At the core of this challenge lies the passivating nature of Li 2 S, which restricts ionic and electronic transport, suppresses interfacial activity, and severely impedes the reversibility of electrochemical reactions. In this study, we elucidate the mechanistic origins of these limitations by resolving how charge and discharge species form, grow, and spatially evolve within the cathode microstructure under varied current densities and electrode compositions. By resolving the species distribution at the particle scale and coupling it with Raman spectroscopy and X-ray diffraction, we demonstrate how Li 2 S formation induces localized surface passivation that progressively limits electrochemical accessibility within the cathode microstructure. Sulfur utilization is found to be strongly governed by the interplay between sulfur loading, residual porosity, and interfacial architecture. High sulfur contents result in buried, electrochemically isolated domains due to poor solid electrolyte (SE) percolation, while low sulfur contents trigger SE degradation via parasitic reactions. The resulting sulfur-porosity maps delineate the mechanistic boundaries between reversible and transport-limited regimes, offering actionable design guidance for SSLS cathodes with enhanced sulfur utilization.

electrode microstructure↗
DOE OSTI2024

A Comprehensive Experimental Study on Microstructure‐Graded Graphite Anodes for Enhancing Fast‐Charging Capability of Lithium‐Ion Batteries

Lithium‐ion batteries with high gravimetric capacity density and improved cycle life performance under fast‐charging conditions are crucial for widespread electric vehicle (EV) adoption. This study investigates how designing graphite anode microstructure, specifically porosity, and particle‐size gradients, improves lithium‐ion (Li + ) transport during fast‐charging conditions. Three‐layered graphite anodes with varying porosity (24%, 36%, 46%) and particle size gradients (3, 5, 10 μm) were compared to a conventional single‐layered electrode in half‐cell configurations. At room temperature and high discharge rate (2C), both gradient structures showed significantly enhanced capacity retention (80% and 67% vs. 50%) compared to the conventional electrode, highlighting the effectiveness of microstructure engineering for fast charging. The study also investigated the temperature's impact on cycle life. After 200 cycles at 2°C and 45°C, all gradient structures demonstrated superior capacity retention (≈80%) compared to the conventional electrode (35%), suggesting the gradients mitigate degradation rate at high temperatures. Electrochemical impedance spectroscopy confirmed superior Li+ diffusion and lower resistivity in gradient electrodes. Simulations explored the influence of gradient profiles on reaction kinetics across the electrode thickness. Overall, this research demonstrates that the fast‐charging capability of graphite electrodes can be greatly enhanced by engineering the electrode microstructure, thereby making EV technology more accessible and appealing.

Ahmadi, Soma↗
DOE OSTI2019

Transforming Porous Organic Cages into Porous Ionic Liquids via a Supramolecular Complexation Strategy

Porous liquids are a type of porous materials that engineer permanent porosity into unique flowing liquids, exhibiting promising functionalities for a variety of applications. In this study, a Type I porous liquid is synthesized by transforming porous organic cages into porous ionic liquids via a supramolecular complexation strategy. Simple physical mixing of 18-crown-6 with task-specific anionic porous organic cages affords a porous ionic liquid with anionic porous organic cages as the anionic parts and 18-crown-6/potassium ion complexes as the cationic parts. In contrast, mixing of 15-crown-5 and anionic porous organic cages in a 2:1 ratio gives only solids, while the addition of excess 15-crown-5 affords a Type II porous liquid. The permanent porosity in the cage-based porous liquids has been also confirmed by molecular simulation, positron (e + ) annihilation lifetime spectroscopy, and enhanced gas sorption capacity compared with pure crown ethers.

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

Fully Conjugated Poly(phthalocyanine) Scaffolds Derived from a Mechanochemical Approach Towards Enhanced Energy Storage

Phthalocyanines (Pc)-derived materials represent an attractive category of porous organic scaffolds featured by extensive π-conjugated networks, but their construction is still limited to the solution-based pathways, producing materials with inferior conductivity and porosity. Herein, a mechanochemistry-driven approach was developed leveraging the on-surface polymerization of aromatic nitrile monomers with ortho-positioned dicyano groups in the presence of metal catalysts (magnesium, zinc, or aluminum) under neat and ambient conditions. Diverse Pc-functionalized conjugated porous networks (Pc-CPNs) were obtained featured by extensively and fully π-conjugated skeletons, high surface areas, and hierarchical porosities. The monomers in this mechanochemical approach could be extended to those difficult to be handled in solution-based procedures. In this work, the Pc-CPNs displayed attractive electrochemical performance as supercapacitor and anodes in batteries, together with superb long-term stability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Fabrication of co-continuous poly(ε-caprolactone)/polyglycolide blend scaffolds for tissue engineering

The apparent inability of a single biomaterial to meet all the requirements for tissue engineering scaffolds has led to continual research in novel engineered biomaterials. One method to provide new materials and fine-tune their properties is via mixing materials. Here in this study, a biodegradable powder blend of poly(ε-caprolactone) (PCL), polyglycolide (PGA), and poly(ethylene oxide) (PEO) was prepared and three-dimensional interconnected porous PCL/PGA scaffolds were fabricated by combining cryomilling and compression molding/polymer leaching techniques. The resultant porous scaffolds exhibited co-continuous morphologies with ~50% porosity. Mean pore sizes of 24 and 56 μm were achieved by varying milling time. The scaffolds displayed high mechanical properties and water uptake, in addition to a remarkably fast degradation rate. The results demonstrate the potential of this fabrication approach to obtain PCL/PGA blend scaffolds with interconnected porosity. In general, these results provide significant insight into an approach that will lead to the development of new composites and blends in scaffold manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Investigation of porous polydimethylsiloxane structures with tunable properties induced by the phase separation technique

This article reports the fabrication and characterization of porous polydimethylsiloxane (PDMS) structures developed by the solvent evaporationinduced phase separation technique. Here, ternary systems containing water/ tetrahydrofuran (THF)/PDMS with various concentrations are produced to form a stable solution. The porous PDMS structures are formed by removing the solvent (THF) and nonsolvent (water) phases during the stepping heat treatment procedure. The analytical ternary phase diagram is constructed based on the thermodynamic equilibrium state in the polymer solution to explain the stable/unstable formulations and the possible composition change path. The results show that the isolated pores with the adjustable pore size ranging from 330 to 1900 μm are obtained by tuning the water to the THF ratio. The mechanical properties of the porous PDMS structures are determined by conducting the tensile tests on the prepared dog bone-shaped specimens. A wide range of elastic modulus ranging between 0.49 and 1.05 MPa was achieved without affecting the density of the porous sample by adjusting the solvent and non-solvent content in the solution. It is shown that the flexibility of the porous structures can be improved by reducing the ratio of water to THF and decreasing the PDMS content. The porosity measurements reveal that the PDMS concentration is the major phase controlling the porosity of the structure, while the effect of water/THF is negligible.

42 ENGINEERING↗
DOE OSTI2020

Kinetics and Mechanisms of ZnO to ZIF-8 Transformations in Supercritical CO2 Revealed by in situ X-ray Diffraction

ZIF-8 was synthesized in supercritical carbon dioxide (scCO2). In situ powder X-ray diffraction, ex situ microscopy and simulations, provides a encompassing view of the formation of ZIF-8 and intermediary ZnO@ZIF-8 composites in this nontraditional solvent. Time-resolved imaging exposed divergent physicochemical reaction pathways from previous studies of the growth of anisotropic ZIF-8 core@shell structures in traditional solvents. Synthetically relevant physio-chemical properties of scCO2 were integrated into classical nucleation theory, relating interfacial forces with 3D nu-cleation outcomes. The kinetics of crystallization were examined and displayed a characteristic signature of time- and temperature-dependent mechanisms over the extent of the reaction. Lastly, we show that subtle factors, such as the extent of reaction and the size/shape of sacrificial templates can tailor ZIF-8 composition and size, eliciting control over hierarchical porosity in a nonconventional green solvent.

Sinnwell, Michael A.↗