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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Highly Flexible Dielectric Films from Solution Processable Covalent Organic Frameworks**

Covalent organic frameworks (COFs) are known to be a promising class of materials for a wide range of applications, yet their poor solution processability limits their utility in many areas. Here we report a pore engineering method using hydrophilic side chains to improve the processability of hydrazone and β-ketoenamine-linked COFs and the production of flexible, crystalline films. Further, mechanical measurements of the free-standing COF films of COF-PEO-3 (hydrazone-linked) and TFP-PEO-3 (β-ketoenamine-linked), revealed a Young's modulus of 391.7 MPa and 1034.7 MPa, respectively. The solubility and excellent mechanical properties enabled the use of these COFs in dielectric devices. Specifically, the TFP-PEO-3 film-based dielectric capacitors display simultaneously high dielectric constant and breakdown strength, resulting in a discharged energy density of 11.22 J cm -3 . This work offers a general approach for producing solution processable COFs and mechanically flexible COF-based films, which hold great potential for use in energy storage and flexible electronics applications.

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

Bulk‐Heterojunction Electrocatalysts in Confined Geometry Boosting Stable, Acid/Alkaline‐Universal Water Electrolysis

Abstract Alkaline water splitting electrocatalysts have been studied for decades; however, many difficulties remain for commercialization, such as sluggish hydrogen evolution reaction (HER) kinetics and poor catalytic stability. Herein, by mimicking the bulk‐heterojunction morphology of conventional organic solar cells, a uniform 10 nm scale nanocube is reported that consists of subnanometer‐scale heterointerfaces between transition metal phosphides and oxides, which serves as an alkaline water splitting electrocatalyst; showing great performance and stability toward HER and oxygen evolution reaction (OER). Interestingly, the nanocube electrocatalyst reveals acid/alkaline independency from the synergistic effect of electrochemical HER (cobalt phosphide) and thermochemical water dissociation (cobalt oxide). From the spray coating process, nanocube electrocatalyst spreads uniformly on large scale (≈6.6 × 5.6 cm 2 ) and is applied to alkaline water electrolyzers, stably delivering 600 mA cm −2 current for >100 h. The photovoltaic‐electrochemical (PV‐EC) system, including silicon PV cells, achieves 11.5% solar‐to‐hydrogen (STH) efficiency stably for >100 h.

Chemistry↗
DOE OSTI2020

Correlating Oxidation State and Surface Area to Activity from Operando Studies of Copper CO Electroreduction Catalysts in a Gas-Fed Device

Copyright © 2020 American Chemical Society. The rational design of high-performance electrocatalysts requires a detailed understanding of dynamic changes in catalyst properties, including oxidation states, surface area, and morphology under realistic working conditions. Oxide-derived Cu catalysts exhibit a remarkable selectivity toward multicarbon products for the electrochemical CO reduction reaction (CORR), but the exact role of the oxide remains elusive for explaining the performance enhancements. Here, we used operando X-ray absorption spectroscopy (XAS) coupled with simultaneous measurements of the catalyst activity and selectivity by gas chromatography (GC) to study the relationship between oxidation states of Cu-based catalysts and the activity for ethylene (C2H4) production in a CO gas-fed cell. By utilizing a custom-built XAS cell, oxidation states of Cu catalysts can be probed in device-relevant settings and under high current densities (>80 mA cm-2) for the CORR. By employing an electrochemical oxidation process, we found that the Cu oxidation states and specific ion species do not correlate with C2H4 production. The difference in the CORR activity is also investigated in relation to electrochemical surface area (ECSA) changes. While the hydrogen evolution reaction (HER) activity is positively correlated to the ECSA changes, the increased C2H4 activity is not proportional to the ECSA. Ex situ characterization from microscopic techniques suggests that the changes in the C2H4 activity and selectivity may arise from a morphological transformation that evolves into a more active structure. These comprehensive results give rise to the development of a cell regeneration method that can restore the performance of the Cu catalyst without cell disassembly. Our study establishes a basis for the rational design of highly active electrocatalysts for broad-range reactions in a gas-fed device.

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

MicroBooNE investigations on the photon interpretation of the MiniBooNE low energy excess

The MicroBooNE experiment is a liquid argon time projection chamber with 85-ton active volume at Fermilab, operated from 2015 to 2020 to collect neutrino data from Fermilab's Booster Neutrino Beam. One of MicroBooNE's physics goals is to investigate possible explanations of the low-energy excess observed by the MiniBooNE experiment in $\nu_{\mu}\rightarrow \nu_{e}$ neutrino oscillation measurements. MicroBooNE has performed searches to test hypothetical interpretations of the MiniBooNE low-energy excess, including the underestimation of the photon background or instrinic $\nu_{e}$ background. This thesis presents MicroBooNE's searches for two neutral current (NC) single-photon production processes that contribute to the photon background of the MiniBooNE measurement: NC $\Delta$ resonance production followed by $\Delta$ radiative decay: $\Delta \rightarrow N\gamma$, and NC coherent single-photon production. Both searches take advantage of boosted decision trees to yield efficient background rejection, and a high-statistic NC $\pi^0$ measurement to constrain dominant background, and make use of MicroBooNE's first three years of data. The NC $\Delta \rightarrow N\gamma$ measurement yielded a bound on the $\Delta$ radiative decay process at 2.3 times the predicted nominal rate at 90\% confidence level(C.L.), disfavoring a candidate photon interpretation of the MiniBooNE low-energy excess as a factor of 3.18 times the nominal NC Δ radiative decay rate at the 94.8\% C.L. The NC coherent single photon measurement leads to the world's first experimental limit on the cross-section of this process below 1 GeV, of $1.49 \times 10^{-41} \text{cm}^2$ at 90\% C.L., corresponding to 24.0 times the nominal prediction.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Two-band optical gain and ultrabright electroluminescence from colloidal quantum dots at 1000 A cm−2

Abstract Colloidal quantum dots (QDs) are attractive materials for the realization of solution-processable laser diodes. Primary challenges towards this objective are fast optical-gain relaxation due to nonradiative Auger recombination and poor stability of colloidal QD solids under high current densities required to obtain optical gain. Here we resolve these challenges and achieve broad-band optical gain spanning the band-edge (1S) and the higher-energy (1P) transitions. This demonstration is enabled by continuously graded QDs with strongly suppressed Auger recombination and a current-focusing device design, combined with short-pulse pumping. Using this approach, we achieve ultra-high current densities (~1000 A cm −2 ) and brightness (~10 million cd m −2 ), and demonstrate an unusual two-band electroluminescence regime for which the 1P band is more intense than the 1S feature. This implies the realization of extremely large QD occupancies of up to ~8 excitons per-dot, which corresponds to complete filling of the 1S and 1P electron shells.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

H i 21-cm absorption in radio-loud AGN with double-peaked [O iii ] emission

ABSTRACT Different physical processes in galaxy evolution, such as galaxy mergers that lead to coalescence of dual Active Galactic Nuclei (AGN) and outflows emanating from the narrow line region, can leave their imprint on the optical spectra of AGN in the form of double-peaked narrow emission lines. To investigate the neutral gas in the centres of such AGN, we have conducted a pilot survey of H i 21-cm absorption, using the upgraded Giant Metrewave Radio Telescope (uGMRT), in radio-loud AGN whose optical spectra show double-peaked [O iii] emission lines at z ≤ 0.4 (median z ≈ 0.14). Among the eight sources for which we could obtain clean spectra, we detect H i 21-cm absorption in three sources (detection rate of $38^{+36}_{-20}$ per cent) and find tentative indication of absorption in two other sources. The detection rate of H i 21-cm absorption is tentatively higher for the systems that show signatures of interaction or tidal disturbance (≳ 50 per cent) in the ground-based optical images than that for the systems that appear single and undisturbed (≈25 per cent). This is consistent with the high incidence of H i 21-cm absorption observed in z ≤ 0.2 galaxy mergers. Higher spatial resolution spectroscopy is required to confirm the origin of the H i absorbing gas, i.e. either gas infalling on to the radio-loud AGN, outflowing gas ejected by the AGN, or gas in rotation on the galactic-scale or circumnuclear discs.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Regulating Li Nucleation and Growth Heterogeneities via Near-Surface Lithium-Ion Irrigation for Stable Anode-Less Lithium Metal Batteries

The inhomogeneous nucleation and growth of Li dendrite combined with the spontaneous side reactions with the electrolytes dramatically challenge the stability and safety of Li metal anode (LMA). Despite tremendous endeavors, current success relies on the use of significant excess of Li to compensate the loss of active Li during cycling. Herein, a near-surface Li + irrigation strategy is developed to regulate the inhomogeneous Li deposition behavior and suppress the consequent side reactions under limited Li excess condition. The conformal polypyrrole (PPy) coating layer on Cu surface via oxidative chemical vapor deposition technique can induce the migration of Li + to the interregional space between PPy and Cu, creating a near-surface Li + -rich region to smooth diffusion of ion flux and uniform the deposition. Moreover, as evidenced by multiscale characterizations including synchrotron high-energy X-ray diffraction scanning, a robust N-rich solid-electrolyte interface (SEI) is formed on the PPy skeleton to effectively suppress the undesired SEI formation/dissolution process. Strikingly, stable Li metal cycling performance under a high areal capacity of 10 mAh cm -2 at 2.0 mA cm -2 with merely 0.5 × Li excess is achieved. The findings not only resolve the long-standing poor LMA stability/safety issues, but also deepen the mechanism understanding of Li deposition process.

25 ENERGY STORAGE↗
DOE OSTI2023

Development of a continuous synthesis process for carbamazepine using validated in-line Raman spectroscopy and kinetic modelling for disturbance simulation

Mitigation of failure modes in the continuous synthesis (CS) of a drug substance (DS) has the potential to widen the adoption of continuous manufacturing (CM) technologies by the pharmaceutical industry. Here, this work demonstrates the development of a robust continuous process for the synthesis of carbamazepine (CBZ), an essential medicine as per the World Health Organization (WHO), facilitated by kinetic modelling and monitored by in-line Raman spectroscopy. Accurate kinetic modelling and the use of validated process analytical technology (PAT) models for quantitative measurement were found to play an important role in developing CS of drug substances. Kinetic data for the formation of CBZ from iminostilbene (ISB) were collected by batch reaction sampling and high-performance liquid chromatography (HPLC) analysis. A non-linear solver and iterative method was applied to determine two sets of Arrhenius parameters simultaneously for the reaction system by minimizing the standard error of the model fit. The start-up and dynamic equilibrium stages for the CS of CBZ using a continuous stirred tank reactor (CSTR) were modelled based on the batch kinetic data and employed to optimize conversion and simulate process disturbances. An in-line Raman spectroscopy method was successfully developed, validated, and integrated to determine the concentrations of CBZ and ISB within the operating range for the CS. The CS kinetic model was evaluated experimentally from startup to dynamic equilibrium over 10 residence times with monitoring by HPLC and in-line Raman spectroscopy. The developed kinetic model in tandem with in-line Raman spectroscopy successfully predicted disturbances due to changes in process variables and can serve as a useful tool in the future design of advanced process control strategies for the continuous synthesis of CBZ.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Spatially and temporally resolved plasma parameter estimations of laser heated MagLIF relevant gas pipes at NIF

The ability to control laser pre-heat is an integral part of the inertial confinement fusion concept known as Magnetized Liner Inertial Fusion. This process is studied at the National Ignition Facility (NIF) where 4 of the 192 laser beams are propagated through a 1-cm long gas cell where they deposit >20 kJ of energy into the gaseous fuel via inverse bremsstrahlung absorption. This process ionizes the gas, producing a plasma that follows behind the laser front and expands over the radius of the cell. Emission from this plasma, as viewed by a gated x-ray detector, can be used to build spatially and temporally resolved estimations of the pre-heat plasma's density and temperature profiles. This can then be used to estimate the plasma pressure, internal energy, and radiation losses. Estimations show the evolution of the plasma in magnetized and unmagnetized gas cells filled with ambient temperature neopentane (C5H12) +1% Ar, as well as unmagnetized cryogenically cooled (32 K) deuterium +1% Ne filled targets. This analysis shows the effects of initial gas-fill density, composition, and axial magnetization on the time-dependent plasma parameters. Previously, these parameters at the NIF had not been experimentally characterized, and these estimations provided a potential new means of testing radiation magneto-hydrodynamic predictive capability models. Results in unmagnetized targets have strong agreement with simulations. However, in targets with a 19 T applied axial magnetic field, this method yields electron temperatures up to 100% hotter than those predicted by HYDRA codes.

Bremsstrahlung↗
DOE OSTI2026

Findings from Large Bench-Scale Testing of Denitration Electrolyzers for the EDCGe Project

This report highlights the key findings and outcomes relevant to the processability of waste supernatant at Hanford using a denitration electrolyzer. The Electrosynthesis Company issued a Phase 1 report to the Savannah River National Laboratory (SRNL), summarizing the evaluation of large bench-scale denitration electrolyzers to support the electrochemical denitration and caustic generation (EDCGe) project. The Electrosynthesis Company’s report (attached as Appendix A) provides insights into the initial steps required to implement an electrolyzer system at Hanford. Phase 1 experiments focused on validating the denitration electrolyzer’s performance, operating parameters, and reaction products. The robustness of the electrochemical denitration process was demonstrated by two electrolyzer flow cell systems (a 100 cm 2 ElectroCell MP and a 150 cm 2 NESI NS01 cell), both of which achieved significant nitrate and nitrite removal (>50%) with a current efficiency of ~95% for both systems. Higher current densities (500 mA cm –2 ) improved nitrate and nitrite removal rates compared to lower current densities (333 mA cm –2 ), while maintaining a current efficiency of ~94%. The NS01 cell achieved a nitrate species removal rate of ~0.41 mol h –1 at 5 kA m –2 (equiv. to 500 mA cm –2 ). The primary reaction product was ammonia (NH 3 ), constituting 78.3–91.6% of the products (excluding OH – formation). NH 3 was predominantly retained in the catholyte liquid phase rather than being off-gassed. Additionally, the NS01 cell reported an NH 3 generation rate of ~0.36 mol h –1 at 5 kA m –2 . Other gas formation included ~7% N 2 , ~7% H 2 , and trace amounts of N 2 O. The estimated power requirement (extrapolated from the 0.015 m 2 cell data) for a full-scale denitration electrolyzer is approximated to be ~1.6 MW (DC-only) to treat 50% of nitrate and nitrite in a waste stream and generates ~2.1 kmol h –1 of NH 3 with an initial concentration of 4 M NO 3 – /NO 2 – at 300 gal h –1 . Simulated waste containing aluminate, carbonate, oxalate, and halogens exhibited no adverse effects on denitration performance. A preliminary experiment comparing alkaline anolyte (5 M NaOH) with a nickel based anode to acidic media (2 M H 2 SO 4 ) with a DSA-O 2 anode showed a lower operating voltage and generated less H 2 than the acid media. Maintaining a stable 5 M OH – concentration in the anolyte through periodic additions of caustic did not significantly impact denitration performance. This operational mode will be required for long-term experiments. All the experiments demonstrated that electrochemical denitration is a promising approach for treating nitrate and nitrite in simulated waste streams, achieving significant conversion and robustness across varying experimental conditions and electrochemical cell configurations. Lastly, the ability to generate a nearly pure NH 3 stream may prove advantageous for processing at other locations within the Hanford site.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Radial-velocity Precision of ESPRESSO Through the Analysis of the Solar Twin HIP 11915

Different stellar phenomena affect radial velocities (RVs), causing variations large enough to make it difficult to identify planet signals from the stellar variability. RV variations caused by stellar oscillations and granulation can be reduced through some methods, but the impact of rotationally modulated magnetic activity on RV, due to stellar active regions, is harder to correct. New instrumentation promises an improvement in precision of one order of magnitude, from about 1 m s{sup -1} to about 10 cm s{sup -1}. In this context, we report our first results from 24 spectroscopic Echelle SPectrograph for Rocky Exoplanets and Stable Spectroscopic Observations (ESPRESSO)/Very-Large Telescope observations of the solar twin star HIP 11915, spread over 60 nights. We used a Gaussian Process approach and found for HIP 11915 a RV residual rms scatter of about 20 cm s{sup -1}, representing an upper limit for the performance of ESPRESSO.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

High-Voltage CMOS Active Pixel Sensor

The high-voltage CMOS (HVCMOS) sensors are a novel type of CMOS active pixel sensors for ionizing particles that can be implemented in CMOS processes with deep n-well option. The pixel contains one sensor electrode formed with a deep n-well implanted in a p-type substrate. CMOS pixel electronics, embedded in shallow wells, are placed inside the deep n-well. By biasing the substrate with a high negative voltage and by the use of a lowly doped substrate, a depleted region depth of at least 30 µm can be achieved. The electrons generated by a particle are collected by drift, which induces fast detectable signals. This publication presents a 4.2-cm 2 large HVCMOS pixel sensor implemented in a commercial 180-nm process on a lowly doped substrate and its characterization.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

Graphite Intercalation Compounds Derived by Green Chemistry as Oxygen Reduction Reaction Catalysts

Precious group metal (PGM) catalysts such as Pt supported on carbon supports are expensive catalysts utilized for the oxygen reduction reaction (ORR) due to their unmatched catalytic activity and durability. As an alternative, PGM-free ORR electrocatalysts that offer respectable catalytic activity are being pursued. Most of the notable PGM-free catalysts are obtained either from a bottom-up approach synthesis utilizing nitrogen-rich polymers as building blocks, or from a top down approach, where nitrogen and metal moieties are incorporated to carbonaceous matrixes. The systematic understanding of the origin of catalytic activity for either case is speculative and currently employed synthesis techniques typically generate large amounts of hazardous waste such as acids, oxidizing agents, and solvents. Herein, for the first time, we investigate the catalytic activity of graphite-based materials obtained via intercalation strategies that minimally perturb the graphitic backbone. Here, our outlined approaches demonstrate initial efforts to not only elucidate the role of each element but also significantly reduce the use of hazardous chemicals, which remains a pressing challenge. Graphite intercalation compounds (GIC) were obtained using fewer steps and solvent-free processes. X-ray diffraction and Raman results confirm the successful intercalation of FeCl 3 between graphite layers. Electrochemical data shows that the ORR performance of FeCl 3 -intercalated GIC displays slight improvement where the onset potential reaches 0.77 V vs RHE in alkaline environments. However, expansion of the graphite and solvent-free incorporation of iron and nitrogen moieties resulted in a significant increase in ORR activity with onset potential to 0.89 V vs RHE, a maximum half-wave of 0.72 V vs RHE, and a limiting current of about 2.5 mA cm –2 . We anticipate that the use of near solvent-free processes that result in a high yield of catalysts along with the fundamental insight into the origin of electrochemical activity will tremendously impact the methodologies for developing next-generation ORR catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Methanediol from cloud-processed formaldehyde is only a minor source of atmospheric formic acid

Atmospheric formic acid is severely underpredicted by models. A recent study proposed that this discrepancy can be resolved by abundant formic acid production from the reaction ( 1 ) between hydroxyl radical and methanediol derived from in-cloud formaldehyde processing and provided a chamber-experiment-derived rate constant, k 1 = 7.5 × 10 −12 cm 3 s −1 . High-level accuracy coupled cluster calculations in combination with E,J -resolved two-dimensional master equation analyses yield k 1 = (2.4 ± 0.5) × 10 −12 cm 3 s −1 for relevant atmospheric conditions ( T = 260–310 K and P = 0–1 atm). We attribute this significant discrepancy to HCOOH formation from other molecules in the chamber experiments. More importantly, we show that reversible aqueous processes result indirectly in the equilibration on a 10 min. time scale of the gas-phase reaction HCHO + H 2 O ⇌ HOCH 2 OH (2) with a HOCH 2 OH to HCHO ratio of only ca . 2%. Although HOCH 2 OH outgassing upon cloud evaporation typically increases this ratio by a factor of 1.5–5, as determined by numerical simulations, its in-cloud reprocessing is shown using a global model to strongly limit the gas-phase sink and the resulting production of formic acid. Based on the combined findings in this work, we derive a range of 1.2–8.5 Tg/y for the global HCOOH production from cloud-derived HOCH 2 OH reacting with OH. The best estimate, 3.3 Tg/y, is about 30 times less than recently reported. The theoretical equilibrium constant K eq (2) determined in this work also allows us to estimate the Henry’s law constant of methanediol (8.1 × 10 5 M atm −1 at 280 K).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Dry-processed electrodes enabled by polytetrafluoroethylene fibrillation for high-performance lithium-ion batteries

The dry processing technique of polytetrafluoroethylene (PTFE) fibrillation offers significant advancements in cost reduction, environmental impact, and electrochemical performance. Dry processing alone allows for ∼ 20–60% cost reduction and increases of up to 40 mg cm⁻2 of areal loading – it typically comes at a reduction of rate capability. By leveraging the network structure of fibers, this method enhances rate capability and cycling performance, providing a compelling alternative to the conventional and currently predominant wet processing. The review delves into PTFE fibrillation mechanisms and examines critical influencing factors including material properties and processing parameters. It also discusses challenges associated with the electrodes fabricated by PTFE fibrillation, including structural instability due to insufficient PTFE fibrillization, compromised electrical conductivity from an insufficient conductive network, inhomogeneous dispersion resulting from the absence of solvents, restricted ionic transport due to increased electrode thickness, inadequate adhesion to current collector because of low surface energy of PTFE, electrochemical degradation due to low lowest unoccupied molecular orbital (LUMO) level of PTFE, particle damage during processing and environmental concerns related PTFE being a perfluoroalkyl and polyfluoroalkyl substances (PFAS). Recent research innovations aimed at mitigating these issues, their application in beyond-lithium batteries, and future research directions are thoroughly discussed.

Park, Hyunji↗
DOE OSTI2026

Proliferated Resilient Economical Half-Meter Aperture Space Telescopes (PREEMPT)

The PREEMPT LDRD was motivated by a major national need for better space-based imaging systems that are both high performing and affordable for the US Government. Current optical payloads for intelligence, surveillance and reconnaissance (ISR) and space domain awareness (SDA) missions can cost hundreds of millions of dollars and take years to develop, which makes it difficult to build the large constellations required for persistent, world-wide coverage. To address this, the team aimed to advance a different kind of large-aperture (>25 cm) telescope, called a monolithic telescope, in which key optical surfaces are built into a single piece of fused silica. This design greatly reduces payload and spacecraft complexity, the need for precision focus actuators, improves mechanical and thermal robustness, and lowers cost when compared with traditional Cassegrain telescopes that rely on many precisely aligned components. The project focused on five primary thrusts. The first thrust was to advance the concept of a V10, 25 cm, monolithic telescope forward from optical design to flight-ready stage. This was accomplished in partnership with Optimax, who delivered the first test unit in the early stages of the LDRD. The team developed several technologies necessary for this optic to be integrated into a flight demonstration. These include carbon fiber housings, highly detailed structural and thermal models and stress-reducing elastic averaging Hirth groove designs. These technologies resulted in a successful maturation of the optic, which is now slated to fly in late 2026/early 2027 for a demonstration mission. The second thrust was to advance the manufacturability of these optics. In collaboration with NIF’s optical manufacturing shop, we reduced polishing time from 480 hours to 65 hours through the implementation of optimized processes and new tools. The NIF team utilized a conceptual V8 (18 cm) optic to demonstrate this optimization, though it can be applied to the rest of the monolithic optic portfolio. Third, the team developed the first conceptual V20 (50 cm) payload, which is slated to be the next generation of LLNL optical payload systems. A set of structural, dynamic and thermal simulations were performed to identify potential challenges in the future development of this payload. Early-stage simulations suggest the payload is feasible, though thermal management will be the key focus area to maintain optimal performance. Fourth, a non-linear model of Viton was developed, to further enhance the reliability of our structural and dynamic models for future payloads. Viton acts as the primary interface material between the optic and its housing. Lastly, the team focused on successfully displaying the feasibility of using additively manufactured metal composites for optical space payloads. The team successfully demonstrated layer by layer deposition of Al-SiC composites, which have highly tunable structural and coefficient of thermal expansion (CTE) properties. These are crucial for optical payloads because CTE mismatch is one of the causes for degraded optical performance for telescopes in orbit. Overall, the work showed that monolithic telescopes could become a practical, lower-cost path to high-resolution space imaging for both national security and scientific missions.

42 ENGINEERING↗
DOE OSTI2025

Tomographic Volumetric Additive Manufacturing of Silica Glass with In Situ Error Calculation and Projection Tiling

The optical, thermal, and chemical properties of glass make it an ideal material for use in a wide range of applications, from optics and chemistry reactionware to consumer products. Tomographic volumetric additive manufacturing (tVAM) creates 3D objects by selectively gelling material within a rotating vial of photo-sensitive material by exposure to a series of tomographically-determined images. Here, in this study, tVAM is investigated for fabrication of complex, centimeter-scale, 3D silica glass parts. By optimizing the post-processing procedure, fully-dense glass parts with up to 2 cm 2 cross sectional area are achieved. The changes in optical properties during printing are leveraged for in situ metrology during printing, and the non-Newtonian nature of the glass-filled photoresin system to facilitate larger fabrication volumes via tiled projections. Printed structures are finally demonstrated for applications as MEMS components, optics, fluidics, and consumer products.

Materials science↗