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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

A conformal heat-drying direct ink writing 3D printing for high-performance lithium-ion batteries

High areal capacity electrodes hold great potential for high-energy density lithium-ion batteries (LIBs), but their poor electrochemical kinetics limit their power density. Here, in this study, high areal capacity 3D-structured LiNi 0.8 Mn 0.1 Co 0.1 O 2 cathodes (4.3 mAh cm -2 ) are prepared via 3D printing with a manner of direct ink writing. The electrodes had an enlarged electrode–electrolyte contact area, shortened diffusion pathway, and reduced intercalation-induced stress, thereby delivering enhanced rate capability and cyclability in LIBs, which is 143.6 mAh g -1 at 3C and a 60.2 % capacity retention over 800 cycles at 1C. Moreover, at electrode level, the 3D-NMC exhibits an energy and power densities of 313.1 Wh kg -1 and 657.9 W kg -1 , respectively. Furthermore, the theoretical calculation suggests that reducing the gap width will be highly beneficial to the energy and power densities. This work establishes a milestone in understanding the cycling effect on the electrode local structure, including the void area and the LiNi 0.8 Mn 0.1 Co 0.1 O 2 region, which confirms the effectiveness of 3D printing for electrode preparation.

25 ENERGY STORAGE↗
DOE OSTI2021

Fabrication and Characterization of Single-Particle Compacts

The programmatic objective of the advanced low enriched uranium (aLEU) fuel Project within the Office of Nonproliferation Research and Development (NA-22) is to advance the development of nuclear reactor designs, fuel materials, and fabrication technologies capable of meeting a number of challenging customer requirements, including reactor stability, extended lifetime, and power density without refueling, while using only low-enriched uranium (i.e., less than 20% enrichment of 235 U). The tandem requirements of delivering sufficient power density and maintaining fuel performance over the course of a multidecade fuel lifetime tightly constrain the field of potential fuel options. Monolithic fuel forms (e.g., fuel pellets) provide maximized density of fissile material, but they may face challenges in maintaining their structure and performance over the long reactor lifetimes envisioned in this program. Dispersion fuel forms with an inert matrix provide enhanced long-term stability but sacrifice fissile material density, and they may not provide sufficient power density over the reactor lifetime with the limit of low enrichment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

High-temperature analysis of optical coupling using AlGaAs/GaAs LEDs for high-density integrated power modules

A low-temperature co-fired ceramic (LTCC)-based optocoupler design is demonstrated as a possible solution for optical isolation in high-density integrated power modules. The design and fabrication of LTCC based package are discussed. Commercially available aluminum gallium arsenide/gallium arsenide (AlGaAs/GaAs) double heterostructure is used both as emitter and photodetector in the proposed optocoupler. A detailed study on the electroluminescence and spectral response of the AlGaAs/GaAs structure is conducted at elevated temperatures. The material figure of merit parameter, D*, is calculated in the temperature range 77–800 K. The fabricated optocoupler is tested at elevated temperatures, and the results are presented.

42 ENGINEERING↗
DOE OSTI2022

NMR and Theoretical Study of In-Pore Diffusivity of Ionic Liquid–Solvent Mixtures

We report despite having a lower energy density than common batteries, electric double-layer capacitors (EDLCs) offer several advantages for high-power applications, including high power density, quick charge and discharge time, and long cycle life. Room-temperature ionic liquids (RTILs) have been intensely studied as promising electrolytes for applications in ELDCs because of their wide potential window, low volatility, as well as thermal and chemical stability. The main deficiency of neat RTILs in such applications is the sluggish diffusivity, which restricts the EDLCs’ power density. To alleviate the slow diffusivity, RTILs can be used in a mixture with organic solvents. In this study, we applied two-dimensional exchange nuclear magnetic resonance spectroscopy (2D EXSY NMR) and molecular dynamics (MD) simulations to investigate the diffusivity of anions of an RTIL, namely, 1-butyl-3-methyl-imidazolium bis(trifluoromethylsulfonyl)imide (BMIM + –TFSI – ), dissolved in five different organic solvents, in the micropores of activated carbon. We determined that the relative concentrations of ions in solutions in the micropores were higher than those in the bulk solutions and were also solvent-dependent. The ion diffusivities in the pores were found to be almost 2 orders of magnitude slower than in the bulk solutions, with methanol showing the largest relative disparity. These results suggested that the interactions of solvents with the activated carbon are critical not only to the power density of EDLCs but also to the energy density. The comparisons of ion diffusivities between the experiments and the MD simulations suggest the need to consider also the surface functionalities of activated carbon for the simulation of ion diffusion in the micropores of activated carbon.

electric double layer capacitors↗
DOE OSTI2022

Power Electronics Thermal Management

This project conducts research to develop new power electronics thermal management technologies to increase power density, enable high WBG temperature operation, and decrease cost. One of the main challenges to achieving high power densities is associated with packaging of high-temperature (up to 250 degrees C) WBG devices near lower-temperature-rated components (e.g., electrical boards and capacitors). Additionally, the high junction temperatures of the WBG devices will result in large temperature gradients through the power module layers, which will present reliability challenges and require higher-temperature substrates and bonding materials.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Development of Solid Synchronous Reluctance Rotors With Multi-Material Additive Manufacturing

Synchronous reluctance (SynR) machines are promising rare-earth material-free alternatives to permanent magnet machines. However, structural challenges limit their operating speed and power density. This paper proposes and investigates multi-material additive manufacturing (MMAM) as a key-enabler to realize power-dense and high-speed SynR machines. It does so by proposing designs that guide magnetic flux through solid rotors realized by selective placement of magnetic and non-magnetic materials. To explore this concept, first, material samples are additively manufactured and experimentally characterized to assess the structural and magnetic properties that can be expected for the proposed rotors. Second, the design space of each rotor type is explored using these measured properties within finite element analysis. The results reveal that MMAM can enable fabrication of SynR motors with power density levels that are at the leading edge of all conventional electric machine topologies. It is shown that tip speeds in excess of 300 m/s can be achieved, resulting in 3-4x improvement in power density over conventional SynR motors. A solid SynR rotor is printed in an experimental MMAM laser powder bed fusion system. The rotor is paired with an existing stator to create a functional SynR motor with a saliency ratio of 2.59 and torque rating of 4.15 Nm. This is the first publication of a SynR rotor prototype constructed via MMAM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

High Performance Flow Battery with Inexpensive Inorganic Reactants: DAYS Program (Final Technical Report)

RTRC’s DAYS projects focused on new flow battery (FB) chemistries for long duration energy storage: one that pairs aqueous polysulfide and manganese active materials in strongly alkaline electrolytes (S/Mn); another explores ligand-modified metal (LMM) chemistries in moderate pH electrolyte conditions. The S/Mn chemistry met durability targets by running for over 500 cycles and 1000 hours. Combined with this durability, power densities of up to 60 mW/cm2 at 80% round-trip efficiency, and exceptionally low-cost S and Mn active materials, the S/Mn FB offers a pathway to meeting the <5¢/kW-hr levelized cost of storage (LCOS) target first proposed by the DAYS Program and accepted by the DOE Energy Storage Grand Challenge. The LMM chemistry made impressive progress as well, including durability tests that retained performance over 600 hours of cycling. Cell optimization allowed this chemistry to operate as high as 500 mW/cm2 at 80% round-trip efficiency, nearly 10x the power density of S/Mn and comparable to the power density achieved in RTRC’s flow battery stacks using acidic vanadium battery solutions. This enabled the LMM chemistry to also offer a pathway to the <5¢/kW-hr LCOS DAYS and DOE targets. The promising results from the LMM chemistry have led to a recent DOE AMO award to advance the technology to a 5 kW, 20 kW-hr prototype.

25 ENERGY STORAGE↗
DOE OSTI2024

Performance of plane wavefront Fizeau interferometers in power spectral density measurements with tilted plane optics

Binary pseudo-random array (BPRA) test samples are useful devices for calibrating the instrument transfer function (ITF) of Fizeau interferometers, interferometric microscopes, and other optical and non-optical surface and wavefront metrology instruments. The intrinsic white noise character of the power spectral density (PSD) function of the BPRA pattern simplifies the extraction of the ITF from the measured PSD. The ITF determined in a dedicated calibration experiment can be used to reconstruct the surface height profile from the measured data, effectively enhancing the instrument’s spatial resolution. For a high confidence reconstruction procedure, a reliable analytical model of the IFT is desirable. Usually, the model accounts for the contributions to the ITF related the imperfections of the instrument’s optical and detector systems. Here, we experimentally demonstrate that in the case of surface height metrology with Fizeau interferometers, the PSD measurements and, therefore, the efficacy of the ITF calibration of the tool, are strongly affected by the instrument data acquisition and processing procedures, as well as by the shape of the optic under test and its alignment with respect to the interferometer.

Yashchuk, V V↗
DOE OSTI2024

Stable and high voltage and power output of CEA-MFCs internally connected in series (iCiS-MFC)

The voltage output of a single MFC is normally less than 0.8 V, often less than 0.3 V at maximum power output, which greatly limits the application of MFCs. When MFCs are scaled up, however, increasing reactor size has typically resulted in decreased power density. In this study, we developed a novel MFC configuration that contains multiple cloth electrode assemblies in which the MFCs were internally connected in series (iCiS-MFC). The iCiS-MFC, equivalent to 3 CEA-MFCs, produced a high voltage output over 1.8 V and a maximum power density of 3.5 W m -2 using carbon cloth cathodes containing activated carbon as the catalyst. This power density is 6% higher than that reported for a similar smaller CEA-MFC, indicating that power can be maintained during scale-up with a greater than 33-fold increase in total cathode surface area and greater than 20-fold increase in reactor volume. High stability was also demonstrated based on the performance of the iCiS-MFC over a period of one year of operation. The high power and stability is likely due, in part, to a more efficient means of current collection through the internal series connection, which also avoids the use of expensive current collectors. These results clearly demonstrate the great potential of this MFC design for further scaling-up.

25 ENERGY STORAGE↗
DOE OSTI2025

A novel approach for large-scale wind energy potential assessment

Increasing wind energy generation is central to grid decarbonization, yet methods to estimate wind energy potential are not standardized, leading to inconsistencies and even skewed results. This study aims to improve the fidelity of wind energy potential estimates through an approach that integrates geospatial analysis and machine learning (i.e., Gaussian process regression). We demonstrate this approach to assess the spatial distribution of wind energy capacity potential in the Contiguous United States (CONUS). We find that the capacity-based power density ranges from 1.70 MW/km2 (25th percentile) to 3.88 MW/km2 (75th percentile) for existing wind farms in the CONUS. The value is lower in agricultural areas (2.73 ± 0.02 MW/km2, mean ± 95 % confidence interval) and higher in other land cover types (3.30 ± 0.03 MW/km2). Notably, advancements in turbine manufacturing could reduce power density in areas with lower wind speeds by adopting low specific-power turbines, but improve power density in areas with higher wind speeds (>8.35 m/s at 120m above the ground), highlighting opportunities for repowering existing wind farms. Wind energy potential is shaped by wind resource quality and is regionally characterized by land cover and physical conditions, revealing significant capacity potential in the Great Plains and Upper Texas. The results indicate that areas previously identified as hot spots using existing approaches (e.g., the west of the Rocky Mountains) may have a limited capacity potential due to low wind resource quality. Improvements in methodology and capacity potential estimates in this study could serve as a new basis for future energy systems analysis and planning.

Dai, Tao↗
DOE OSTI2022

Pressure–strain interaction. I. On compression, deformation, and implications for Pi-D

The pressure–strain interaction describes the rate per unit volume that energy is converted between bulk flow and thermal energy in neutral fluids or plasmas. The term has been written as a sum of the pressure dilatation and the collisionless analog of viscous heating referred to as Pi–D , which isolates the power density due to compressible and incompressible effects, respectively. It has been shown that Pi–D can be negative, which makes its identification as collisionless viscous heating troubling. We argue that an alternate decomposition of pressure–strain interaction can be useful for interpreting the underlying physics. Since Pi–D contains both normal deformation and shear deformation, we propose grouping the normal deformation with the pressure dilatation to describe the power density due to converging/diverging flows, with the balance describing the power density purely due to shear deformation. We then develop a kinetic theory interpretation of compression, normal deformation, and shear deformation. We use the results to determine the physical mechanisms that can make Pi–D negative. We argue that both decompositions can be useful for the study of energy conversion in weakly collisional or collisionless fluids and plasmas, and implications are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Coupled neutronics, thermochemistry, corrosion modeling and sensitivity analyses for isotopic evolution in molten salt reactors

This study presents a computational methodology for analyzing isotopic evolution and associated uncertainties in molten salt reactors (MSRs), focusing on both fluoride- and chloride-based fuel salts. The primary goal is to enhance the understanding of isotopic behavior in MSRs and provide data to support future experimental efforts. The methodology integrates transport-coupled depletion calculations using OpenMC, equilibrium thermodynamics modeling with Thermochimica, and a corrosion model. Sensitivity analyses are performed to evaluate the impact of power density, air ingress, and humidity content on isotopic evolution in MSR concepts. This study examines representative F- and Cl-based MSR designs, highlighting the dominant influence of power density on isotopic composition, which significantly affects isotope production and depletion rates, accounting for approximately 76% of the observed variance in element concentration. Air ingress and humidity content also affect the redox potential, solubility of heavier elements, and corrosion rates, thereby altering the expected isotopic evolution in the reactor. On average, air ingress accounts for around 17% of the variance in element concentrations, while humidity explains the remaining 7%. These variances differ significantly from element to element, depending on the element’s role in depletion, redox potential evolution, and galvanic corrosion. The findings indicate that power density, air ingress, and humidity content are all critical factors for optimizing reactor design and operational strategies. Furthermore, the study provides expected ranges for key impurities in the fuel salt, which are crucial for guiding future experimental studies and refining MSR designs. Finally, this study demonstrates the importance of modeling depletion coupled with the evolution of redox potential and chemical interactions in MSR fuel salts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Development of High Bs Fe-Ni Based Metal Amorphous Nanocomposite by Optimization of Glass Forming Ability

A growing interest in electric vehicles challenges soft magnetic materials to improve efficiency and power density. Metal amorphous nanocomposites (MANCs) have lower coercivities and eddy current losses, allowing for greater efficiency and higher switching frequency. The later allows for high motor speeds and improved power density. However, commercially available and laboratory demonstrated MANCs have shortcomings. Fe-based MANCs, such as FINEMET have excellent magnetic properties, but mechanical properties limit their application in high speed electric motors (HSMs). Fe-Co based MANCs, such as HITPERM, have high saturation inductions and good mechanical properties, but elevated magnetostrictive losses. Co-based MANCs and more recent Fe-Ni based MANCs have low losses and good mechanical properties, but lower saturation inductions (1-1.2 T), that limit power density in HSMs. Recently, much work has explored improving saturation induction in MANCs by increasing the content of magnetic elements, which comes at the cost of glass-forming ability (GFA). These efforts where generally limited to trial and error testing. Additionally, all work to date has focused on Fe-based alloys. In this work, a method of using Thermocalc simulation to locate near-eutectic compositions has been applied to Fe-Ni based alloys. Minima in liquidus temperature and solidification range were found for a ternary composition range and used to identify compositions that retain good GFA as the percentage of magnetic elements is increased. The (Fe 70 Ni 30 ) x (B-Si-Nb) 100-x alloy system for x=82% and x=85% was explored by Thermocalc simulations. This is an increase in magnetic element content compared to previously developed x=80% alloys. 3 compositions in the x=82% system, and 1 alloy in the x=85% system where identified and successfully cast as amorphous ribbon. The amorphous nature of the ribbon was confirmed by a bend test and XRD. Magnetic testing was performed by PPMS to measure saturation induction and Curie temperature of the amorphous material. The Curie temperatures increased to 407-438 °C for the x=82% alloys, and 462 °C for the x=85% alloy. Saturation induction increased to 1.28-1.36 T for the x=82% alloy and 1.48 T for the x=85% alloy, which is a significant improvement over the ~370 °C Curie temperature and 1.2 T saturation of previous Fe-Ni alloy. Crystallization behavior was studied by XRD for the x=85% alloy, showing that crystallization process follows a 2-step process of Amorphous → BCC+FCC+Amorphous → BCC+FCC+Fe 3 B+Fe 23 B 6 . Post annealing magnetic properties were studied by strip testing, and saturation induction as high as 1.48 T was seen after optimal annealing. TEM was used to study structure of as cast and annealed material. 2 alloys with x=82% compositions were identified with an optimal crystalline size of 10-20 nm, while the x=85% alloy had this structure in the as cast state. This opens the possibility of using the alloy in the as cast state, without requiring annealing. In conclusion, alloys with good GFA and improved magnetic properties were identified by Thermocalc simulation.

Krimer, Yuval↗
DOE OSTI2021

Seismically Detecting Nuclear Reactor Operations Using a Power Spectral Density (PSD) Misfit Detector

To explore the ability to indirectly detect and attribute various operations conducted at a nuclear reactor using waveform data, we investigated the seismic signals recorded near the High Flux Isotope Reactor (HFIR) located at Oak Ridge National Laboratory in Oak Ridge, Tennessee. Specifically, we processed seismic data collected from a single seismoacoustic station, WACO, near the HFIR facility, and employed a power spectral density misfit detector to identify signals of interest and associate the detections with operational events. Initial results suggest that this method provides a promising means of regularly detecting at least 19 unique operations. Furthermore, with additional station deployment and more comprehensive data logs, we anticipate that future analysis will offer an additional means to seismically monitor nuclear reactors (such as HFIR) health and performance more accurately.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

The Silencing of U.S. Campuses Following the COVID-19 Response: Evaluating Root Mean Square Seismic Amplitudes Using Power Spectral Density Data

In response to the COVID-19 global pandemic, many populated and active regions have become deserted and show significant reductions in their background seismicity, especially campuses across the United States (U.S.). Seismic sensors located in the vicinity of or within U.S. campuses show that anthropogenic seismic noise remains elevated during the ordinary, nonpandemic, academic year, only subduing during periods of recess (e.g., winter break). Here, we use power spectral density (PSD) data computed by the Incorporated Research Institutions for Seismology Data Management Center for quality assessment to calculate root mean square (rms) amplitude and analyze the effects of the COVID-19 school closures. We processed and analyzed PSD data for 46 seismic stations located within 50 m of a U.S. university or college. Results show that 42 campus stations show an overall rms drop following a statewide school closure.

58 GEOSCIENCES↗
DOE OSTI2025

Overcoming the Conductance versus Crossover Trade-off in State-of-the-Art Proton Exchange Fuel-Cell Membranes by Incorporating Atomically Thin Chemical Vapor Deposition Graphene

Permeance–selectivity trade-offs are inherent to polymeric membranes. In fuel cells, thinner proton exchange membranes (PEMs) could enable higher proton conductance and increased power density with lower area-specific resistance (ASR), smaller ohmic losses, and lower ionomer cost. However, reducing thickness is accompanied by an increase in undesired species crossover harming performance and long-term efficiency. Here, we show that incorporating atomically thin monolayer graphene synthesized via scalable chemical vapor deposition (CVD) and tunable defect density into PEMs (Nafion, ~5–25 μm thick) can allow for reduced H 2 crossover (~34–78% of Nafion of a similar thickness) while maintaining adequate areal proton conductance for applications (>4 S cm –2 ). In contrast to most prior work using >50 μm symmetric Nafion sandwich structures, we elucidate the interplay of graphene defect density and Nafion proton transport resistance on the performance of Nafion|graphene composite membranes and find high-quality low-defect density CVD graphene (G) supported on Nafion 211 (~25 μm); i.e., N211|G has a high areal proton conductance (~6.1 S cm –2 ) and the lowest H 2 crossover (~0.7 mA cm –2 ). Fully functional centimeter-scale N211|G fuel-cell membranes demonstrate performance comparable to that of state-of-the-art Nafion N211 at room temperature as well as standard operating conditions (~80 °C, ~150–250 kPa-abs) with H 2 /air (power density ~0.57–0.63 W cm –2 ) and H 2 /O 2 feed (power density ~1.4–1.62 W cm –2 ) and markedly reduced H 2 crossover (~53–57%).

25 ENERGY STORAGE↗