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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Graphite Oxidation Rate Study on ET-10 and ETU-10 Grades - Task 4: QA Support and Testing for Structural Graphite Oxidation

INL performed targeted oxidation tests to measure oxidation rates for samples of ET-10 and ETU-10 graphite under CRADA No. 21CRA22 Mod. 3, Annex A, “Tritium Testing to Support Kairos Power Advanced Reactor Demonstration” (04/02/2024). All testing was conducted within INL’s Carbon Characterization Laboratory (CCL) using test standard ASTM D7542-21 "Standard Test Method for Air Oxidation of Carbon and Graphite in the Kinetic Regime" [ASTM International, 2021]. Kairos Power provided all test specimens through its graphite vendor Ibiden, Inc. to INL and ASTM specimen specified dimensions. Information within this report only provides the Arrhenius oxidation rate plots as a function of temperature for each graphite grade tested. The raw mass loss per time data will be provided on the Nuclear Data Management and Analysis System (NDMAS) portal located on the INL information system.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Pulse Shaping and Matched Filters for EMAT Communication System

Electromagnetic acoustic transducer (EMAT) is used as a noncontact sensor for acoustic communication in a stainless-steel plate channel. The acoustic wave multipath propagations within the channel cause intersymbol interference (ISI). ISI highly degrades the signal-to-noise ratio (SNR). The poor SNR will result in a low bitrate and a high bit error rate (BER). In this study, a test platform is designed to estimate the performance of the EMAT communication system. Two periodic-permanent-magnet (PPM) EMATs are designed to be used as a transmitter and a receiver. EMAT generates shear-horizontal (SH) wave propagating through the stainless-steel plate channel. We present methods to minimize the ISI effect and recover the message embedded in the received signals hampered by interference, reverberation and multipath effects. The root raised cosine (RRC) filters are introduced as a pulse-shaping filter for transmission and a matched filter for receiving messages. Amplitude Shift Keying (ASK) method is used for modulating the transmitted binary message. The pulse shaping and matched filters reduced the ISI caused by the undesirable multipath effect significantly to the extent that a 5-kbps bitrate can be achieved without any error (zero BER).

Huang, Xin↗
DOE OSTI2022

Modelling and Experimental Validation of Improved Performance of Lithium-Ion Batteries Having Thick Electrodes with Laser-Ablated Micro-Structures

For widespread adoption of electric vehicles, lithium-ion batteries (LiBs) need to achieve energy densities of >275 Wh/kg, cost less than $100/Wh, and charge to more than 80% capacity within 15 minutes. Increasing the battery electrode thicknesses is one way to increase cell energy densities while also saving on cell manufacturing cost by increasing the ratio of electrode active material to inactive material within each cell. However, increased electrode loading is often accompanied by decreased Li+-ion diffusion across the full thick electrodes. This leads to significant cell polarization that prevents full capacity utilization and accelerates cell degradation, especially at fast charging/discharging rates. The introduction of secondary pore networks in thick battery electrodes alleviates some of the trade-offs between energy and power performance. These microstructures provide low tortuosity pathways for facile Li+-ion diffusion deep into the thick electrodes, diminishing detrimental concentration gradients within the cell. Ultrafast-pulsed laser ablation is a promising method to introduce micro pores or channels in thick battery electrodes as it allows for precise control of pattern geometries, results in minimal damage to the electrode and can be introduced into existing roll-to-roll electrode manufacturing lines. Herein, the limitations of thick planer electrodes and the advanced predictive models to identify optimal electrode patterns for improved cycling performance will be presented. The impact of electrode laser patterning to create secondary pore networks also will be discussed. Materials characterization techniques (SEM-EDS, XRD) were used to explore the affect ultrafast laser ablation had on the electrode materials’ morphology and structure. The improvements in the patterned electrodes’ electrochemical cycling performances and degrees of wetting will be compared to a pristine baseline case. Finally, the discrepancies between experimentally obtained data and model predictions will be explained.

DIRECT ENERGY CONVERSION,ENERGY STORAGE↗
DOE OSTI2017

Determination of a Generic Human Error Probability Distribution, Part 2: A Dynamic SPAR-H Example Application

Humans are an integral part of a nuclear power plant (NPP) from its construction, to its everyday maintenance and operation. In the nuclear industry there are many approaches to quantifying component reliability, which is called probability risk assessment (PRA). In PRA there are two considerations given to the quantification, static and dynamic. Static is quantified before or after an operation; and dynamic is time dependent, in that the probability changes as real time data are provided. In PRA, the importance of the components is calculated, but what of the importance of the human component? There are several methods for human reliability analysis (HRA), which include but are not limited to: THERP, ATHEANA, CREAM, SPAR-H, ASEP, and SLIM. Each of these methods aims to provide a more accurate and objective human error probability (HEP) quantification. Of the methods listed above, ASEP, THERP, and SPAR-H are all inextricably linked. The Standardized Plant Analysis Risk-Human Reliability Analysis (SPAR-H) method was generated to better generalize the Technique for Human Error Rate Prediction (THERP) and Accident Sequence Precursor (ASEP). THERP is mapped to specific scenario templates, and ASEP is a simplified screening method, while SPAR-H employs generalizations to describe the spectrum of human behavior while maintaining the same theoretical underpinnings. SPAR-H is a well-known and accepted HRA method that uses performance shaping factors (PSFs) to classify inputs to the human component. PSFs capture a wide variety of input data, including plant status, crew dynamics, task description, and psychological aspects of the human operator. Current efforts have been focused to further generalize SPAR-H in to a dynamic framework. These methods can fit into dynamic NPP simulations such as RAVEN / RELAP-7. In order to do this, a dynamic methodology is applied to model the human as would be applied to the components. This method is applied in part one in the accompanying paper.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Effects of scan rate on the corrosion behavior SS 304 stainless steel in the nanofluid measured by Tafel polarization methods

The Effects of scan rate on the Tafel polarization curve that is obtained to determine corrosion rate are conducted. The tafel polarization curves are obtained at different scan rates for Stainless Steel 304 in nanofluids contain 0.01 gpl nano particle ZrO{sub 2}. The corrosion stainless steel in nanofluid contains adm+0.01 gpl ZrO{sub 2} nanoparticles at different scan rate was performed by Tafel polarization. The results show that according corrosion potential examination of the stainless steel in nanofluid media 0.01gpl ZrO{sub 2} nanoparticle was actively corroded. The value of cathodic Tafel slope stainless steel in nanofluid at different scan rate relatively unchanged after polarization testing. Mean while the value of anodic Tafel slope stainless steel in nanofluid increase at different scan rate. The results of Tafel polarization technique show that corrosion rate of stainless steel in nanofluid increase with increasing scan rate. X ray diffraction examination of stainless steel after Tafel polarization depict that γ Fe phase is major phase in the surface of alloy.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2016

Investigating ion recombination effects in a liquid-filled ionization chamber array used for IMRT QA measurements

Purpose: PTW’s Octavius 1000 SRS array performs IMRT quality assurance (QA) measurements with liquid-filled ionization chambers (LICs) to allow closer detector spacing and higher resolution, compared to air-filled QA devices. However, reduced ion mobility in LICs relative to air leads to increased ion recombination effects and reduced collection efficiencies that are dependent on Linac pulse frequency and pulse dose. These pulse parameters are variable during an IMRT delivery, which affects QA results. In this study, (1) 1000 SRS collection efficiencies were measured as a function of pulse frequency and pulse dose, (2) two methods were developed to correct changes in collection efficiencies during IMRT QA measurements, and the effects of these corrections on QA pass rates were compared. Methods: To obtain collection efficiencies, the OCTAVIUS 1000 SRS was used to measure open fields of varying pulse frequency, pulse dose, and beam energy with results normalized to air-filled chamber measurements. Changes in ratios of 1000 SRS to chamber measured dose were attributed to changing collection efficiencies, which were then correlated to pulse parameters using regression analysis. The usefulness of the derived corrections was then evaluated using 6 MV and 10FFF SBRT RapidArc plans delivered to the OCTAVIUS 4D system using a TrueBeam (Varian Medical Systems) linear accelerator equipped with a high definition multileaf collimator. For the first correction, MATLAB software was developed that calculates pulse frequency and pulse dose for each detector, using measurement and DICOM RT Plan files. Pulse information is converted to collection efficiency, and measurements are corrected by multiplying detector dose by ratios of calibration to measured collection efficiencies. For the second correction the MU/min in the daily 1000 SRS calibration was chosen to match the average MU/min of the volumetric modulated arc therapy plan. Effects of the two corrections on QA results were examined by performing 3D gamma analysis comparing predicted to measured dose, with and without corrections. Results: Collection efficiencies correlated linearly to pulse dose, while correlations with pulse frequency were less defined, generally increasing as pulse frequency decreased. After complex MATLAB corrections, average 3D gamma pass rates improved by [0.07%,0.40%,1.17%] for 6 MV and [0.29%,1.40%,4.57%] for 10FFF using [3%/3 mm,2%/2 mm,1%/1 mm] criteria. Maximum changes in gamma pass rates were [0.43%,1.63%,3.05%] for 6 MV and [1.00%,4.80%,11.2%] for 10FFF using [3%/3 mm,2%/2 mm,1%/1 mm] criteria. On average, pass rates of simple daily calibration corrections were within 1% of complex MATLAB corrections. Conclusions: OCTAVIUS 1000 SRS ion recombination effects have little effect on 6 MV measurements. However, the effect could potentially be clinically significant for higher pulse dose unflattened beams when using tighter gamma tolerances, especially when small aperture sizes are used, as is common for SRS/SBRT. In addition, ion recombination effects are strongly correlated to changing MU/min, therefore MU/min used in daily 1000 SRS calibrations should be matched to the expected average MU/min of the IMRT plan.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2014

Solution of relativistic quantum optics problems using clusters of graphical processing units

Numerical solution of relativistic quantum optics problems requires high performance computing due to the rapid oscillations in a relativistic wavefunction. Clusters of graphical processing units are used to accelerate the computation of a time dependent relativistic wavefunction in an arbitrary external potential. The stationary states in a Coulomb potential and uniform magnetic field are determined analytically and numerically, so that they can used as initial conditions in fully time dependent calculations. Relativistic energy levels in extreme magnetic fields are recovered as a means of validation. The relativistic ionization rate is computed for an ion illuminated by a laser field near the usual barrier suppression threshold, and the ionizing wavefunction is displayed.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2015

TU-F-CAMPUS-J-05: Fast Volumetric MRI On An MRI-Linac Enables On-Line QA On Dose Deposition in the Patient

Purpose: The introduction of the MRI-linac in radiotherapy brings MRI-guided treatment with daily plan adaptions within reach. This paradigm demands on-line QA. With its ability to perform continuous volumetric imaging in an outstanding soft-tissue contrast, the MRI- linac promises to elucidate the dose deposition process during a treatment session. Here we study for a prostate case how dynamic MRI combined with linac machine parameters and a fast dose-engine can be used for on-line dose accumulation. Methods: Prostate imaging was performed in healthy volunteer on a 1.5T MR-scanner (Philips, Best, NL) according to a clinical MR-sim protocol, followed by 10min of dynamic imaging (FLASH, 4s/volume, FOV 40×40×12cm{sup 3}, voxels 3×3×3mm{sup 3}, TR/TE/α=3.5ms/1.7ms/5°). An experienced radiation oncologist made delineations, considering the prostate CTV. Planning was performed on a two-compartment pseudoCT (air/water density) according to clinical constraints (77Gy in PTV) using a Monte-Carlo (MC) based TPS that accounts for magnetic fields. Delivery of one fraction (2.2Gy) was simulated on an emulator for the Axesse linac (Elekta, Stockholm, SE). Machine parameters (MLC settings, gantry angle, dose rate, etc.) were recorded at 25Hz. These were re-grouped per dynamic volume and fed into the MC-engine to calculate a dose delivered for each of the dynamics. Deformations derived from non-rigid registration of each dynamic against the first allowed dose accumulation on a common reference grid. Results: The DVH parameters on the PTV compared to the optimized plan showed little changes. Local deformations however resulted in local deviations, primarily around the air/rectum interface. This clearly indicates the potential of intra-fraction adaptations based on the accumulated dose. Application in each fraction helps to track the influence of plan adaptations to the eventual dose distribution. Calculation times were about twice the delivery time. Conclusion: The current Result paves the way to perform on-line treatment delivery QA on the MRI-linac in the near future.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

High Energy, Long Cycle Life Lithium-ion Batteries for PHEV Application

High-loading and high quality PSU Si anode has been optimized and fabricated. The electrochemical performance has been utilized. The PSU Si-graphite anode exhibits the mass loading of 5.8 mg/cm2, charge capacity of 850 mAh/ g and good cycling performance. This optimized electrode has been used for full-cell fabrication. The performance enhancement of Ni-rich materials can be achieved by a diversity of strategies. Higher Mn content and a small amount of Al doping can improve the electrochemical performance by suppressing interfacial side reactions with electrolytes, thus greatly benefiting the cyclability of the samples. Also, surface coatings of Li-rich materials and AlF 3 are able to improve the performance stability of Ni-rich cathodes. One kilogram of optimized concentration-gradient LiNi 0.76 Co 0.10 Mn 0.14 O 2 (CG) with careful control of composition, morphology and electrochemical performance was delivered to our collaborators. The sample achieved an initial specific capacity close to 190 mA h g -1 at C/10 rate and 180 mA h g -1 at C/3 rate as well as good cyclability in pouch full cells with a 4.4 V upper cut-off voltage at room temperature. Electrolyte additive with Si-N skeleton forms a less resistant SEI on the surface of silicon anode (from PSU) as evidenced by the evolution of the impedance at various lithiation/de-lithiation stages and the cycling data The prelithiation result demonstrates a solution processing method to achieve large area, uniform SLMP coating on well-made anode surface for the prelithiation of lithium-ion batteries. The prelithiation effect with this method is applied both in graphite half cells, graphite/NMC full cells, SiO half cells, SiO/NMC full cells, Si-Graphite half cells and Si-Graphite/NMC full cells with improvements in cycle performance and higher first cycle coulombic efficiency than their corresponding cells without SLMP prelithiation. As to the full cell fabrication and test, full pouch cells with high capacity of 2.2 Ah and 1.2 Ah have been fabricated and delivered. The cells show great uniformity and good cycling performance. The prelithiation method effectively compensate the loss in the first cycle. The cell with high energy density and long-cycle life has been achieved.

25 ENERGY STORAGE↗
DOE OSTI2014

Redwing: A MOOSE application for coupling MPACT and BISON

Fuel performance and whole core neutron transport programs are often used to analyze fuel behavior as it is depleted in a reactor. For fuel performance programs, internal models provide the local intra-pin power density, fast neutron flux, burnup, and fission rate density, which are needed for a fuel performance analysis. The fuel performance internal models have a number of limitations. These include effects on the intra-pin power distribution by nearby assembly elements, such as water channels and control rods, and the further limitation of applicability to a specified fuel type such as low enriched UO2. In addition, whole core neutron transport codes need an accurate intra-pin temperature distribution in order to calculate neutron cross sections. Fuel performance simulations are able to model the intra-pin fuel displacement as the fuel expands and densifies. These displacements must be accurately modeled in order to capture the eventual mechanical contact of the fuel and the clad; the correct radial gap width is needed for an accurate calculation of the temperature distribution of the fuel rod. Redwing is a MOOSE-based application that enables coupling between MPACT and BISON for transport and fuel performance coupling. MPACT is a 3D neutron transport and reactor core simulator based on the method of characteristics (MOC). The development of MPACT began at the University of Michigan (UM) and now is under the joint development of ORNL and UM as part of the DOE CASL Simulation Hub. MPACT is able to model the effects of local assembly elements and is able calculate intra-pin quantities such as the local power density on a volumetric mesh for any fuel type. BISON is a fuel performance application of Multi-physics Object Oriented Simulation Environment (MOOSE), which is under development at Idaho National Laboratory. BISON is able to solve the nonlinearly coupled mechanical deformation and heat transfer finite element equations that model a fuel element as it is depleted in a nuclear reactor. Redwing couples BISON and MPACT in a single application. Redwing maps and transfers the individual intra-pin quantities such as fission rate density, power density, and fast neutron flux from the MPACT volumetric mesh to the individual BISON finite element meshes. For a two-way coupling Redwing maps and transfers the individual pin temperature field and axially dependent coolant densities from the BISON mesh to the MPACT volumetric mesh. Details of the mapping are given. Redwing advances the simulation with the MPACT solution for each depletion time step and then advances the multiple BISON simulations for fuel performance calculations. Sub-cycle advancement can be applied to the individual BISON simulations and allows multiple time steps to be applied to the fuel performance simulations. Currently, only loose coupling where data from a previous time step is applied to the current time step is performed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

A Novel Bio-based Polyaspartic Acid Copolymer: Synthesis, Structure and Performance of Degradation

A novel bio-based polyaspartic acid copolymer, as a multifunctional polymer was fabricated via in-site melting polymerization method using L-aspartic acid, γ-aminobutyric acid, L-phenylalanine and L-alanine as raw materials. The synthetic conditions were studied in detail, and the structure and degradation assays of these copolymers were investigated by FT-IR, XRD, weight loss rate, pH values, intrinsic viscosity and SEM. According to the results, all of the copolymers were found to have similar structure and excellent degradability. Additionally, the optimized copolymer C7 [L-aspartic acid (0.45 mol), γ-aminobutyric acid (0.35 mol), L-phenylalanine (0.05 mol) and L-alanine (0.15 mol)] exhibited the highest weight loss rate among all the copolymers. The weight loss rates on the 28th day in aqueous medium, phosphate buffered saline solution, 5.0 wt% trypsin solution and soil culture medium reached up to 44.74 wt%, 99.75 wt%, 90.67 wt% and 83.58 wt%, respectively. And the appropriate introduction of bio-based amino acids could control the degradation of polyaspartic acid distinctly. All of these results indicated that the bio-based polyaspartic acid copolymer could be used for reference as a good understanding of description the degradation of other environmentally friendly bio-based polymers.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2016

MO-FG-CAMPUS-IeP3-01: Evaluation of Specific Absorption Rate and Temperature Increase Induced by Artificial Medical Implants During MRI Scan

Purpose: Heating of patients or burning of biological tissues around medical implants by RF power during MRI scan is a significant patient safety concern. The purpose of this study is to not only measure SAR values, but also RF-induced temperature elevation due to artificial hip joints during MRI scans. Methods: SAR measurement experiment was performed on three discrete manufacturers at 1.5 and 3T. Three MRI RF sequences (T1w TSE, T2w inversion recovery, and T2w TSE) with imaging parameters were selected. A gelled saline phantom mimicking human body tissue was made (Fig.1). FDTD method was utilized to calculate the SAR distribution using Sim4Life software. Based on the results of the simulation, 4 electrical field (E-field) sensors were located around two artificial hip joints inside the phantom. 56 Fiber Bragg Grating (FBG) temperature sensors (28 sensors on each artificial hip joint) were located on both left and right artificial hip joints to measure temperature change during MRI scan (Fig.1). Both E-field and FBG temperature sensors were calibrated with traceability at Korea Research Institute of Standards and Science (KRISS). Results: Simulation shows that high SAR values occur in the head and tail of the implanted artificial hip joints (Fig.1 lower right). 3T MRI scanner shows that the local averaged-SAR values measured by probe 1, 2, and 3 are 2.30, 2.77, and 1.68 W/kg, compared to MRI scanner-reported whole body SAR value (≤1.5 W/kg) for T1w TSE and T2w-IR (Table 1). The maximum temperature elevation measured by FBG sensors is 1.49°C at 1.5 T, 2.0°C at 3 T, and 2.56°C at 3 T for T1w TSE, respectively (Table 2). Conclusion: It is essential to assess the safety of MRI system for patient with medical implant by measuring not only accurate SAR deposited in the body, but also temperature elevation due to the deposited SAR during clinical MRI.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Optimization of oncological {sup 18}F-FDG PET/CT imaging based on a multiparameter analysis

Purpose: This paper describes a method to achieve consistent clinical image quality in {sup 18}F-FDG scans accounting for patient habitus, dose regimen, image acquisition, and processing techniques. Methods: Oncological PET/CT scan data for 58 subjects were evaluated retrospectively to derive analytical curves that predict image quality. Patient noise equivalent count rate and coefficient of variation (CV) were used as metrics in their analysis. Optimized acquisition protocols were identified and prospectively applied to 179 subjects. Results: The adoption of different schemes for three body mass ranges (<60 kg, 60–90 kg, >90 kg) allows improved image quality with both point spread function and ordered-subsets expectation maximization-3D reconstruction methods. The application of this methodology showed that CV improved significantly (p < 0.0001) in clinical practice. Conclusions: Consistent oncological PET/CT image quality on a high-performance scanner was achieved from an analysis of the relations existing between dose regimen, patient habitus, acquisition, and processing techniques. The proposed methodology may be used by PET/CT centers to develop protocols to standardize PET/CT imaging procedures and achieve better patient management and cost-effective operations.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2024

Enhanced mobility of dislocation network nodes and its effect on dislocation multiplication and strain hardening

Understanding plastic deformation of crystals in terms of the fundamental physics of dislocations has remained a grand challenge in materials science for decades. To overcome this, the Discrete Dislocation Dynamics (DDD) method has been developed, but its lack of atomistic resolution leaves open the possibility that certain key mechanisms may be overlooked. Here, by comparing large-scale Molecular Dynamics (MD) with DDD simulations performed under identical conditions we uncover significant discrepancies in the predicted strength and microstructure evolution in BCC crystals under high-strain rate conditions. These are traced to unexpected behaviors of dislocation network nodes forming at dislocation intersections, that can move in ways not previously anticipated as revealed by MD. Once these newfound freedoms of nodal motion are incorporated, DDD simulations begin to closely match plastic evolution observed in MD. This additional mechanism of motion whereby non-screw dislocations can change their glide plane profoundly affects fundamental processes of dislocation multiplication, recovery and storage that define strength of metals.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Modeling fission product diffusion in TRISO fuel particles with BISON

Diffusion of fission products in intact TRISO particles depends on particle geometry, fission product source rates, time, temperature, and temperature-dependent diffusion coefficients. Simulating this diffusion process requires models for source rates and diffusion coefficients, plus computation of the temperature field if not prescribed. In addition, simulation quality depends on discretization of the geometry, appropriate time stepping, and the accuracy of the solution method. In this paper, we explore the simulation of fission product diffusion in TRISO fuel particles using the finite element method via the fuel performance code Bison. Recent material model development has occurred in Bison for each material present in tri-structural isotropic (TRISO) fuel particles: the buffer, inner pyrolytic carbon, silicon carbide, and outer pyrolytic carbon layers, as well as the fuel kernel. Also, new mesh generation and fission product release fraction capabilities have been added. Diffusion capabilities are shown to converge to the correct solution via formal verification tests. A large number of code benchmarking problems are also given, with good results, showing that Bison’s computed release fractions closely match those of other software tools. Finally, a significant validation effort is detailed in which fission product release, measured as part of the AGR-1 capsule experiments, is compared to Bison outputs. Bison outputs compare very well to the experimental data and to PARFUME results.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Electrodeposited nickel coatings for exceptional corrosion mitigation in industrial grade molten chloride salts for concentrating solar power

Molten chloride salt eutectics are attractive candidates for use as thermal energy storage media and heat transfer fluids in generation-three concentrating solar thermal power (Gen3 CSP) plants. However, corrosion of alloys in molten chloride salts, especially at high temperatures, is an extremely challenging problem that studies focus on lower temperatures, shorter durations, or analytical grade, and high-purity, salts. To date, there has been no study on corrosion or corrosion mitigation in an industrial-grade salt at a high temperature such as 750 °C. To alleviate this knowledge gap, the study presents new multiscale fractal-textured Ni coatings on various alloy surfaces for effective corrosion mitigation at 750 °C in molten chloride salts. Using the electrodeposition method, durable double-layer textured coatings were formed on stainless steel alloys (SS316, SS310, and SS347) and In800H. The corrosion performance of the coatings is investigated in both analytical-grade purity and, for the first time, practically relevant industrial-grade chloride salts. Ni-coated ferrous alloys showed an exceptionally reduced corrosion rate in the range of 350–480 μm/y in analytical-grade salts, and between 450 and 490 μm/y in purified industrial-grade salts at 750 °C. Ni coatings on ferrous alloys reduced corrosion rates by as much as 70% compared to uncoated surfaces and were comparable to the expensive Ha230 alloy with a high Ni content. As a result, by the use of innovative fractal corrosion mitigation coatings, for the first time, low-cost structural alloys are rendered viable for use with industrial-grade chloride salts, which is profoundly beneficial in practical systems.

14 SOLAR ENERGY↗
DOE OSTI2025

Forecasting Battery Electrode Performance via Electrochemical Fluorescence Microscopy and Machine-Learning

Predicting lithium-ion battery performance is hindered by microscale electrode heterogeneities invisible to conventional diagnostics. Here, we combine electrochemical fluorescence microscopy (EFM), which maps electronic connectivity by visualizing an electrofluorophore reaction distribution, with a multitask ElasticNet regression to forecast discharge capacity from spatial heterogeneity. Analyzing 196 images from six pilot-scale LiNi 0.5 Mn 0.3 Co 0.2 O 2 cathodes with varying carbon loadings, we extract 62 descriptors that capture morphology and texture. A compact five-feature model predicts capacity across eight discharge rates, achieving a per-target R 2 of up to 0.63 and an overall R 2 of 0.92, with a mean absolute percentage error of less than 2%. This performance rivals impedance-based approaches while avoiding their reliance on postformation data and incomplete electronic network information. Our facile and rapid, image-driven method may enable electrode quality control upstream of costly cell assembly to offer a transformative tool for data-driven battery research and manufacturing.

battery electrodes↗
DOE OSTI2024

Sliceable, Moldable, and Highly Conductive Electrolytes for All-Solid-State Batteries

All-solid-state batteries (ASSBs) require solid electrolytes with high ionic conductivity, stability, and deformability for optimal energy and power density. Here, we developed lithium-deficient lithium yttrium bromide (LYB) solid electrolytes, Li 3–x YBr 6–x (0 ≤ x ≤ 0.50), using a comelting method with controlled lithium deficiency. These electrolytes exhibit favorable mechanical properties such as high moldability and sliceability. The Li 2.65 YBr 5.65 composition has an ionic conductivity of 4.49 mS cm –1 at 25 °C and an activation energy of 0.28 eV. Compared to Li 3 YBr 6 , Li 2.65 YBr 5.65 demonstrates improved rate performance and cycling stability in ASSBs. High-resolution X-ray diffraction confirms the formation of the LYB phase with a C2/m space group. Structural analysis reveals increased cation disorder and larger polyhedral volumes for x > 0 in Li 3–x YBr 6–x , contributing to reduced Li + migration energy barriers. Bond valence site energy calculations and molecular dynamics simulations reveal enhanced 3D lithium-ion transport. NMR spectroscopy further highlights increased Li + dynamics and impurity elimination.

Poudel, Tej P. [Florida State Univ., Tallahassee, ↗