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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 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Java-based Graphical User Interface for MAVERIC-II

A computer program entitled "Marshall Aerospace Vehicle Representation in C II, (MAVERIC-II)" is a vehicle flight simulation program written primarily in the C programming language. It is written by James W. McCarter at NASA/Marshall Space Flight Center. The goal of the MAVERIC-II development effort is to provide a simulation tool that facilitates the rapid development of high-fidelity flight simulations for launch, orbital, and reentry vehicles of any user-defined configuration for all phases of flight. MAVERIC-II has been found invaluable in performing flight simulations for various Space Transportation Systems. The flexibility provided by MAVERIC-II has allowed several different launch vehicles, including the Saturn V, a Space Launch Initiative Two-Stage-to-Orbit concept and a Shuttle-derived launch vehicle, to be simulated during ascent and portions of on-orbit flight in an extremely efficient manner. It was found that MAVERIC-II provided the high fidelity vehicle and flight environment models as well as the program modularity to allow efficient integration, modification and testing of advanced guidance and control algorithms. In addition to serving as an analysis tool for techno logy development, many researchers have found MAVERIC-II to be an efficient, powerful analysis tool that evaluates guidance, navigation, and control designs, vehicle robustness, and requirements. MAVERIC-II is currently designed to execute in a UNIX environment. The input to the program is composed of three segments: 1) the vehicle models such as propulsion, aerodynamics, and guidance, navigation, and control 2) the environment models such as atmosphere and gravity, and 3) a simulation framework which is responsible for executing the vehicle and environment models and propagating the vehicle s states forward in time and handling user input/output. MAVERIC users prepare data files for the above models and run the simulation program. They can see the output on screen and/or store in files and examine the output data later. Users can also view the output stored in output files by calling a plotting program such as gnuplot. A typical scenario of the use of MAVERIC consists of three-steps; editing existing input data files, running MAVERIC, and plotting output results.

Seo, Suk Jai↗
DOE OSTI2025

Three-Dimensional Bubble Fluidics in Architected Porous Media

Gas bubble flows in porous media often exhibit complex and seemingly unpredictable behaviors that are difficult to control. This lack of control limits the ability to design effective devices which manage multiphase flows. Here, we show how the design of 3D printed pores can deterministically control the flow path of an injected gas stream. Open cell structures can be designed to shape the gas/liquid interface with fidelity to control how the two phases are distributed throughout a porous material. The distributed gas volume is free to interact physically and chemically with the surrounding liquid phase, an effect we exploit to create a logical control gate to redirect flows within a lattice. This also allows us to design architectures for reactive capture and aerating bioreactors, resulting in patterned boundaries which can make more effective use of the liquid and gas reagents.

3D microfluidics↗
DOE OSTI2026

Differentiable multiphase flow model for physics-informed machine learning in reservoir pressure management

Accurate subsurface reservoir pressure control is extremely challenging due to geological heterogeneity and multiphase fluid-flow dynamics. Predicting behavior in this setting relies on high-fidelity physics-based simulations that are computationally expensive. Yet, the uncertain, heterogeneous properties that control these flows make it necessary to perform many of these expensive simulations, which is often prohibitive. To address these challenges, we introduce a physics-informed machine learning workflow that couples a fully differentiable multiphase flow simulator, which is implemented in the DPFEHM framework with a convolutional neural network (CNN). The CNN learns to predict fluid extraction rates from heterogeneous permeability fields to enforce pressure limits at critical reservoir locations. By incorporating transient multiphase flow physics into the training process, our method enables more practical and accurate predictions for realistic injection-extraction scenarios compared to previous works. To speed up training, we pretrain the model on single-phase, steady-state simulations and then finetune it on full multiphase scenarios, which dramatically reduces the computational cost. We demonstrate that high-accuracy training can be achieved with fewer than three thousand full-physics multiphase flow simulations – compared to previous estimates requiring up to ten million. This drastic reduction in the number of simulations is achieved by leveraging transfer learning from much less expensive single phase simulations.

25 ENERGY STORAGE↗
DOE OSTI2020

Enhancement of Unsteady and 3D Aerodynamics Models using Machine Learning

Unsteady aerodynamics will be an important part of the floating wind turbines of the future operating under high shear across the rotor disk coupled with platform motion and atmospheric turbulence. We develop an unsteady aerodynamics and dynamic stall model using a long short-term memory variant of recurrent neural networks. The neural network model is trained using the oscillating airfoil data set from Ohio State University. The predictions from our machine learning (ML)-based model show good agreement with the experimental data and other state-of-the-art dynamic stall models for a wide range of airfoils, Reynolds numbers and reduced frequencies. In some cases the predictions are better than the Beddoes-Leishman model implementation in OpenFAST, when using the default coefficients. The ML-based model is also able to capture the key physics associated with dynamic stall, such as the precedence of moment stall before lift stall and cycle-to-cycle variations in the aerodynamic response. The new unsteady aerodynamics model is expected to improve prediction of fatigue loads for yaw-based wake-steering control scenarios in actuator-line and actuator-disc simulations of wind farms. Our methodology for training the ML-model provides a pathway for improving design level tools using high-fidelity computational fluid dynamics (CFD) simulations in the future.

17 WIND ENERGY↗
DOE OSTI2026

ELG×LRG Distribution through Dark Matter Halo Dynamics

We investigate the clustering and halo occupation distribution (HOD) of DESI Y1 emission-line (ELGs) and luminous red (LRGs) galaxies at 0.8 < z < 1.1, including their cross-correlation (ELG×LRG), using the A BACUS S UMMIT suite and a new Halo Occupation Model (H OME ) for galaxy multitracers. This integrates intrahalo dynamics, halo exclusion, and quenching, bridging insights from hydrodynamical, HOD, abundance-matching, and semianalytic studies. Leveraging full phase-space information from the Uchuu N-body simulation, and sampling satellites from dark-matter particle positions via physically motivated prescriptions, Home reproduces the anisotropic clustering down to s = 200 h −1 kpc with unprecedented accuracy. Model parameters are inferred solely from two-point statistics using a two-level Bayesian framework, yielding high-fidelity ELG, LRG, and cross-reference catalogs. We find that satellite ELGs behave as incoherent flows within their parent halos, dominating the clustering below 4 h −1 Mpc. The HOD from the best-fit Home has the following properties: (i) 90.50% (85.91%) of ELGs (LRGs) are central galaxies without satellites, residing in halos of M vir ∼ 6.6 × 10 11 (1.2 × 10 13 ) h −1 M ⊙ ; (ii) the ELG×LRG cross-correlation is governed by central-central pairs and shaped by halo exclusion on 2–5 h −1 Mpc scales; (iii) 9.50% (14.09%) of ELGs (LRGs) are satellites, of which 1.09% (3.52%) inhabit halos with a central galaxy of the same species in a maximally conformal configuration, 7.02% (0.005%) orbit complementary hosts in a minimally conformal state, and 0.58% (10.57%) are orphans. The high sensitivity of Home precisely captures the dynamics of satellites in different host environments, opening a promising avenue for understanding systematics and the dynamical nature of dark matter, potentially distinguishing gravity models.

Favole, Ginevra [Universidad de La Laguna (Spain);↗
NASA NTRS2005

Behavioral health in Antarctica: implications for long-duration space missions

Ideally, evidence from long-duration spaceflight should be used to predict likely occurrences of behavioral health events and for planning management strategies for such events. With small numbers of space travelers, and limited long-duration missions of a year or more, Earth analogues and simulations must be used as the evidence base, despite such analogues lacking microgravity, radiation, rapidly altering photoperiodicity, and fidelity to space. Antarctic health data are reviewed and an assessment made of the likely frequency of behavioral health events. Based on the Antarctic evidence, the likelihood of behavioral health problems in space is low. However, such cases may be serious and of high consequence, placing considerable demands on the mission crew and ground support to achieve a successful outcome, given the availability of pharmaceuticals and resources.

Review↗
DOE OSTI2023

Using in-situ strain measurements to evaluate the accuracy of stress estimation procedures from fracture injection/shut-in tests

Fracture injection/shut-in tests are commonly used to measure the state of stress. Injection creates a hydraulic fracture (or in some cases, opens a preexisting fracture), and then the pressure after shut-in is monitored to identify fracture closure. Different interpretation procedures have been proposed for estimating closure, and the procedures sometimes yield significantly different results. In this study, direct, in-situ strain measurements are used to observe fracture reopening and closure. The tests were performed as part of the EGS Collab project, a mesoscale project performed at 1.25 and 1.5 km depth at the Sanford Underground Research Facility. The tests were instrumented with the SIMFIP tool, a double-packer probe with a high-resolution three-dimensional borehole displacement sensor. The measurements provide a direct observation of the fracture closure signature, enabling a high-fidelity estimate of the fracture closure stress (ie, the normal stress on the fracture). In two of the four tests, injection created an opening mode fracture, and so the closure stress can be interpreted as the minimum principal stress. In the other two tests, injection probably opened preexisting natural fractures, and so the closure stress can be interpreted as the normal stress on the fractures. The strain measurements are compared against different proposed methods for estimating closure stress from pressure transients. The shut-in transients are analyzed with two techniques that are widely used in the field of petroleum engineering – the ‘tangent’ method and the ‘compliance’ method. In three of the four tests, the tangent method significantly underestimates the closure stress. The compliance method is reasonably accurate in all four tests. Closure stress is also interpreted using two other commonly-used methods – ‘first deviation from linearity’ and the method of Hayashi and Haimson. In comparison with the SIMFIP data, these methods tend to overestimate the closure stress, evidently because they identify closure from early-time transient effects, such as near-wellbore tortuosity. In two of the tests, microseismic imaging provides an independent estimate of the size of the fracture created by injection. When combined with a simple mass balance calculation, the SIMFIP stress measurements yield predictions of fracture size that are reasonably consistent with the estimates from microseismic. In conclusion, the calculations imply an apparent fracture toughness 2-3x higher than typical laboratory-derived values.

58 GEOSCIENCES↗
NASA NTRS2017

Lessons Learned from OSIRIS-Rex Autonomous Navigation Using Natural Feature Tracking

The Origins, Spectral Interpretation, Resource Identification, Security-Regolith Explorer (Osiris-REx) spacecraft is scheduled to launch in September, 2016 to embark on an asteroid sample return mission. It is expected to rendezvous with the asteroid, Bennu, navigate to the surface, collect a sample (July 20), and return the sample to Earth (September 23). The original mission design called for using one of two Flash Lidar units to provide autonomous navigation to the surface. Following Preliminary design and initial development of the Lidars, reliability issues with the hardware and test program prompted the project to begin development of an alternative navigation technique to be used as a backup to the Lidar. At the critical design review, Natural Feature Tracking (NFT) was added to the mission. NFT is an onboard optical navigation system that compares observed images to a set of asteroid terrain models which are rendered in real-time from a catalog stored in memory on the flight computer. Onboard knowledge of the spacecraft state is then updated by a Kalman filter using the measured residuals between the rendered reference images and the actual observed images. The asteroid terrain models used by NFT are built from a shape model generated from observations collected during earlier phases of the mission and include both terrain shape and albedo information about the asteroid surface. As a result, the success of NFT is highly dependent on selecting a set of topographic features that can be both identified during descent as well as reliably rendered using the shape model data available. During development, the OSIRIS-REx team faced significant challenges in developing a process conducive to robust operation. This was especially true for terrain models to be used as the spacecraft gets close to the asteroid and higher fidelity models are required for reliable image correlation. This paper will present some of the challenges and lessons learned from the development of the NFT system which includes not just the flight hardware and software but the development of the terrain models used to generate the onboard rendered images.

Navigation↗
DOE OSTI2025

Cooperative On-Ramp Merging with Time-Varying Vehicle-to-Vehicle Communication Delay Compensation via a Model-Free Approach

Cooperative merging strategies enabled by vehicle-to-vehicle (V2V) communication have shown promise in addressing congestion, fuel inefficiency, and collision risks. However, their performance can be severely degraded by time-varying and uncertain communication delays-an issue often overlooked in existing research, which primarily focuses on merging sequence determination and trajectory planning. Furthermore, practical considerations such as heterogeneous vehicle dynamics, varying road conditions, and real-time implementation complexities are frequently neglected. This paper presents a model-free, online planning framework for cooperative on-ramp merging of connected and automated vehicles (CAVs), explicitly accounting for time-varying V2V communication delays. Without relying on detailed vehicle dynamics, the proposed method introduces a data-driven delay compensation scheme. A co-simulation platform integrating high-fidelity vehicle dynamics, traffic simulation (SUMO), and V2V communication within MATLAB/Simulink is developed to evaluate the proposed method. Simulation results demonstrate that unaddressed V2V communication delays significantly impair merging performance. In contrast, the proposed framework enhances intervehicle distance tracking and maintains low CO2 emissions and fuel consumption, under communication delay across different communication frequencies. In conclusion, its lightweight design also facilitates real-time implementation, making it well-suited for deployment in practical CAV systems.

Accounting↗
DOE OSTI2026

Holistic Transportation and Energy Modeling

This project advances the development and application of the TEMPO transportation energy systems model to support DOE analysis of evolving mobility futures. Recent work has focused on improving model transparency, performance, and fidelity through a redesigned software architecture and updated technology adoption scenarios aligned with the latest data and assumptions. Ongoing efforts aim to expand TEMPO's ability to assess transportation affordability and consumer decision-making, including vehicle ownership dynamics and distributional impacts across households. These enhancements position TEMPO to better inform policy and R&D decisions by providing more behaviorally realistic and policy-relevant insights into transportation energy use, technology adoption, and system-level outcomes.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Particle collisionality in scaled kinetic plasma simulations

Kinetic plasma processes, such as magnetic reconnection, collisionless shocks, and turbulence, are fundamental to the dynamics of astrophysical and laboratory plasmas. Simulating these processes often requires particle-in-cell (PIC) methods, but the computational cost of fully kinetic simulations can necessitate the use of artificial parameters, such as a reduced speed of light and ion-to-electron mass ratio, to decrease expense. While these approximations can preserve overall dynamics under specific conditions, they introduce nontrivial impacts on particle collisionality that are not yet well understood. In this work, we develop a method to scale particle collisionality in simulations employing an artificial speed of light and/or an artificial ion-to-electron mass ratio. By introducing species-dependent scaling factors, we independently adjust inter- and intra-species collision rates to better replicate the collisional properties of the physical system. Our approach maintains the fidelity of electron and ion transport properties while preserving critical relaxation rates, such as energy exchange timescales, within the limits of weakly collisional plasma theory. Furthermore, we demonstrate the accuracy of this scaling method through benchmarking tests against theoretical relaxation rates and connecting to fluid theory, highlighting its ability to retain key transport properties. Existing collisional PIC implementations can be easily modified to include this scaling, which will enable deeper insights into the behavior of marginally collisional plasmas across various contexts.

Totorica, S. R. [Princeton Univ., NJ (United State↗
DOE OSTI2026

Development of MOSCATO: A CFD-Level Electrochemistry and Corrosion Simulator for Molten Salt Systems

For both coolant and fueled variants of molten salt reactors (MSRs), the corrosion of structural materials is a significant challenge. The corrosion stems from chemical and electrochemical reactions initiated by fissile material, fission products, and impurities in the salt. Lower-fidelity models rely on empirical correlations for mass transfer, simplified lumped temperature profiles, and similar assumptions. They do not capture detailed spatial variations in complex geometries, creating the need for high-fidelity modeling to bridge this gap.As we approach the demonstration and possible deployment of MSRs in this decade, the development of a high-fidelity, high-performance simulator becomes imperative. To simulate the complex electrochemical environment and corrosion within molten salt systems, we have developed the Molten Salt Chemistry And TranspOrt (MOSCATO) code. This endeavor is comprised of three essential components. First, mass transfer equations are coupled with the Navier-Stokes equations in order to account for the transport of species in the salt. Second, the diffusion of alloy constituents, such as Cr, Fe, Ni, etc. is simulated within the structural metals. Third, the alloy and salt domains are coupled to account for the heterogeneous chemical and electrochemical reactions that occur at the salt-alloy interface.MOSCATO manages all three components within the framework of the highly scalable, open-source spectral element method computational fluid dynamics code Nek5000/NekRS. This integration enables MOSCATO to harness the immense computational power of modern high-performance computing resources, ensuring both high fidelity and computational speed.In addition to code development, we have initiated a comprehensive verification and validation campaign, utilizing data from diverse sources. First, MOSCATO's electrochemical solver was verified with reference numerical data. Then validation occurred against experiments: one of a thermal galvanic cell and the other for corrosion in flowing molten salt of FLiNaK (LiF-NaF-KF). This campaign verified and validated MOSCATO as a reliable tool for simulating electrochemical environments and corrosion in molten salt systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

A Finite-Time Ensemble Method for Mixed Layer Model Comparison

Here, this work evaluates the fidelity of various upper-ocean turbulence parameterizations subject to realistic monsoon forcing and presents a finite-time ensemble vector (EV) method to better manage the design and numerical principles of these parameterizations. The EV method emphasizes the dynamics of a turbulence closure multimodel ensemble and is applied to evaluate 10 different ocean surface boundary layer (OSBL) parameterizations within a single-column (SC) model against two boundary layer large-eddy simulations (LES). Both LES include realistic surface forcing, but one includes wind-driven shear turbulence only, while the other includes additional Stokes forcing through the wave-average equations that generate Langmuir turbulence. The finite-time EV framework focuses on what constitutes the local behavior of the mixed layer dynamical system and isolates the forcing and ocean state conditions where turbulence parameterizations most disagree. Identifying disagreement provides the potential to evaluate SC models comparatively against the LES. Observations collected during the 2018 monsoon onset in the Bay of Bengal provide a case study to evaluate models under realistic and variable forcing conditions. The case study results highlight two regimes where models disagree 1) during wind-driven deepening of the mixed layer and 2) under strong diurnal forcing.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRSDate not supplied

Model-Based Systems Engineering, Real-Time Operations, and Autonomy

Model-Based Systems Engineering has been enabled by the development of the SysML language and software tools to create systems models. Systems models described in SysML incorporate frames (Diagrams) that represent behaviors (activities, sequences, state machines, use cases), requirements, and structure (definitions, internal structure, parametric formulation, and packaging). The SysML models are, in turn, used by applications to do analysis and studies of the designs and operational capabilities. These uses of the model are based on simulations, and do not include hardware. This paper presents a software environment and processes that enables more comprehensive systems models for MBSE, and use of these rich models for real-time operations. The paper describes a software platform that enables creation of comprehensive models, beyond what is now possible with SysML and related software tools, called the NASA Platform for Autonomous Systems (NPAS). The platform encapsulates a paradigm and infrastructure for creating systems models with complexity levels comparable to the ones handled by SysML software tools, but with additional fidelity that includes detailed design diagrams encompassing sensors, components, and design topologies. Furthermore, NPAS enables incorporation of data, information, and knowledge (DIaK) to implement autonomy and Integrated System Health Management (ISHM) and the inherent integration of content encompassing SysML structure and behavior diagrams throughout the NPAS modelAnd lastly, the NPAS models are used in real-time operations, taking advantage of the fidelity and complexity encompassed in the models in order to implement “thinking” ISHM and/or autonomous operations. . Incorporation of SysML model content into an NPAS model is briefly discussed.

MBSE↗
DOE OSTI2026

Impact of Time-Dependent Reactor and Sensor Physics on Core Power Synthesis (Rev.1)

Online synthesis of power distribution is critical in the operation and control of nuclear power reactors to ensure that the core is operating within safety margins and to provide essential knowledge associated with the burnup of the fuel. In light-water reactors, power synthesis is achieved by using some a priori knowledge of the state of the reactor core and updating based on the signals coming from in-core sensors—namely, self-powered neutron detectors (SPNDs). This report examines the effects of fuel burnup and sensor degradation on the ability to accurately synthesize the power distribution in a pressurized water reactor (PWR), considering the typical low-enriched uranium (LEU, 3%-5% enrichment) fuel cycle as well as the higher enrichment LEU+ (5%-8% enrichment) fuel cycle. Several modeling tools were used to simulate power synthesis based on the responses of SPNDs, with emitters made out of Rh or V. A representative PWR LEU core was modeled using the Polaris/Purdue Advanced Reactor Core Simulator (PARCS) approach. The Monte Carlo N-Particle Transport 6 (MCNP6) code was used as well to calculate response functions between different segments of fuel to individual SPNDs; this is a crucial parameter for power synthesis. The Oak Ridge Isotope GENeration (ORIGEN) package in the Standardized Computer Analyses for Licensing Evaluation (SCALE) code was used to model the time-dependent isotopic transmutation in the SPND emitters. All these data were fed into a custom code that enacted the point-based iterative method to simulate power synthesis. Developmental work was also performed on high-fidelity SPND models in the GEometry ANd Tracking 4 (Geant4) code, which enables higher-accuracy modeling of the current responses from SPNDs. In this work, five sets of time-dependent power synthesis test cases were conducted. In these test cases, systematic changes in the input conditions enabled an analysis of the effect of (1) slightly inaccurate a priori power distribution assumptions with respect to fuel burnup, (2) highly inaccurate a priori power distribution assumptions with respect to fuel burnup (such that burnup is not included in the a priori assumed distribution), and (3) differences between Rh and V SPNDs in terms of downstream consequences of the transmutation in the emitters and the extended nature of the LEU+ fuel cycle in comparison with LEU. The authors discovered that one may permissibly have slightly inaccurate a priori assumptions of the fuel burnup (such that the level of burnup may be slightly underapproximated or overapproximated by the accumulated burnup in approximately 9.3 full power days), but to not account for burnup at all in the a priori assumptions leads to severe levels of error, approaching 25% at maximum (for LEU). The authors also discovered that V SPNDs are extraordinarily robust in both the LEU and LEU+ fuel cycles considered in this modeling work, whereas Rh SPNDs undergo significant transmutation that can result in large errors in the synthesized power distribution.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

60 years of science in ICF: from conception to scientific breakeven on the National Ignition Facility

The recent achievements of a burning plasma, fusion ignition, and scientific energy gain with deuterium-tritium (DT) fuel at Lawrence Livermore National Laboratory’s National Ignition Facility (NIF) represents a major milestone in the development of inertial confinement fusion (ICF) and all of fusion research. In these experiments, fuel pressures well in excess of hundreds of GBars were achieved in the compressed fuel, and robust alpha heating of the fuel, far in excess of the energy provided by the implosion, were demonstrated for the first time. These achievements occurred 60 years after the inception of ICF and the first laser demonstration, and were made possible by more than five decades of research at laser facilities around the world. Advances in laser technology both in wavelength and precision, motivated by improved understanding of laser-plasma interaction physics and the demands of targets; improvements in target fabrication inspired by the need to control and minimize hydrodynamic instabilities in the implosion; and multi-dimensional simulations and diagnostics have been critical to this achievement. This paper will summarize the scientific and technical advances, the surprises, and the challenges that had to be overcome to achieve these goals.

fusion↗
DOE OSTI2020

WRF Modelling of Deep Convection and Hail for Wind Power Applications

Deep convection and the related occurrence of hail, intense precipitation and wind gusts represent a hazard to a range of energy infrastructure including wind turbine blades. Wind turbine blade leading edge erosion (LEE) is caused by the impact of falling hydrometeors onto rotating wind turbine blades. It is a major source of wind turbine maintenance costs and energy losses from wind farms. In the United States Southern Great Plains (SGP), where there is widespread wind energy development, deep convection and hail events are common, increasing the potential for precipitation-driven LEE. A 25-day Weather Research and Forecasting (WRF) model simulation conducted at convection-permitting resolution and using a detailed microphysics scheme is carried out for the SGP to evaluate the effectiveness in modelling the wind and precipitation conditions relevant to LEE potential. WRF output for these properties is evaluated using radar observations of precipitation (including hail) and reflectivity, in situ wind speed measurements and wind power generation. This research demonstrates some skill for the primary drivers of LEE. Wind speeds, rainfall rates and precipitation totals show good agreement with observations. Here, the occurrence of precipitation during power producing wind speeds is also shown to exhibit fidelity. Hail events frequently occur during periods when wind turbines are rotating and are especially important to LEE in the SGP. The presence of hail is modelled with a mean proportion correct of 0.77 and an odds ratio 4.55. Further research is needed to demonstrate sufficient model performance to be actionable for the wind energy industry and there is evidence for positive model bias in cloud reflectivity.

17 WIND ENERGY↗
DOE OSTI2025

3D Printing of Highly Porous Polypropylene Separators for Lithium‐Ion Batteries Using Fused Deposition Modeling and Thermally Induced Phase Separation

Appearing as one of the key-components of lithium-ion batteries (LIBs), this work specifically focuses on the additive manufacturing (AM) of custom-shape separators, facilitated by the filament material extrusion process, also called fused deposition modeling (FDM). The development and optimization of composite thermoplastic filament feedstocks combining polypropylene and paraffin wax, followed by the 3D printing of the separator membranes is shown. A post-processing step, based on thermal induced phase separation (TIPS), is introduced to promote porosity formation through removal of the paraffin wax sacrificial phase within the 3D printed items. Separators with different polypropylene/paraffin wax ratios are developed and the impact on printability, mechanical strength, porosity, and electrochemical performances, is thoroughly discussed. X-ray micro-computed tomography is employed to assess the geometric fidelity and to detect printing defects in a complex 3D lattice structure. The performance of the 3D printed porous separators is also compared to a commercial separator. This pioneering research establishes a foundation for the creation of porous separators that can adapt to and conform into 3D printed battery architectures with novel form factors, and also creates opportunities for the use of FDM and TIPS for a wide range of applications that employ porous structures beyond the energy storage field.

3D printing↗