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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 1,657 records · Page 92
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Fabrication and Performance Evaluation of Double-Sided Copper Nanowire Arrays as Thermal and Electrical Interfacial Layers

Reducing contact interface thermal and electrical resistances is in great demand across various industries, particularly in the semiconductor industry. This study introduces an approach using double-sided copper nanowire (Cu NW) arrays on copper sheets as both thermal and electrical interfacial layers, designed to effectively accommodate the topographical inconsistencies between contact surfaces. Further, experimental outcomes reveal a significant reduction in thermal contact resistance (TCR), with a value of 2.5 mm 2 K W –1 , thereby exceeding the efficiency of reported nanostructural thermal interface materials (TIMs). Additionally, when utilized as an electrical interfacial layer, these double-sided Cu NWs arrays dramatically reduced electrical contact resistance (ECR), outperforming traditional conductive grease in applications necessitating separable bonding, though showing comparable performance to costly silver-based conductive epoxies required for permanent, inseparable bonds. The promising results of the double-sided Cu NWs arrays in reducing both TCR and ECR, confirmed by finite element simulation, highlight their substantial potential in advancing TIMs and electrical interconnection applications across various sectors.

42 ENGINEERING↗
DOE OSTI2024

Reducing Thermal Degradation of Perovskite Solar Cells during Vacuum Lamination by Internal Diffusion Barriers

Current photovoltaic (PV) panels typically contain interconnected solar cells that are vacuum laminated with a polymer encapsulant between two pieces of glass or glass with a polymer backsheet. This packaging approach is ubiquitous in conventional photovoltaic technologies such as silicon and thinfilm solar modules, contributing to thermal management, mechanical reinforcement, and environmental protection to enable the long lifetimes necessary to become financially acceptable. Commercial vacuum lamination processes typically occur at 150 °C to ensure cross-linking and/or glass bonding of the encapsulant to the glass and PV cells. Perovskite solar cells (PSCs) have emerged as a promising next-generation PV technology that is known to degrade under thermal stresses, especially at temperatures above 100 °C. In this study, we determine degradation modes during lamination and engineer internal diffusion barriers within the PSC to withstand the harsh thermal conditions of vacuum lamination. PSCs with self-assembled monolayers at the ITO interface and SnO X layers deposited by atomic layer deposition at the electron extraction side of the device endured vacuum lamination at conditions typical of commercial PV processes (150 °C) without degradation. This work demonstrates that perovskite PV can be integrated into the existing module lamination process, enabling future single- and multijunction modules utilizing perovskite absorbers.

14 SOLAR ENERGY↗
DOE OSTI2026

Mechanism-Informed Breakdown: Understanding Degradation by Controlling Voltage-Hold Patterns in Proton Exchange Membrane Water Electrolyzers

Low catalyst loadings pose challenges to performance stability in proton exchange membrane (PEM) water electrolysis over extended operation. To study the impact of degradation mechanisms and voltage loss rates, different stress tests are applied to membrane electrode assemblies. Potential cycling conditions were observed to induce higher degrees of iridium (Ir) oxide crystallization, ionomer degradation, and catalyst layer (CL) thinning, which likely contributed to higher kinetic loss rates. On the other hand, while Ir migrating into the PEM (Ir band) generally impairs performance, the interconnected and more uniform Ir band formed under a constant 2 V hold may allow for Ir at the catalyst/membrane interface to remain electronically connected and kinetically accessible, as well as indicate greater Ir site access during the applied stressor. The 2 V hold also demonstrates improved kinetic durability through a lower Tafel slope, faster polarization kinetics, and reduced charge transfer resistance. In contrast, potential cycling caused the migration of disconnected Ir agglomerates into the membrane bulk and created a steady increase in charge transfer resistance, a more dramatic decrease in capacitance (46.7% loss), and significant damage to the surrounding ionomer, indicating a decline in both the quality and quantity of active sites in the anode CL. This work underscores the distinct degradation pathways associated with load holds versus cycling, highlighting the role of catalyst-ionomer interactions in kinetic performance and long-term stability. These insights can inform operational strategies for PEM electrolyzers powered by intermittent energy sources, aiming to minimize efficiency losses over extended operation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Direct Construction of Mesoporous Metal Sulfides via Reactive Spray Deposition Technology

In this work, a rapid one-step flame combustion deposition method was developed to fabricate the mesoporous metal sulfides directly on nickel foam without binder and template. The first-row transition metal sulfides, Co 9 S 8 , Ni 3 S 4 , NiCo 2 S 4 , and FeS, were successfully synthesized with three-dimensional architecture, large specific surface area (around 110 m 2 g –1 ), and interconnected pore networks. The binary meso-NiCo 2 S 4 exhibited a high specific capacitance (1350 F g –1 at 10 A g –1 ), excellent rate capability, and robust cycling stability in both three-electrode half-cells and asymmetric supercapacitor. This study demonstrated a new scalable strategy to obtain mesoporous metal sulfides with high electrochemical performance.

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

Evaluation of Cr-Tolerance of the Sr 2 Fe 1.5 Mo 0.5 O 6-δ Cathode for Solid Oxide Fuel Cells

Sr 2 Fe 1.5 Mo 0.5 O 6-δ (SFM) is a promising electrode material recently studied for intermediate temperature solid oxide fuel cells (IT-SOFCs). In this work, Cr-tolerance of SFM has been systematically assessed. Due to the presence of Sr at the A-site, SFM has been found to be vulnerable to Cr species resulted from the metallic interconnects. The main product of Cr-poisoning for SFM is SrCrO 4 deposited on the SFM surface. Furthermore, the Cr-poisoning mechanism of the SFM material has been evaluated both experimentally and thermodynamically. To enhance Cr-tolerance of SFM, LaCoO 3-δ -infiltrated SFM (LC@SFM) has been developed. LC hinders the direct contact of SFM with Cr species and LC@SFM has significantly enhanced Cr-tolerance than SFM. This study provides valuable guidance for the wide application of SFM cathode in IT-SOFCs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Small-Angle X-ray Scattering Analysis of Colloidal Crystals and Replica Materials Made from L-Arginine-Stabilized Silica Nanoparticles

Colloidal crystals made from sub-100 nm silica nanoparticles have provided a versatile platform for the template-assisted synthesis of three-dimensionally interconnected semiconducting, metallic, and magnetic replicas. However, the detailed structure of these materials has not yet been characterized. Here, we investigated the structures of colloidal crystalline films and germanium replicas by scanning electron microscopy and small angle X-ray scattering. The structures of colloidal crystals made by evaporative assembly depends on the size of L-arginine-capped silica nanoparticles. Particles smaller than ~31 nm diameter assemble into non-close-packed arrangements (bcc) whereas particles larger than 31 nm assemble into random close-packed structures with disordered hexagonal phase. Polycrystalline films of these materials retain their structures and long-range order upon infiltration at high temperature and pressure, and the structure is preserved in Ge replicas. The shear force during deposition and dispersity of silica nanoparticles contributes to the size-based variation in the structure and to the size of crystal domains in the colloidal crystal films.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Plasticized Polymer Interlayer for Low-Temperature Fabrication of a High-Quality Silver Nanowire-Based Flexible Transparent and Conductive Film

Silver nanowires (AgNWs) are one of the most promising materials to replace commercially available indium tin oxide in flexible transparent conductive films (TCFs); however, there are still numerous problems originating from poor AgNW junction formation and improper AgNW embedment into transparent substrates. To mitigate these problems, high-temperature processes have been adopted; however, unwanted substrate deformation prevents the use of these processes for the formation of flexible TCFs. In this work, we present a novel poly(methyl methacrylate) interlayer plasticized by dibutyl phthalate for low-temperature fabrication of AgNW-based TCFs, which does not cause any substrate deformation. By exploiting the viscoelastic properties of the plasticized interlayer near the lowered glass-transition temperature, a monolithic junction of AgNWs on the interlayer and embedment of the interconnected AgNWs into the interlayer are achieved in a single-step pressing. The resulting AgNW-TCFs are highly transparent (~92% at a wavelength of 550 nm), highly conductive (<90 Ω/sq), and environmentally and mechanically robust. Therefore, the plasticized interlayer provides a simple and effective route to fabricate high-quality AgNW-based TCFs.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Three-Dimensional Graphene–Carbon Nanotube–Ni Hierarchical Architecture as a Polysulfide Trap for Lithium–Sulfur Batteries

We report that despite their high energy density and affordable cost compared to lithium-ion (Li-ion) batteries, lithium-sulfur (Li-S) batteries still endure from slow reaction kinetics and capacity loss induced by the insulating sulfur and severe polysulfide diffusion. To address these issues, we report here nickel nanoparticles filled in vertically grown carbon nanotubes on graphene sheets (graphene-carbon nanotube-nickel composite (Gr-CNT-Ni)) that are coated onto a polypropylene separator as a polysulfide trap for the construction of high-loading sulfur cathodes. The hierarchical porous framework of Gr-CNT physically entraps and immobilizes the active material sulfur, while the strong chemical interaction with Ni nanoparticles in Gr-CNT-Ni inhibits polysulfide diffusion. The covalently interconnected electron conduction channels and carbon shell-confined metal active sites provide feasible paths for the continual regeneration of active material during the charge/discharge process. Benefitting from these novel morphological and structural features, the Li-S cell with the Gr-CNT-Ni as a polysulfide trap demonstrates high specific capacity and good cycle life. Lastly, this work provides new avenues for synergistically combining the advantages of hierarchical porous carbon architectures and metal active sites for the development of high-performance cathodes for Li-S batteries.

25 ENERGY STORAGE↗
DOE OSTI2018

Controlled Synthesis of Sulfur-Rich Polymeric Selenium Sulfides as Promising Electrode Materials for Long-Life, High-Rate Lithium Metal Batteries

High-energy lithium/sulfur (Li/S) batteries still suffer from unsatisfactory cycle life and poor rate capability caused by the polysulfides shuttle and insulating nature of S cathodes. Here, we report our findings in the controlled synthesis of selenium (Se)-containing S-rich co-polymers of various compositions as novel cathode materials through a facile inverse vulcanization of S with selenium disulfide (SeS2) and 1,3- diisopropenylbenzene (DIB) as co-monomers. Nuclear magnetic resonance and X-ray photoelectron spectroscopy results show that divinyl functional groups of DIB were chemically cross-linked with S/SeS2 chain radicals through a ring-opening polymerization. The newly formed bonds of C-S, C-Se, and S-Se in novel S-SeS2-DIB copolymers effectively alleviate the shuttle effects of polysulfides/polyselenides. Furthermore, various electrochemical techniques confirm the positive roles of Secontaining co-polymers in enhancing the electrode reaction kinetics and the formation of stable solid electrolyte interphase layer with low charge-transfer resistance, leading to improved high-rate performances. The as-synthesized co-polymer was then infiltrated into well-interconnected, porous nanocarbon networks (Ketjenblack EC600JD, KB600) to provide effective paths for the fast electron transport. Due to the synergistic combination of chemical and physical confinement of the reaction intermediates during cycling, good reversibility for 500 cycles with a low decay rate of 0.0549% per cycle was achieved at 1000 mA g-1. These encouraging results suggest that the combination of chemical incorporation of SeS2 into S-rich co-polymer and the physical confinement of carbon networks is a promising strategy for advancing Li/S batteries and their viability for practical applications.

Dong, Panpan↗
DOE OSTI2018

Lithiation-Induced Non-Noble Metal Nanoparticles for Li–O 2 Batteries

Low-cost and highly active electrocatalysts are attractive for Li-O 2 applications. Herein, a 3D interconnected plate architecture consisting of ultrasmall Co-Ni grains embedded in lithium hydroxide nanoplates (Co 2 Ni@LiOH) is designed and prepared by a lithiation strategy at room temperature. This catalyst exhibits a remarkably reduced charge potential of similar to 3.4 V at 50 mu A cm -2 , which leads to the high roundtrip efficiency of similar to 79%, among the best levels reported and a cycle life of up to 40 cycles. The well-aligned network facilitates the oxygen diffusion and the electrolyte match penetration into the electrode. The enhanced electrical conductivity net-work improves the charge transport kinetics and more active sites are exposed, which facilitate the adsorption and dissociation of oxygen during the oxygen reduction reaction and the oxygen evolution reaction. This new catalyst design inspires the development of an effective non-noble metal catalyst for Li-O 2 batteries.

25 ENERGY STORAGE↗
DOE OSTI2019

Efficient Thick-Film Polymer Solar Cells with Enhanced Fill Factors via Increased Fullerene Loading

Developing effective methods to make efficient bulk-heterojunction polymer solar cells at roll-to-roll relevant active layer thickness is of significant importance. We investigate the effect of fullerene content in polymer:fullerene blends on the fill factor (FF) and on the performance of thick-film solar cells for four different donor polymers PTB7-Th, PDPP-TPT, BDT-FBT-2T, and poly[5,5'-bis(2-butyloctyl)-(2,2'-bithiophene)-4,4'-dicarboxylate-alt-5,5'-2,2'-bithiophene] (PDCBT). At a few hundreds of nanometers thickness, increased FFs are observed in all cases and improved overall device performances are obtained except for PDCBT upon increasing fullerene content in blend films. This fullerene content effect was studied in more detail by electrical and morphological characterization. The results suggest enhanced electron mobility and suppressed bimolecular recombination upon increasing fullerene content in thick polymer:fullerene blend films, which are the result of larger fullerene aggregates and improved interconnectivity of the fullerene phases that provide continuous percolating pathways for electron transport in thick films. These findings are important because an effective and straightforward method that enables fabricating efficient thick-film polymer solar cells is desirable for large-scale manufacturing via roll-to-roll processing and for multijunction devices.

14 SOLAR ENERGY↗
DOE OSTI2018

High Conductivity Copper–Carbon Nanotube Hybrids via Site-Specific Chemical Vapor Deposition

In this work, site-selective copper nanometal seeding through chemical vapor deposition (CVD) is demonstrated as a viable method in concert with solution electrodeposition of bulk Cu to enhance the electrical conductivity of a porous, low-density (0.12 g/cm 3 , ~9 mg/m) CNT roving. An electrical bias applied directly to the CNT roving promotes Joule heating, which provides the thermal energy necessary for the decomposition of a bis(tert-butylacetoacetato)copper (Cu(tBAOAC) 2 ) precursor. Localized changes in the resistance within the bulk CNT conductor were used to selectively deposit the precursor at thermally active sites, which were evaluated through thermal imaging. The deposition varies from localized Cu deposits at currents producing average temperatures of ~225 °C to a consistent deposition of 10–40 nm Cu particles at applied currents producing average temperatures >300 °C, far above the threshold for the decomposition of the Cu(tBAOAC) 2 precursor. Scanning electron microscopy of a cross section of the roving reveals Cu depositions on the interior of the roving, demonstrating the penetration of the vapor into the CNT network and subsequent decomposition within the roving. A commercial acid-based Cu electroplating solution was used to deposit bulk Cu onto as-prepared and CVD seeded CNT wires, followed by planar densification and H 2 /Ar annealing. The finished conductors with Cu loadings from ~30 to 95% w/w which combine CVD Cu seeding and electrodeposition result in specific conductivity values 3-5 times higher than Cu-CNT conductors produced by electrodeposition alone. Ultimately, a CNT hybrid conductor with 94.2% w/w Cu achieved a specific conductivity of 5632 S m 2 /kg and electrical conductivity of 28.1 MS/m—approaching values previously only seen in metallic conductors. Overall, the present results demonstrate the potential of site-specific CVD toward both seeding metal prior to electroplating and as a possible method toward the enhanced nanometal interconnection of carbon conductors (NICCs).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Self-Supported Hydrous Iridium–Nickel Oxide Two-Dimensional Nanoframes for High Activity Oxygen Evolution Electrocatalysts

Oxygen evolution reaction (OER) electrocatalysts with high activity, high stability, and low costs are needed for proton-exchange membrane (PEM) electrolyzers. Based on the high cost and limited supply of iridium, approaches that result in iridium-based OER catalysts with increased catalytic activity are of significant interest. Here, we report a carbon-free, self-supported hydrous iridium-nickel oxide two-dimensional nanoframe structure synthesized by thermal treatment of iridium-decorated nickel oxide nanosheets under reducing conditions and subsequent chemical leaching in acid. The catalyst nanoarchitecture contains an interconnected network of metallic iridium-nickel alloy domains with hydrous iridium oxide and nickel oxide located in the surface region. The electrochemical oxidation step maintains the three-dimensional nanoarchitecture and results in a thin (~5 A) oxide/hydroxide surface layer. The temperature used for thermal reduction was found to strongly affect the catalyst surface structure and OER activity. Utilizing a lower thermal reduction temperature of 200 degrees C was determined to provide a higher relative surface concentration of hydroxides and nickel oxide and result in higher OER activities compared with materials treated at 300 degrees C. The 200 degrees C-treated hydrous iridium-nickel oxide electrocatalyst showed 15 times higher initial OER mass activity than commercial IrO 2 , and the activity remained 10 times higher than IrO 2 after accelerated durability testing. Density functional theory (DFT) calculations and analysis of the experimental Tafel slopes support that the second electron transfer step is the rate-limiting step for the reaction. The DFT calculations demonstrate that Ni substitution on the IrO 2 surface lowers the activation energy for adsorbed intermediates of the second electron transfer step of the OER reaction. This work establishes that noble metal-decorated metal oxide nanosheets can be transformed into high surface area, carbon-free electrocatalyst nanostructures with high catalytic activities and molecular accessibility and reveals the importance of using controlled thermal reduction temperatures to alter the surface structure and OER activity.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Computationally-Guided Synthetic Control over Pore Size in Isostructural Porous Organic Cages

The physical properties of 3-D porous solids are defined by their molecular geometry. Hence, precise control of pore size, pore shape, and pore connectivity are needed to tailor them for specific applications. However, for porous molecular crystals, the modification of pore size by adding pore-blocking groups can also affect crystal packing in an unpredictable way. This precludes strategies adopted for isoreticular metal-organic frameworks, where addition of a small group, such as a methyl group, does not affect the basic framework topology. Here, we narrow the pore size of a cage molecule, CC3, in a systematic way by introducing methyl groups into the cage windows. Computational crystal structure prediction was used to anticipate the packing preferences of two homochiral methylated cages, CC14-R and CC15-R, and to assess the structure-energy landscape of a CC15-R/CC3-S cocrystal, designed such that both component cages could be directed to pack with a 3-D, interconnected pore structure. The experimental gas sorption properties of these three cage systems agree well with physical properties predicted by computational energy-structure-function maps.

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

Controls of Microstructure and Chemical Reactivity on the Replacement of Limestone by Fluorite Studied Using Spatially Resolved Small Angle X-ray and Neutron Scattering

Fluid-mineral interactions can alter the pore structure and mineral composition of earth materials, sometimes leading to complete replacement of one mineral phase by another. A quantitative understanding of these processes is needed for the prediction of contaminant transport in nuclear waste management, oil and gas exploration, geothermal energy production and in many geological processes. Currently, a detailed understanding of how the original microstructure and chemical reactivity is affecting the replacement rate and porosity development is lacking which would enable the prediction of contaminant transport. Here, we present a systematic experimental study of limestone replacement in the model system calcite-fluorite varying both the texture and chemical reactivity of the parent rock. By combining X-ray ((U)SAXS) and neutron (ultra) small-angle scattering ((U)SANS) we quantified changes in the porosity as a function of depth within the sample and time. By shielding the samples with a set of annular Cd-masks during neutron scattering, we obtained spatially-resolved porosity information. Microstructural changes were investigated using scanning electron microscopy (SEM), and composition changes were accessed using chemical imaging by Time-of-Flight Secondary Ion Mass Spectrometry (ToF—SIMS) and SEM-Energy-Dispersive X-Ray Spectroscopy (SEM-EDX). The replacement of limestone via fluorite takes place via advantageous pathways enhancing the available reactive surface area, e.g. fractures, accessible, interconnected porosity, non-connected porosity grain boundaries and twin boundaries. The results presented in this paper emphasize the importance of a detailed structural and textural assessment of the starting material both in experimental studies and in nature to make accurate predictions about reaction rates.

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

Perovskite/Silicon Tandem Solar Cells: Insights and Outlooks

Organic-inorganic hybrid perovskites have been widely used in silicon-based tandem solar cells for their advantages of tunable bandgap, high light absorption coefficient, and high power conversion efficiency (PCE). However, the maximum PCE of perovskite/silicon tandem solar cells (PSTSCs) is still below the theoretical limit. This Review describes the PSTSCs' working principle and then summarizes the research progress in recent years, including a comparison of perovskite layers, interconnection layers, and silicon bottom cells. Then, the n-i-p PSTSCs and p-i-n PSTSCs are presented based on the PSCs' top cells, and the main factors affecting the efficiency of PSTSCs are discussed in detail. Finally, an outlook on the future development of PSTSCs is discussed.

electrical conductivity↗
DOE OSTI2018

Effect of Pore Connectivity on Li Dendrite Propagation within LLZO Electrolytes Observed with Synchrotron X-ray Tomography

Li 7 La 3 Zr 2 O 12 (LLZO) is a garnet type material that demonstrates promising characteristics for all solid-state battery applications due to its high Li-ion conductivity and its compatibility with Li metal. The primary limitation of LLZO is the propensity for short-circuiting at low current densities. Microstructure features such as grain boundaries, pore character, and density all contribute to this shorting phenomenon. Toward the goal of understanding structure-processing relationships for practical design of solid electrolytes, the present study tracks structural transformations in solid electrolytes processed at three different temperatures (1000, 1050 and 1150 °C) using synchrotron x-ray tomography. A sub volume of 300 μm 3 captures the heterogeneity of the solid electrolyte microstructure while minimizing the computational intensity associated with 3D reconstructions. While the porosity decreases with increasing temperature, the underlying connectivity of the pore region increases. In conclusion, solid electrolytes with interconnected pores short circuit at lower critical current densities than samples with less connected pores.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Unraveling the Unconventional Order of a High-Mobility Indacenodithiophene-Benzothiadiazole Copolymer

We report a new class of donor–acceptor (D-A) copolymers found to produce high charge carrier mobilities competitive with amorphous silicon (>1 cm 2 V –1 s –1 ) exhibit the puzzling microstructure of substantial local order, however lacking long-range order and crystallinity previously deemed necessary for achieving high mobility. Here, we demonstrate the application of low-dose transmission electron microscopy to image and quantify the nanoscale and mesoscale organization of an archetypal D-A copolymer across areas comparable to electronic devices (≈9 μm 2 ). The local structure is spatially resolved by mapping the backbone (001) spacing reflection, revealing nanocrystallites of aligned polymer chains throughout nearly the entire film. Analysis of the nanoscale structure of its ordered domains suggests significant short- and medium-range order and preferential grain boundary orientations. Moreover, we provide insights into the rich, interconnected mesoscale organization of this new family of D-A copolymers by analysis of the local orientational spatial autocorrelations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗