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DOE OSTI2024

Platinum and CeO 2-x Occlusion Electrodeposition at Unsupported Vulcan XC-72R for Methanol and Ethanol Oxidation Reactions in Alkaline Media

Abstract Platinum was electrodeposited in a slurry solution of CeO2 and Vulcan XC-72R to produce Pt/CeO2-x/Vulcan XC-72R catalysts by using the Rotating Disk Slurry Electrodeposition (RoDSE) Technique. The activity of the catalysts was measured towards methanol and ethanol oxidation reactions in alkaline conditions by cyclic voltammetry and chronoamperometry. The electrochemical results were compared to those obtained on commercial catalysts. Pt/CeO2-x/Vulcan XC-72R (with ~ 26 wt.% Pt) catalyst was the most active for both alcohol oxidation reactions when compared to commercial 40 wt.% and 20% /Vulcan XC-72R (ETEK) catalysts. The mass activity increases 2.0x and 2.4x for methanol and ethanol oxidation reactions when compare with 40 and 20 Pt wt. % commercial catalysts, respectively. The Pt/CeO2-x/Vulcan XC-72R catalysts contained Pt nanoparticles growth within the cerium oxide through an occlusion electrodeposition method. These effects were systematically investigated using X-ray Diffraction (XRD), High Resolution Transmission Electron Microscopy (HR-TEM), and X-ray Photoelectron Spectroscopy (XPS).

Suleiman Mahmoud, Amal↗

DOE OSTI2021

Development of High-Performance Ni-base Alloys for Gas Turbine Wheels Using a Coprecipitation Approach (Final Technical Report)

In this project, a synergistic approach involving experiments informed by modelling was used to develop γ'/γ'' coprecipitation-strengthened Ni-base superalloys for land-based gas turbine wheels. In thick sections of such turbine wheels, the slow cooling rate normally observed, as well as variations in cooling rate could potentially result in drastically inhomogeneous and coarsened microstructure. Thus, ten alloy compositions were selected based on coprecipitation and sluggish γ’ growth and coarsening during three iterations of alloy development, assisted by extensive CALPHAD modeling. Phase equilibrium calculations, informed by the characterization of early alloys, were successful in predicting suitable aging treatments to obtain bimodal coprecipitate distribution in several alloys. These aging treatments were applied to the subsequent round of alloys and the resulting microstructures were characterized in detail. Two different cooling rates were used during each of these heat treatments to simulate the range of cooling rates observed in a thick section forging. The microstructures were used to calibrate a multi-phase field model (MPF), which was used to study the formation mechanisms of various coprecipitate morphologies observed in the experiments. Following this, the most promising alloys in each round were selected and studied using high temperature tensile and creep tests. Considering that a slower cooling rate would lead to a strength debit, while a faster cooling rate might lead to a decline in creep rupture life of a full-scale wheel, tensile tests were carried out for slower cooled samples, while creep tests were carried out for faster cooled samples. The deformation microstructures were then characterized using advanced characterization techniques such as Diffraction Contrast-Scanning Transmission Electron Microscopy (DC-STEM) and Electron Channeling Contrast Imaging (ECCI). Further, a mean-field creep model was developed and calibrated using these experimental findings to predict long-term creep behavior of these coprecipitation-strengthened alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2021

The Role of Metal Oxides in Li-S Batteries: A High-Areal-Capacity Sulfur Composite Cathode Investigation

Compared to lithium-ion batteries (LIB), lithium-sulfur (Li-S) batteries have low cost and high theoretical specific energy (2510 Wh/kg or about 10 times of the LIB). However, Li-S batteries have several challenges, including large volume expansion, poor utilization of the end products, sluggish kinetics of polysulfides, and crossover, so-called the "shuttle effect". To address these issues, we have introduced metal oxides to the Li-S electrode to develop a metal-oxide-sulfur composite electrode. We aim to use metal oxides to assist the Li-S formation (dissociation) during discharge (charge) cycles. We elect to focus on LIB-based metal oxides to ensure that the added material can contribute storage capacity to the battery. Our cathodes are fabricated by both the conventional slurry casting and air-controlled electrospray. LIB electrode materials, such as Li(Ni 0.6 Mn 0.6 Co 0.2 )O 2 , LiMn 2 O 4 , Li 2 TiO 3 , etc, were incorporated with the sulfur-carbon composite and their charge-discharge performances are compared. We found that the presence of metal oxides increased sulfur utilization with stable cycling performance, even in cells with high areal capacities. To unveil the interactions between lithium metal oxides and sulfur, the cathodes were analyzed by various characterization techniques, including scanning electron microscopy, X-ray diffraction, thermogravimetric analysis, and electrochemistry. The analysis of the role of the oxides will be presented along with the reaction mechanism.

25 ENERGY STORAGE↗

DOE OSTI2022

High Efficiency InGaN LEDs Emitting in Green, Amber and Beyond (Final Report)

This project focuses on developing high efficiency light emitting diodes (LEDs) with green, amber, and longer wavelengths using two compatible material systems based on III-nitride and II-IV-nitride semiconductor heterostructures. The proposed approach uses low-indium-content InGaN and ZnGeN 2 or ZnSnN 2 heterostructure quantum wells (QWs) as the active regions for high efficiency green and amber LEDs, and therefore to advance high efficiency color-mixed white LED technology. This approach takes advantage of the increased flexibility, afforded by the incorporation of the II-IV-nitrides into the III-nitride layers, to tune the QW active region to lower the emission wavelengths and to increase the electron-hole wave function overlap. This strategy paves a new way to extend the InGaN QW LED emission wavelength without using high-indium-content InGaN. An industrially preferable metalorganic chemical vapor deposition (MOCVD) method was used to develop the growth of ZnGeN 2 and ZnSnN 2 that are compatible with the InGaN growth. The unique dual chamber MOCVD instrument at OSU was used in this project. This program created an opportunity for the two institutions (The Ohio State University and Case Western Reserve University) with complementary expertise to perform this work. Two graduate students (Md Rezaul Karim (OSU) and Benthara Hewage Dinushi Jayatunga (CWRU)) gained experience in MOCVD growth and various characterization methods including scanning electron microscopy, x-ray diffraction spectroscopy, x-ray photoemission spectroscopy, Hall measurements, cathodoluminescence and photoluminescence. Both students successfully defended their PhD dissertations in April/May 2021. Both Karim and Jayatunga have joined Intel as engineers in June/July 2021. Another two graduate students Kaitian Zhang (OSU) and Chenxi Hu (CWRU) joined the project team since spring 2021 to continue on this project. They were trained on MOCVD epitaxy of InGaN QWs and materials characterization including SEM, AFM, PL, CL, XRD, Hall measurements and electroluminescence. A third student, Vijay Gopal Thirupakuzi Vangipuram (OSU), who joined the group in fall 2021 to perform LED fabrication and characterization. The key research accomplishments of the project include: (1) Successful development of MOCVD epitaxy of single crystalline ZnGeN 2 and ZnSnN 2 . MOCVD growth parameters that determine the stoichiometry of ZnGeN 2 and ZnSnN 2 films were identified. (2) Experimentally determined the band offsets between GaN/ZnGeN 2 and GaN/ZnGaSnN 2 hetero-interfaces, which agree very well with the theoretical predictions. (3) Demonstrated the incorporation of thin ZnGeN 2 layer in InGaN QWs. Proof-of-concept of the InGaN-ZnGeN 2 QW design demonstrated as much as 80 nm of red shift without increasing In composition or QW thickness. (4) InGaN/ZnGeN 2 QWs emitting at 480 nm achieved IQE of 47%. Resulted from this project, 7 journal articles were published, and 9 conference papers were presented.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Analysis of harmonically seeded Free-Electron Laser

We revisit Free-Electron Laser (FEL) equations in the presence of a planar undulator to investigate effects on longitudinal FEL dynamics upon seeding by a harmonic for both low-gain and high-gain cases. Then, we extend the FEL equations in 3D to include electron beam emittance and radiation diffraction effects.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Studies on Printability Methodologies and Directed-Energy-Deposition-Fabricated Iron Alloys for Nuclear Applications

This report provides results from a printability study of laser directed energy deposition (DED)-based additive manufacturing of nuclear-grade stainless steels as well as DED process parameter development for austenitic Alloy 709 (A709) and ferritic/martensitic Grade 91 (G91) and Grade 92 (G92) steels. The printability study includes the use of machine learning and physics-based modeling via commercial software such as FLOW-3D for insights into the impact of the alloy composition, particularly the carbon content, on the printability of stainless steels during the DED process. In the DED process development work, 1 cm 3 alloy blocks were deposited with broad ranges of laser powers, scan speeds, and hatch spacings to optimize the build quality, resulting in densities of more than 99.8% for all three alloys. The microstructure and mechanical properties were characterized using electron microscopy, X-ray diffraction, and Vickers hardness measurements. Further, tensile samples were extracted from DED-fabricated alloys utilizing the optimized process parameters. The present work provides guidance and progress towards the successful deployment of the DED process for the fabrication of structural components of nuclear reactors.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

Global battery manufacturers are increasingly worried about the serious supply chain constraint caused by rapid fluctuations in cobalt prices over the years. We present a novel cobalt-free, nickel-rich layered cathode material called NFA class (LiNixFeyAlzO2) to tackle this challenge. Spherical NFA(OH)2 precursors were successfully synthesized by incorporating Ni, Fe, and Al elements using a co-precipitation reaction in a continuous stirred tank reactor. The LiNFAO2 cathode, composed of LiNi0.85Fe0.05Al0.1O2, was synthesized and analyzed using X-Ray diffraction, Mössbauer spectroscopy, and scanning electron microscopy (SEM). The material's electrochemical behavior was evaluated through various techniques at different lithiation/delithiation states in two voltage ranges. The cobalt-free material exhibits a high capacity of 190 mAh/g at 0.1C within the voltage range of 3V-4.5V, as demonstrated by electrochemical performance evaluations. Rate and cycling evaluations showed good rate capability and cycling stability, with 88% capacity retention after 100 cycles at C/3 within the voltage range of 3V-4.3V. Our research shows the great potential of cobalt-free NFA cathodes as a feasible option for developing cost-effective lithium-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

25 ENERGY STORAGE↗

DOE OSTI2022

LiNi 0.8 Fe 0.1 Al 0.1 O 2 as a Cobalt-Free Cathode Material with High Capacity and High Capability for Lithium-Ion Batteries

Obtaining cathode materials with high capacity and cycle stability is one of the main challenges regarding the success of electric vehicle technologies. However, most of the widely used materials with these properties involve the use of toxic and expensive cobalt as the active material. To overcome this challenge, this work proposes a novel cobalt-free cathode material, synthesized for the first time using a solid-state reaction, whose general formula is LiNi 0.8 Fe 0.1 Al 0.1 O 2 (NFA). This class of materials offers high capacity and reduces the battery costs by removing cobalt, without jeopardizing the structural stability and safety of the NFAs. The morphology and the structural properties of the obtained NFA cathode material were characterized using different techniques, e.g., scanning electronic microscopy, X-ray diffraction, X-ray fluorescence, and infrared and Raman spectroscopies. The electrochemical activity and diffusivity of the Li-ion during lithium removal and its insertion into the bulk of the NFA cathode demonstrated high-yield specific capacities of ≈180 mAh g –1 at 0.1C, along with a reasonable rate capability and cycling stability, with a capacity retention of ≈99.6% after 100 charge/discharge cycles at a rate of C/2, and whose operando X-ray diffraction experiments have been used to study the crystallographic transitions during the lithiation–delithiation reaction.

25 ENERGY STORAGE↗

DOE OSTI2025

From Pollutant Removal to Renewable Energy: MoS2-Enhanced P25-Graphene Photocatalysts for Malathion Degradation and H2 Evolution

The widespread presence of pesticides—especially malathion—in aquatic environments presents a major obstacle to conventional remediation strategies, while the ongoing global energy crisis underscores the urgency of developing renewable energy sources such as hydrogen. In this context, photocatalytic water splitting emerges as a promising approach, though its practical application remains limited by poor charge carrier dynamics and insufficient visible-light utilization. Herein, we report the design and evaluation of a series of TiO2-based ternary nanocomposites comprising commercial P25 TiO2, reduced graphene oxide (rGO), and molybdenum disulfide (MoS2), with MoS2 loadings ranging from 1% to 10% by weight. The photocatalysts were fabricated via a two-step method: hydrothermal integration of rGO into P25 followed by solution-phase self-assembly of exfoliated MoS2 nanosheets. The composites were systematically characterized using X-ray diffraction (XRD), Raman spectroscopy, transmission electron microscopy (TEM), UV-Vis diffuse reflectance spectroscopy (DRS), and photoluminescence (PL) spectroscopy. Photocatalytic activity was assessed through two key applications: the degradation of malathion (20 mg/L) under simulated solar irradiation and hydrogen evolution from water in the presence of sacrificial agents. Quantification was performed using UV-Vis spectroscopy, gas chromatography–mass spectrometry (GC-MS), and thermal conductivity detection (GC-TCD). Results showed that the integration of rGO significantly enhanced surface area and charge mobility, while MoS2 served as an effective co-catalyst, promoting interfacial charge separation and acting as an active site for hydrogen evolution. Nearly complete malathion degradation (~100%) was achieved within two hours, and hydrogen production reached up to 6000 µmol g−1 h−1 under optimal MoS2 loading. Notably, photocatalytic performance declined with higher MoS2 content due to recombination effects. Overall, this work demonstrates the synergistic enhancement provided by rGO and MoS2 in a stable P25-based system and underscores the viability of such ternary nanocomposites for addressing both environmental remediation and sustainable energy conversion challenges.

Chemistry↗

DOE OSTI2021

Composition and Pressure Effects on Partitioning of Ferrous Iron in Iron-Rich Lower Mantle Heterogeneities

Both seismic observations of dense low shear velocity regions and models of magma ocean crystallization and mantle dynamics support enrichment of iron in Earth’s lowermost mantle. Physical properties of iron-rich lower mantle heterogeneities in the modern Earth depend on distribution of iron between coexisting lower mantle phases (Mg,Fe)O magnesiowüstite, (Mg,Fe)SiO3 bridgmanite, and (Mg,Fe)SiO3 post-perovskite. The partitioning of iron between these phases was investigated in synthetic ferrous-iron-rich olivine compositions (Mg0.55Fe0.45)2SiO4 and (Mg0.28Fe0.72)2SiO4 at lower mantle conditions ranging from 33–128 GPa and 1900–3000 K in the laser-heated diamond anvil cell. The resulting phase assemblages were characterized by a combination of in situ X-ray diffraction and ex situ transmission electron microscopy. The exchange coefficient between bridgmanite and magnesiowüstite decreases with pressure and bulk Fe# and increases with temperature. Thermodynamic modeling determines that incorporation and partitioning of iron in bridgmanite are explained well by excess volume associated with Mg-Fe exchange. Partitioning results are used to model compositions and densities of mantle phase assemblages as a function of pressure, FeO-content and SiO2-content. Unlike average mantle compositions, iron-rich compositions in the mantle exhibit negative dependence of density on SiO2-content at all mantle depths, an important finding for interpretation of deep lower mantle structures.

Dorfman, Susannah M. (ORCID:0000000239689592)↗

DOE OSTI2022

Silver Nanoparticles Functionalized Nanosilica Grown over Graphene Oxide for Enhancing Antibacterial Effect

The continuous growth of multidrug-resistant bacteria due to the overuse of antibiotics and antibacterial agents poses a threat to human health. Silver nanoparticles, silica-based materials, and graphene-based materials have become potential antibacterial candidates. In this study, we developed an effective method of enhancing the antibacterial property of graphene oxide (GO) by growing nanosilica (NS) of approximately 50 nm on the graphene oxide (GO) surface. The structures and compositions of the materials were characterized through powdered X-ray diffraction (P-XRD), transmission electron microscopy (TEM), scanning electron microscopy coupled with energy dispersive X-ray spectroscopy (SEM-EDS), ultraviolet–visible spectroscopy (UV–VIS), dynamic light scattering (DLS), Raman spectroscopy (RM), Fourier-transform infrared spectroscopy (FTIR), Brunauer–Emmet–Teller (BET) surface area, and pore size determination. The silver nanoparticles (AgNPs) with an average diameter of 26 nm were functionalized on the nanosilica (NS) surface. The composite contained approximately 3% of silver nanoparticles. The silver nanoparticles on nanosilica supported over graphene oxide (GO/NS/AgNPs) exhibited a 7-log reduction of Escherichia coli and a 5.2-log reduction of Bacillus subtilis within one hour of exposure. Both GO/NS and GO/NS/AgNPs exhibited substantial antimicrobial effects against E. coli and B. subtilis.

36 MATERIALS SCIENCE↗

NASA NTRS1973

Investigation of KC-135 flight samples solidified in near-zero gravity

An analysis was conducted of three KC-135 flight samples that had been solidified in near-zero gravity. These samples had been generated during near-zero gravity testing of M553 experiment Skylab flight hardware. The samples evaluated were all Star-J Satellite, a cobalt base alloy. The analytical procedures (optical microscopy, scanning electron microscopy, electron microprobe, X-ray diffraction, differential scanning calorimetry, and microhardness) to be use on the Skylab flight samples were optimized and the analytical results are presented.

Larson, D., Jr.↗

NASA NTRS1975

Effect of magnesium oxide content on oxidation behavior of some superalloy-base cermets

The effect of increasing magnesium oxide (MgO) content on the cyclic oxidation resistance of hot-pressed cermets of MgO in NiCrAlY, MgO in Hoskins-875, MgO in Inconel-702, and MgO in Hastelloy-X was investigated. The cermets with magnesium oxide levels of 5, 10, 20, and 40 vol percent were examined. The cyclic oxidation behavior of these cermets at 1100 and 1200 C in still air was determined by a thermogravimetric method supplemented by X-ray diffraction analysis and light and electron microscopy. In all instances, MgO prevented grain growth in the metallic phase. No evidence of oxidation along interphase boundaries was detected. Cermets of MgO in NiCrAlY and MgO in Hoskins-875 were superior to cermets of MgO in Inconel-702 and MgO in Hastelloy-X. Their oxidation resistance was degraded only when the MgO content was 40 vol percent. The oxidation behavior of MgO-in-Inconel-702 powder cermets containing 5- and 10-vol percent MgO was approximately similar to that of pure Inconel-702 compacts. The 20- and 40-vol percent MgO content reduced the oxidation resistance of MgO-in-Inconel-702 powder cermets relative to that of pure Inconel-702.

Zaplatynsky, I.↗

NASA NTRS1975

Interaction of hydrogen chloride with alumina

The influence of outgas conditions and temperature on the adsorptive properties of two aluminas Alon-c and Al6sG were studied using adsorption isotherm measurements. Alon-C and Al6SG were characterized using X-ray powder diffraction, thermogravimetric analysis (TGA), scanning electron microscopy (SEM) and BET nitrogen surface areas. Some of these techniques were applied to two other aluminas but no isotherm data was obtained. Isotherm data and techniques applied to each alumina are summarized in tabular form.

Bailey, R. R.↗

NASA NTRS1977

Consolidation of silicon nitride without additives

The feasibility of producing a sound, dense Si3N4 body without additives was explored, using conventional gas hot isostatic pressing techniques and an uncommon hydraulic hot isostatic pressing technique. These two techniques produce much higher pressure 275-413 MN/m sq (40,000 - 60,000 psi) than hot-pressing techniques. Evaluation was based on density measurement, microscopic examination, both optical and electron, and X-ray diffraction analysis. The results are summarized as follows: (1) Si3N4 can be densified to high density, greater than 95% of theoretical, without additions. (2) The higher density Si3N4 specimens appear to be associated with a greater amount of alpha to beta transformation. (3) Under high pressure, the alpha to beta transformation can occur at a temperature as low as 1150 C. (4) Grain deformation and subsequent recrystallization and grain refinement result from hot isostatic pressing of Si3N4.

Sikora, P. F.↗

NASA NTRS1979

Consolidation of Si3N4 by hot isostatic pressing

Silicon nitride (Si3N4) is being considered for gas turbine engine applications because present-day metallic alloys are rapidly approaching the limits of their temperature capabilities. The present investigation was undertaken to determine the feasibility of producing a sound, dense Si3N4 body without additives, using conventional gas hot-isostatic-pressing techniques and an uncommon hydraulic hot-isostatic-pressing technique. These two hot-isostatic-pressing (HIP) techniques produce much higher pressure (275-413 MN/sq m) than conventional hot-pressing techniques and have the potential of producing large bodies of desirable shapes. Evaluation was based on density measurement, microscopic examination, both optical and electron, and X-ray diffraction analysis.

Yeh, H. C.↗

NASA NTRS1986

Oxidation and emittance of superalloys in heat shield applications

Recently developed superalloys that form alumina coatings have a high potential for heat shield applications for advanced aerospace vehicles at temperatures above 1095C. Both INCOLOY alloy MA 956 (of the Inco Alloys International, Inc.), an iron-base oxide-dispersion-strengthened alloy, and CABOT alloy No. 214 (of the Cabot Corporation), an alumina-forming nickel-chromium alloy, have good oxidation resistance and good elevated temperature strength. The oxidation resistance of both alloys has been attributed to the formation of a thin alumina layer (alpha-Al2O3) at the surface. Emittance and oxidation data were obtained for simulated Space Shuttle reentry conditions using a hypersonic arc-heated wind tunnel. The surface oxides and substrate alloys were characterized using X-ray diffraction and scanning and transmission electron microscopy with an energy-dispersive X-ray analysis unit. The mass loss and emittance characteristics of the two alloys are discussed.

Wiedemann, K. E.↗