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DOE OSTI2020

Materials Data on TmPS by Materials Project

TmPS crystallizes in the orthorhombic Pnma space group. The structure is three-dimensional. there are two inequivalent Tm3+ sites. In the first Tm3+ site, Tm3+ is bonded in a 9-coordinate geometry to four equivalent P1- and five S2- atoms. All Tm–P bond lengths are 3.05 Å. There are a spread of Tm–S bond distances ranging from 2.73–2.86 Å. In the second Tm3+ site, Tm3+ is bonded in a 9-coordinate geometry to four equivalent P1- and five S2- atoms. There are two shorter (2.88 Å) and two longer (3.05 Å) Tm–P bond lengths. There are a spread of Tm–S bond distances ranging from 2.70–2.81 Å. P1- is bonded in a 6-coordinate geometry to four Tm3+ and two equivalent P1- atoms. There are one shorter (2.24 Å) and one longer (2.28 Å) P–P bond lengths. There are two inequivalent S2- sites. In the first S2- site, S2- is bonded in a 5-coordinate geometry to five Tm3+ atoms. In the second S2- site, S2- is bonded to five Tm3+ atoms to form a mixture of distorted corner and edge-sharing STm5 trigonal bipyramids.

36 MATERIALS SCIENCE↗

DOE OSTI2026

In Situ EXAFS Study of Mo–P Bond Dynamics in Molybdenum Phosphide during CO 2 Reduction and Hydrogen Evolution

Transition Metal Phosphides (TMPs) are widely studied as catalysts in reactions like hydrogen evolution, oxygen reduction, and hydrodesulfurization. TMPs have demonstrated remarkable efficiency in accelerating reactions by providing active sites for adsorption and facilitating the transformation of reaction intermediates, a feature that has increased the interest of TMPs in the electrochemical carbon dioxide reduction reaction (eCO 2 RR). Despite their growing use, the potential-dependent structural behavior of TMPs under operating electrochemical conditions remains insufficiently understood. This work investigates the dynamics of the Mo−P bond during eCO 2 RR and hydrogen evolution reaction (HER) using in situ extended X-ray absorption spectroscopy (EXAFS) studies at the Mo−K edge. Structural characterization of the synthesized MoP nanoparticles was performed by powder X-ray diffraction (XRD) and transmission electron microscopy (TEM). Results of the overall electrochemical activity of MoP are presented through linear sweep voltammetry (LSV) experiments in the potential range of 0 to −1.5 V versus Ag/AgCl and chronoamperometry (CA). Liquid products were analyzed by 1 H NMR spectroscopy. The synthesized catalyst showed increasing activity with the highest Faradaic efficiency of 11.75% for C 2+ products at −1.3 V vs Ag/AgCl. In situ EXAFS revealed a change in the average Mo−P bond distance during eCO 2 RR, whereas no such change was observed during the hydrogen evolution reaction (HER). This finding suggests that phosphorus, particularly through modulation of the Mo−P bond length, plays an important role in the eCO 2 RR and demonstrates how in situ EXAFS can track local structural perturbations in MoP catalysts during electrochemical operation, providing complementary structural insight that correlates with electrochemical behavior.

Catalysts↗

DOE OSTI2020

Li-Metal Anode in Dilute Electrolyte LiFSI/TMP: Electrochemical Stability Using Ab Initio Molecular Dynamics

Ab initio molecular dynamics simulations were performed for Li + conducting electrolytes based on trimethyl phosphates (TMP) and lithium bis(fluorosulfonyl)imide (Li + FSI – ) salt in contact with a Li-metal electrode. We focused on the transient-state behavior at the electrolyte, interfacial electrolyte–Li-metal electrode, and lithium reference electrode–electrolyte–Li-metal electrode to study dynamics and activation energy barriers of the Li + ion, electrochemical and thermal stability of the interface electrode-electrolyte, and potential behavior of the Li-metal electrode, respectively. Our results show that in the most stable state, Li + ions are tetrahedrally coordinated to three TMPs and one FSI – . The inner solvation shell of a Li-ion is composed of three TMP and one FSI – in one contact ion-pair and four TMPs in a solvent-separated ion-pair. On the other hand, Li-ions transport through electrolyte cages takes place when they are coordinated with three or less molecules that could be a combination of TMPs and FSI – . The decomposition pathway of the LiFSI salt when in direct contact with the Li-metal anode starts with defluorination of FSI – , rapidly losing F– to the lithium surface, forming LiF species. The remaining FSO 2 NSO 2 –2 with the addition of 2e – from the Li-metal decomposes into SO 2 –2 and NFSO 2 –2 . SO 2 –2 deposits on the Li-surface and decomposes into Li 2 O and Li 2 S. The remaining NFSO 2 –2 defluorinates, losing F – ion to the lithium surface, resulting in LiF and the remaining NSO 2 –1 deposits on the lithium surface and decomposes in the following picoseconds, forming several binary compounds such as Li 3 N, Li 2 S and Li 2 O. In contrast, when the salt is solvated by the TMP molecules, avoiding a direct contact with the Li metal electrode, only one defluorination occurs, decomposing the FSI – into FSO 2 NSO 2 –2 and a F – . The two anions remain stable as they are solvated by the TMP molecules. Furthermore, we also analyzed the open circuit potential energy (OCPE) of the Li-metal electrode during the SEI formation. OCPE is calculated from the average local potential profile difference within the Li-metal electrode and a pristine Li-crystal reference electrode (LRE). When no SEI is formed, the Li-metal electrode has an average OCPE of +0.36 eV vs LRE. Due to the formation of a SEI, the Li-metal electrode has an average OCPE between -0.07 and -0.21 eV vs LRE. The OCPE of the Li-metal electrode decreases by ~0.42 eV when a SEI is formed.

25 ENERGY STORAGE↗

DOE OSTI2021

UIR-Net: Object Detection in Infrared Imaging of Thermomechanical Processes in Automotive Manufacturing

Thermomechanical processes (TMPs) such as resistance spot welding (RSW) and hot stamping are widely used in automotive manufacturing. Recent advancement in sensing technology has led to an increasing adoption of thermographic cameras to capture the infrared (IR) radiation of a metal part (or component of a part) during its thermomechanical processing or immediately after the process when the part is still hot. Detecting the object(s) of interest from raw IR images is an essential step in analyzing these data. Deep learning (DL) has been a recent success for object detection (OD), but the application of DL-based OD for industrial IR images in manufacturing is largely lagging behind. The major contribution of this work, which is also the distinction from previous OD studies, is the capability of building the OD model with unlabeled IR images, i.e., imaging data without accurate information indicating the object position. Here, the architecture of Unsupervised IR Image Net (UIR-Net) is designed to accommodate the unique characteristics of IR images from TMPs in manufacturing. This study presents a novel method for OD in unlabeled IR images from TMPs. The proposed method, called UIR-Net, consists of two components: label generation and DL model construction. Two case studies from automotive manufacturing, RSW and hot stamping, are reported to demonstrate the feasibility and effectiveness of the proposed method.

42 ENGINEERING↗

DOE OSTI2025

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗

DOE OSTI2025

Countercurrent flow characteristics of next generation solvent in novel 3D printed columns for carbon capture

Solvent based absorption for carbon dioxide capture in a packed column is being considered as an efficient technology for the decarbonization process of point source. Significant efforts are underway to improve the design of packings with the cutting edge 3D printing technology for efficient carbon capture. Accordingly, multiphase flow studies were conducted to assess the performance of novel 3D printed columns with various triply periodic minimal surface (TPMS) designs. The effects of solvent properties, liquid and gas loads on the performance of TPMS columns are extensively explored. Hydrodynamics of the potential water-lean solvents (EEMPA) as well as aqueous monoethanolamine (MEA) solvent for carbon capture are evaluated and compared. The interfacial area and liquid holdup increase with increasing liquid loads (q L ) for TPMS columns. Schwarz column consistently shows the highest liquid holdup value. The EEMPA exhibits higher values for the interfacial area (10–15 %) and liquid holdup (~4 %) in comparison to the MEA. TPMS columns exhibit the intermediate value of dry pressure drop between the random and the structure packed columns. Among selected TPMS columns, the gyroid packing shows the lowest pressure drop. The gas load has marginal impact on the interfacial area at lower value while a higher gas load leads to column’s flooding. Prior to the flooding, the interfacial area in TMPS packings rises with increased gas load at a fixed liquid load except Schwarz packing where interfacial area is incentive to the gas load. Additionally, the liquid holdup and wet pressure drop rise as gas load increases in TPMS columns. Overall, Fisher Koch packing is more susceptible to flood as compared to other TPMS packings. Flow regimes: loading and flooding are also delineated in the TPMS packings.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Probing of the Noninnocent Role of P in Transition-Metal Phosphide Hydrogen Evolution Reaction Electrocatalysts via Replacement with Electropositive Si

Transition-metal phosphides (TMP) have been identified as promising electrocatalysts for the hydrogen evolution reaction (HER). Despite recent computational investigations identifying P sites as being crucial for hydrogen adsorption, the main mode of optimization for TMPs has been focused on changing the metal sites. Here, to experimentally verify computational hypotheses and provide a route for HER electrocatalyst optimization via ternary compounds, we performed systematic experimental studies of structurally related NiSi 1–x P x phases, namely, Ni 2 SiP, Ni 5 Si 2 P 3 , Ni 3 SiP 2 , and Ni 7 Si 2 P 5 , which are ordered derivatives of the NiSi structure (Pnma, oP-8, MnP structure type). We found that P played a significant role in modulating HER activity in an acidic electrolyte because the incorporation of P in NiSi reduced the overpotential at current density j = 10 mA/cm 2 from η 10 = 529 mV (NiSi) to η 10 = 97 mV (Ni 2 SiP). Ni 2 SiP outperformed the current state-of-the-art Ni5P4 electrocatalyst prepared and studied in identical conditions both in terms of activity and stability, which is attributed to the presence of covalent Ni–Si bonding in the structure. Within the family of ternary Ni–Si–P compounds, electrocatalytic activity correlates with the number of Ni-3d states at the Fermi energy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Mechanical Performance of Additively Manufactured ODS 316L and 316H Stainless Steels

This work package within the Advanced Materials and Manufacturing Technologies (AMMT) program focused on the mechanical and microstructural characterization of oxide dispersion strengthened (ODS) stainless steels produced using advanced manufacturing techniques. The research aimed to identify an accelerated development path for ODS alloys by integrating additive manufacturing (AM) technologies with recent advancements in ODS materials and traditional manufacturing methods. For FY 24, the research specifically targeted exploring an accelerated development path for ODS alloys by combining AM technologies with these advancements. Novel AM and post-build processing routes were developed for ODS austenitic alloys, including Fe-Cr-Ni alloys such as 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the impact of process variables on microstructure and properties, with the goal of optimizing these properties economically. Traditionally, producing ODS alloys involves multi-day, high-energy mechanical milling of alloy powder with yttria powder, followed by milled-powder consolidation through extrusion or other methods, and additional thermomechanical processing (TMP) for property control. To overcome the challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes that emphasize AM and traditional TMP methods. The new processing routes for ODS alloys have achieved significantly higher strengths—several times greater than those of wrought stainless steels—while maintaining substantial ductility and fracture toughness. This report outlines the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

36 MATERIALS SCIENCE↗