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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Strongly Correlated States of Transition Metal Spin Defects: The Case of an Iron Impurity in Aluminum Nitride

We investigate the electronic properties of an exemplar transition metal impurity in an insulator, with the goal of accurately describing strongly correlated defect states. Here, we consider iron in aluminum nitride, a material of interest for hybrid quantum technologies, and we carry out calculations with quantum embedding methods, density matrix embedding theory (DMET) and quantum defect embedding theory (QDET), and with spin-flip time-dependent density functional theory (TDDFT). We show that both DMET and QDET accurately describe the ground state and low-lying excited states of the defect and that TDDFT yields photoluminescence spectra in agreement with experiments. In addition, we provide a detailed discussion of the convergence of our results as a function of the active space used in the embedding methods, thus defining a protocol to obtain converged data directly comparable with experiments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Laser blow-off with photodiode detection system at the helically symmetric experiment

Abstract A laser blow-off (LBO) system has been installed in the HSX stellarator to investigate impurity transport. A Nd:YAG laser is used to ablate a target area on a glass slide that has been coated with a thin film of aluminum and rapidly deposits a small, controlled quantity of aluminum atoms into HSX plasma. To study the radial propagation and confinement of the injected aluminum impurities, time-resolved emission measurements are made using a 20 channel AXUV photodiode detection system. The LBO system has achieved its design purpose, most notably the ability to make controlled impurity injection without significant perturbation to the background plasma. A detailed description of the setup as well as initial results of operation are presented.

Instruments & Instrumentation↗
DOE OSTI2020

Advanced cast aluminum alloys for automotive engine application with superior high-temperature properties

A high fatigue strength aluminum alloy comprises in weight percent copper 3.0-3.5%, iron 0-1.3%, magnesium 0.24-0.35%, manganese 0-0.8%, silicon 6.5-12.0%, strontium 0-0.025%, titanium 0.05-0.2%, vanadium 0.20-0.35%, zinc 0-3.0%, zirconium 0.2-0.4%, a maximum of 0.5% other elements and balance aluminum plus impurities. The alloy defines a microstructure having an aluminum matrix with the Zr and the V in solid solution after solidification. The matrix has solid solution Zr of at least 0.16% after heat treatment and solid solution V of at least 0.20% after heat treatment, and both Cu and Mg are dissolved into the aluminum matrix during the heat treatment and subsequently precipitated during the heat treatment. A process for heat treating an Al—Si—Cu—Mg—Fe—Zn—Mn—Sr-TMs alloy comprises heat treating the alloy to produce a microstructure having a matrix with Zr and V in solid solution after solidification.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Upcycling of aluminum Twitch scrap via Shear Assisted Processing and Extrusion (ShAPE)

Aluminum is publicly perceived as recyclable, but mixed alloys and impurities in aluminum scrap require dilution via energy-intensive primary aluminum or downcycling to low-quality castings. In this study, cast billets of shredded aluminum scrap (Twitch) were blended with pre-consumer AA 6061, extruded into tubes via Shear Assisted Processing and Extrusion (ShAPE), and aged to T1 and T6 tempers. Microscopy reveals that ShAPE refined and distributed the deleterious AlFeSi phases. Furthermore, the Twitch extrusions had tensile properties comparable to AA 6061 yet without homogenizing or adding primary aluminum. Energy savings were 85% compared to conventional extrusion of primary aluminum alloys.

ShAPE↗
DOE OSTI2025

Unveiling the Role of Critical Impurities in Spent LiFePO 4 Cathodes for Scalable Direct Regeneration

Direct regeneration offers a promising alternative to recycling End-of-Life (EoL) batteries by restoring metal elements and preserving the material structure, yet scaling these technologies to handle practical cathode black mass (CBM) with impurities remains challenging. Here, this study investigates the evolution of impurities, including aluminum (Al), polyvinylidene difluoride (PVDF) binder, and residual carbon (C), during direct recycling of spent LiFePO 4 (LFP) cathodes and their impact on electrochemical performance. Using various ex situ and in situ analyses, it is shown that the formation of lithium fluoride (LiF) during the traditional direct recycling process hinders lithium diffusion and deteriorates the reversible capacity. To address this major challenge, the combination of pH-controlled hydrothermal purification and the two-step sintering process is proposed effectively to regenerate spent LFP cathodes, eliminating the negative effect of Al and fluorine (F) impurities while mitigating any potential impacts of carbon residuals. The regenerated LFP from spent CBM achieves superior performance, retaining 152.5 mAh g −1 at 0.1 C and 133 mAh g −1 at 1 C with 98.7% capacity retention after 200 cycles. This approach is further validated using three distinct waste feedstocks from battery modules, enhancing impurity management and scalability in direct recycling. These findings present a sustainable and economically viable solution for large-scale LFP regeneration.

25 ENERGY STORAGE↗
DOE OSTI2023

Influence of graphite geography on the yield of mechanically exfoliated few-layer graphene

Some of graphene's exciting properties that inspired countless studies over the last two decades are exclusive to defect-free, few-layer graphene (FLG, ≤4 layers) produced by mechanical exfoliation. Despite graphite exfoliation having been thoroughly studied, the influence of the graphite source on the successful exfoliation of FLG remains unexplored. Here, in this work, we examine the physicochemical properties and exfoliation performance of various graphite types (e.g., natural crystalline flake, natural vein, and synthetic) from around the globe (e.g., Alaska, Tanzania, China, etc.). We first established a normalization method for the facile comparison of FLG (Φ) yields between separately exfoliated graphites. Using this approach, we find that the relative yield of FLG ranges from 0% to 22% across graphite types, with regular natural crystalline flakes (NCF-R) performing the best overall (Φ NCF-R = 16% ± 5%). FLG yield was also found to depend on source geography, evidenced by Φ NCF-R ranging from 8% to 22% for NCF-R sourced from Alabama and Canada, respectively. We employed machine learning and Pearson correlation analysis to determine the graphite characteristics that govern FLG yield. Graphite source-dependent properties such as graphite surface area and mineral impurities, including aluminum and calcium, were found to be critically important. Our findings highlight the importance of the graphite source when trying to maximize the yield of mechanically exfoliated FLG and represent an important step toward producing higher quantities of defect-free FLG for graphene-based research.

42 ENGINEERING↗
DOE OSTI2021

Microcalorimeter measurement of x-ray spectra from a high-temperature magnetically confined plasma

A NASA-built x-ray microcalorimeter spectrometer has been installed on the MST facility at the Wisconsin Plasma Physics Laboratory and has recorded x-ray photons emitted by impurity ions of aluminum in a majority deuterium plasma. Much of the x-ray microcalorimeter development has been driven by the needs of astrophysics missions, where imaging arrays with few-eV spectral resolution are required. The goal of our project is to adapt these single-photon-counting microcalorimeters for magnetic fusion energy research and demonstrate the value of such measurements for fusion science. Microcalorimeter spectrometers combine the best characteristics of the x-ray instrumentation currently available on fusion devices: high spectral resolution similar to an x-ray crystal spectrometer and the broadband coverage of an x-ray pulse height analysis system. Fusion experiments are increasingly employing high-Z plasma-facing components and require measurement of the concentration of all impurity ion species in the plasma. This diagnostic has the capability to satisfy this need for multi-species impurity ion data and will also contribute to measurements of impurity ion temperature and flow velocity, Zeff, and electron density. Here, we introduce x-ray microcalorimeter detectors and discuss the diagnostic capability for magnetic fusion energy experiments. We describe our experimental setup and spectrometer operation approach at MST, and we present the results from an initial measurement campaign.

Eckart, M. E. (ORCID:0000000338945889)↗
DOE OSTI2022

Magnetoquantum oscillations in the specific heat of a topological Kondo insulator

Surprisingly, magnetoquantum oscillations (MQOs) characteristic of a metal with a Fermi surface have been observed in measurements of the topological Kondo insulator SmB 6 . As these MQO have only been observed in measurements of magnetic torque (dHvA) and not in measurements of magnetoresistance (SdH), a debate has arisen as to whether the MQO are an extrinsic effect arising from rare-earth impurities, defects, and/or aluminum inclusions or an intrinsic effect revealing the existence of charge-neutral excitations. In this work, we report the first observation of MQO in the low-temperature specific heat of SmB 6 . The observed frequencies and their angular dependence for these flux-grown samples are consistent with previous results based on magnetic torque for SmB 6 but the inferred effective masses are significantly larger than previously reported. Such oscillations can only be observed if the MQO are of bulk thermodynamic origin; the measured magnetic-field dependent oscillation amplitude and effective mass allow us to rule out suggestions of an extrinsic, aluminum inclusion-based origin for the MQO.

topological materials↗
DOE OSTI2021

Unveiling the Influence of Carbon Impurity on Recovered NCM622 Cathode Material

With the proliferation of market demand for lithium-ion batteries (LIBs) over the past decades, battery recycling has aroused extensive attention due to the environmental, supply, and economic issues caused by waste batteries. Here, the hydrometallurgical recycling method has been widely adopted to recover cathode materials as a result of its wide applicability and high productivity. However, it is hard to completely eliminate impurities such as copper, aluminum, and carbon, which could bring significant impacts on recovered materials. Here, the influence of the carbon impurity on recovered LiNi 0.6 Co 0.2 Mn 0.2 O 2 (NCM622) cathode material is systematically investigated. It shows that the carbon impurity promotes nucleation during coprecipitation and forms holes in the cathode secondary particles after sintering which could enhance cyclability of the NCM622 cathode. The cathode with 0.2 atom % of carbon impurity displays the highest capacity of 159.9 mAh/g with a striking capacity retention rate of 97.9% after 100 cycles at 0.33C, but performs worse at high rates. Nonetheless, excess carbon (5 atom %) results in severe cation disorder and lattice distortion which significantly deteriorates the electrochemical properties of the NCM622 cathode. Therefore, it is important to strictly control carbon impurity during the recycling process for spent LIBs.

25 ENERGY STORAGE↗
DOE OSTI2026

Localizing tetrahedral aluminum in nitrate-bearing gibbsite to constrain defect-impurity coupling

The enhanced radiolytic stability of gibbsite (α-Al(OH) 3 ) containing trace nitrate (NO 3 − ) is a phenomenon in nuclear waste management, but its structural origins remain unresolved. Motivated by the detection of minority tetrahedral aluminum (T d ) defects in synthetic gibbsite, we hypothesized that these sites may participate in NO 3 − retention or mediate H 2 suppression. To evaluate this, we combined orthogonal techniques comprised of spatially selective solid-state 27 Al MAS NMR, comparative spectroscopy, and density functional theory (DFT) modeling. Paramagnetic editing and dynamic nuclear polarization (DNP) MAS NMR confirm that T d defects are confined to the particle interior. DFT calculations reveal no energetic stabilization of NO 3 − near T d sites. Comparative NMR analysis shows that T d is also present in chloride-bearing gibbsite, which exhibits high radiolytic hydrogen yields. These three independent disqualifications rule out T d as a structural contributor to nitrate-mediated suppression and narrow the scope of defect-driven explanations. The findings redirect mechanistic attention away from coordination defects and toward redox-active impurity pathways, providing a refined foundation for understanding radiation tolerance in Al(OH) 3 .

Graham, Trent R. [Pacific Northwest National Labor↗
DOE OSTI2026

Detecting impurity-specific effects on structure and radiolytic hydrogen production in aluminum hydroxide

While radiolytic hydrogen (H 2 ) generation is an intrinsic property of aqueous and mineral radiolysis in nuclear waste systems, detection of the sub-ns events leading to H 2 generation is challenging. Interfacial processes involving key mineral phases in the sludge, e.g., gibbsite (α-Al(OH) 3 ), have been implicated, with impurities affecting the amount of H 2 generated. To understand why gibbsite synthesized from nitrate precursors produces less H 2 than gibbsite from chloride precursors, we paired 27 Al multiple quantum magic angle spinning (MQMAS) NMR spectroscopy to determine structural heterogeneity with transverse-field muon spin rotation (TF-μSR) to probe electron availability. MQMAS revealed greater structural disorder in the gibbsite synthesized with nitrate (NO 3 -gibbsite). Correspondingly, TF-μSR showed a larger diamagnetic fraction for NO 3 -gibbsite, indicating reduced persistence of μ + -electron bound states (muonium or other radicals) and thus fewer electrons available for reaction on the sub-ns timescale. This establishes a correlation between impurity-induced disorder and electron loss. The diamagnetic fraction serves as a signature for these sub-ns events, as it provides a key constraint for predictive models without currently resolving whether the electron is lost to direct chemical scavenging or trapping at lattice defects.

Graham, Trent R. [Pacific Northwest National Labor↗
DOE OSTI2020

Electrochemical Deposition of Aluminum-Based Coatings From Aqueous Systems

The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks. These adaptations yield metallic aluminum depositions with significant impurities affecting its properties. In addition, this approach requires a great capital investment and cost of process maintenance. An alternative approach to Al electrodeposition has been developed based on the the use of organic ligands to stabilize the Al3+ ion in water-based solutions. By using a ligation approach, we can create aluminum species that remain stable in water while lowering the reduction potential of the aluminum complex by 0.5V. This improvement in reduction potential gives the possibility for the deposition of aluminum without significant competition from hydrogen evolution. With this platform we can deposit highly adherent aluminum-based layers on metal surfaces. The aluminum/aluminum oxide layers appear as thin, coherent and highly adherent coatings. This aluminum/alumina layer can then be chemically treated to achieve desirable surface properties which were previously inaccessible. For example, the coating can be made hydrophobic, highly adherent to different polymer coatings or even dyed using common anodizing dyes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

ELECTROCHEMICAL DEPOSITION OF ALUMINUM-BASED COATINGS FROM AQUEOUS SYSTEMS

The electroplating of aluminum has represented a challenge for the coatings industry for decades. The reactivity of aluminum metal leads to a very negative reduction potential. This leads to abundant gas evolution instead of aluminum reduction in water. Current aluminum deposition technology overcomes this limitation by excluding oxygen and water from the process with rigorously dry solvent and airtight plating tanks. These adaptations yield metallic aluminum depositions with significant impurities affecting its properties. In addition, this approach requires a great capital investment and cost of process maintenance. An alternative approach to Al electrodeposition has been developed based on the the use of organic ligands to stabilize the Al3+ ion in water-based solutions. By using a ligation approach, we can create aluminum species that remain stable in water while lowering the reduction potential of the aluminum complex by 0.5V. This improvement in reduction potential gives the possibility for the deposition of aluminum without significant competition from hydrogen evolution. With this platform we can deposit highly adherent aluminum-based layers on metal surfaces. The aluminum/aluminum oxide layers appear as thin, coherent and highly adherent coatings. This aluminum/alumina layer can then be chemically treated to achieve desirable surface properties which were previously inaccessible. For example, the coating can be made hydrophobic, highly adherent to different polymer coatings or even dyed using common anodizing dyes.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Systematic Study of Al Impurity for NCM622 Cathode Materials

Many recycling processes have been developed for spent Li-ion batteries (LIBs), such as pyrometallurgy, hydrometallurgy, and direct recycling. For all the recycling methods, however, impurities are always introduced from the current collectors or casing materials, especially aluminum (Al), which might lead to negative effects on recovered electrode materials. Therefore, it is significant to determine the impacts of Al impurity on recovered materials. Here, the influence of the Al impurity for the synthesized LiNi 0.6 Co 0.2 Mn 0.2 O 2 (NCM622) precursor and cathode is systematically studied. The cell with 0.2 at % Al impurity displays the highest reversible capacities (145.2, 130.5, and 100.3 mAh g -1 from 2, 3, and 5 C, respectively) and striking cycling capability at 2 C after 100 cycles with the highest retention capacity of 138.5 mAh g -1 . Meanwhile, the excess Al ions (5 at %) lead to the Li/Mn superlattice structure and deteriorate electrochemical performance of the synthesized NCM622 cathode.

25 ENERGY STORAGE↗
DOE OSTI2024

The Beneficial Effect of Iron in Aluminum-Cerium-Based Cast Alloys

Iron (Fe) has been considered a major impurity since it is detrimental to the mechanical properties of many cast aluminum alloys due to the formation of Fe-containing brittle intermetallic phases. Fe is found naturally as an impurity in bauxite ore, resulting in Fe contamination of aluminum alloys with increasing contamination from current recycling practices. The Al–Ce–Fe system was investigated using CALPHAD (CALculation of PHAse Diagrams) modeling and experimental casting techniques. It was found that additions of Fe to the Al–Ce system are beneficial to the strength (slightly) and ductility (significantly) of the ternary alloys, which is attributed to the formation of fine metastable Al 8 CeFe 2 phase with aggregate morphology and equilibrium Al 10 CeFe 2 phase, suppressing coarse proeutectic Al 11 Ce 3 phase in near-eutectic Al–Ce alloys. Heat treatment study showed that the metastable Al 8 CeFe 2 phase transforms to predicted equilibrium Al 10 CeFe 2 phase at 500 °C, with essentially no intermetallic or grain coarsening; thus, the alloy displayed excellent property retention. The Al–Ce–Fe alloy system offers opportunities for sustainable, recyclable alloy development using low-cost Fe and low-cost cerium (a byproduct of rare-earth extraction).

42 ENGINEERING↗
DOE OSTI2024

Impurity transport in PISCES-RF

Linear plasma devices (LPD) utilizing a helicon plasma source, a high density light ion source, can generate impurities due to progressive erosion of the radio frequency (RF) transmission window caused by rectified sheath voltage. These source-born impurities can entrain and be transported by the plasma toward a target, affecting plasma-material interaction studies. Earlier work on material testing in Prototype-Materials Plasma Exposure eXperiment at ORNL revealed significant source impurity deposition on downstream targets. However, using a similar RF source, no target impurity deposition is observed in Plasma Interaction Surface Component Experimental Station (PISCES)-RF despite evidence of RF window erosion in the source region, thereby motivating the present work. Experimentally, using various magnetic field configurations upstream of the PISCES-RF plasma source and seeding titanium (Ti) impurities at various axial locations, impurity transport and deposition along the machine axis were investigated. It was found that Ti deposition was localized to the side of the plasma source where the Ti impurity was seeded. In contrast, aluminum (Al) deposition, originating from the sputtering of the helicon window, occurred predominantly upstream of the plasma source, suggesting an asymmetry in the axial transport of eroded RF window material. These observations suggest a stagnation of the parallel plasma flow immediately downstream of the plasma source, with impurity ions remaining unmagnetized near the source upstream. Al deposition in magnetic field-free regions in PISCES-RF indicates that sputtered Al impurities likely remained neutral due to their large ionization mean-free path under PISCES-RF conditions. Plasma modeling and simulation supported this, indicating that Al-neutrals transport toward the helicon source upstream for low electron density cases. It was found that the Larmor radius of the Al ions was greater than the plasma radius towards the source upstream and remained weakly magnetized in PISCES-RF, meaning that plasma source-born impurities are not efficiently entrained in the plasma flow. These findings provide critical insights into impurity transport in helicon plasma-based LPDs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗