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    New self-assembling material could be the key to recyclable EV batteries

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    Today’s electric vehicle boom is tomorrow’s mountain of electronic waste. And while myriad efforts are underway to improve battery recycling, many EV batteries still end up in landfills.A research team from MIT wants to help change that with a new kind of self-assembling battery material that quickly breaks apart when submerged in a simple organic liquid. In a new paper published in Nature Chemistry, the researchers showed the material can work as the electrolyte in a functioning, solid-state battery cell and then revert back to its original molecular components in minutes.The approach offers an alternative to shredding the battery into a mixed, hard-to-recycle mass. Instead, because the electrolyte serves as the battery’s connecting layer, when the new material returns to its original molecular form, the entire battery disassembles to accelerate the recycling process.“So far in the battery industry, we’ve focused on high-performing materials and designs, and only later tried to figure out how to recycle batteries made with complex structures and hard-to-recycle materials,” says the paper’s first author Yukio Cho PhD ’23. “Our approach is to start with easily recyclable materials and figure out how to make them battery-compatible. Designing batteries for recyclability from the beginning is a new approach.”Joining Cho on the paper are PhD candidate Cole Fincher, Ty Christoff-Tempesta PhD ’22, Kyocera Professor of Ceramics Yet-Ming Chiang, Visiting Associate Professor Julia Ortony, Xiaobing Zuo, and Guillaume Lamour.Better batteriesThere’s a scene in one of the “Harry Potter” films where Professor Dumbledore cleans a dilapidated home with the flick of the wrist and a spell. Cho says that image stuck with him as a kid. (What better way to clean your room?) When he saw a talk by Ortony on engineering molecules so that they could assemble into complex structures and then revert back to their original form, he wondered if it could be used to make battery recycling work like magic.That would be a paradigm shift for the battery industry. Today, batteries require harsh chemicals, high heat, and complex processing to recycle. There are three main parts of a battery: the positively charged cathode, the negatively charged electrode, and the electrolyte that shuttles lithium ions between them. The electrolytes in most lithium-ion batteries are highly flammable and degrade over time into toxic byproducts that require specialized handling.To simplify the recycling process, the researchers decided to make a more sustainable electrolyte. For that, they turned to a class of molecules that self-assemble in water, named aramid amphiphiles (AAs), whose chemical structures and stability mimic that of Kevlar. The researchers further designed the AAs to contain polyethylene glycol (PEG), which can conduct lithium ions, on one end of each molecule. When the molecules are exposed to water, they spontaneously form nanoribbons with ion-conducting PEG surfaces and bases that imitate the robustness of Kevlar through tight hydrogen bonding. The result is a mechanically stable nanoribbon structure that conducts ions across its surface.“The material is composed of two parts,” Cho explains. “The first part is this flexible chain that gives us a nest, or host, for lithium ions to jump around. The second part is this strong organic material component that is used in the Kevlar, which is a bulletproof material. Those make the whole structure stable.”When added to water, the nanoribbons self-assemble to form millions of nanoribbons that can be hot-pressed into a solid-state material.“Within five minutes of being added to water, the solution becomes gel-like, indicating there are so many nanofibers formed in the liquid that they start to entangle each other,” Cho says. “What’s exciting is we can make this material at scale because of the self-assembly behavior.”The team tested the material’s strength and toughness, finding it could endure the stresses associated with making and running the battery. They also constructed a solid-state battery cell that used lithium iron phosphate for the cathode and lithium titanium oxide as the anode, both common materials in today’s batteries. The nanoribbons moved lithium ions successfully between the electrodes, but a side-effect known as polarization limited the movement of lithium ions into the battery’s electrodes during fast bouts of charging and discharging, hampering its performance compared to today’s gold-standard commercial batteries.“The lithium ions moved along the nanofiber all right, but getting the lithium ion from the nanofibers to the metal oxide seems to be the most sluggish point of the process,” Cho says.When they immersed the battery cell into organic solvents, the material immediately dissolved, with each part of the battery falling away for easier recycling. Cho compared the materials’ reaction to cotton candy being submerged in water.“The electrolyte holds the two battery electrodes together and provides the lithium-ion pathways,” Cho says. “So, when you want to recycle the battery, the entire electrolyte layer can fall off naturally and you can recycle the electrodes separately.”Validating a new approachCho says the material is a proof of concept that demonstrates the recycle-first approach.“We don’t want to say we solved all the problems with this material,” Cho says. “Our battery performance was not fantastic because we used only this material as the entire electrolyte for the paper, but what we’re picturing is using this material as one layer in the battery electrolyte. It doesn’t have to be the entire electrolyte to kick off the recycling process.”Cho also sees a lot of room for optimizing the material’s performance with further experiments.Now, the researchers are exploring ways to integrate these kinds of materials into existing battery designs as well as implementing the ideas into new battery chemistries.“It’s very challenging to convince existing vendors to do something very differently,” Cho says. “But with new battery materials that may come out in five or 10 years, it could be easier to integrate this into new designs in the beginning.”Cho also believes the approach could help reshore lithium supplies by reusing materials from batteries that are already in the U.S.“People are starting to realize how important this is,” Cho says. “If we can start to recycle lithium-ion batteries from battery waste at scale, it’ll have the same effect as opening lithium mines in the U.S. Also, each battery requires a certain amount of lithium, so extrapolating out the growth of electric vehicles, we need to reuse this material to avoid massive lithium price spikes.”The work was supported, in part, by the National Science Foundation and the U.S. Department of Energy. 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      New method could monitor corrosion and cracking in a nuclear reactor

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      MIT researchers have developed a technique that enables real-time, 3D monitoring of corrosion, cracking, and other material failure processes inside a nuclear reactor environment.This could allow engineers and scientists to design safer nuclear reactors that also deliver higher performance for applications like electricity generation and naval vessel propulsion.During their experiments, the researchers utilized extremely powerful X-rays to mimic the behavior of neutrons interacting with a material inside a nuclear reactor.They found that adding a buffer layer of silicon dioxide between the material and its substrate, and keeping the material under the X-ray beam for a longer period of time, improves the stability of the sample. This allows for real-time monitoring of material failure processes.By reconstructing 3D image data on the structure of a material as it fails, researchers could design more resilient materials that can better withstand the stress caused by irradiation inside a nuclear reactor.“If we can improve materials for a nuclear reactor, it means we can extend the life of that reactor. It also means the materials will take longer to fail, so we can get more use out of a nuclear reactor than we do now. The technique we’ve demonstrated here allows to push the boundary in understanding how materials fail in real-time,” says Ericmoore Jossou, who has shared appointments in the Department of Nuclear Science and Engineering (NSE), where he is the John Clark Hardwick Professor, and the Department of Electrical Engineering and Computer Science (EECS), and the MIT Schwarzman College of Computing.Jossou, senior author of a study on this technique, is joined on the paper by lead author David Simonne, an NSE postdoc; Riley Hultquist, a graduate student in NSE; Jiangtao Zhao, of the European Synchrotron; and Andrea Resta, of Synchrotron SOLEIL. The research was published Tuesday by the journal Scripta Materiala.“Only with this technique can we measure strain with a nanoscale resolution during corrosion processes. Our goal is to bring such novel ideas to the nuclear science community while using synchrotrons both as an X-ray probe and radiation source,” adds Simonne.Real-time imagingStudying real-time failure of materials used in advanced nuclear reactors has long been a goal of Jossou’s research group.Usually, researchers can only learn about such material failures after the fact, by removing the material from its environment and imaging it with a high-resolution instrument.“We are interested in watching the process as it happens. If we can do that, we can follow the material from beginning to end and see when and how it fails. That helps us understand a material much better,” he says.They simulate the process by firing an extremely focused X-ray beam at a sample to mimic the environment inside a nuclear reactor. The researchers must use a special type of high-intensity X-ray, which is only found in a handful of experimental facilities worldwide.For these experiments they studied nickel, a material incorporated into alloys that are commonly used in advanced nuclear reactors. But before they could start the X-ray equipment, they had to prepare a sample.To do this, the researchers used a process called solid state dewetting, which involves putting a thin film of the material onto a substrate and heating it to an extremely high temperature in a furnace until it transforms into single crystals.“We thought making the samples was going to be a walk in the park, but it wasn’t,” Jossou says.As the nickel heated up, it interacted with the silicon substrate and formed a new chemical compound, essentially derailing the entire experiment. After much trial-and-error, the researchers found that adding a thin layer of silicon dioxide between the nickel and substrate prevented this reaction.But when crystals formed on top of the buffer layer, they were highly strained. This means the individual atoms had moved slightly to new positions, causing distortions in the crystal structure.Phase retrieval algorithms can typically recover the 3D size and shape of a crystal in real-time, but if there is too much strain in the material, the algorithms will fail.However, the team was surprised to find that keeping the X-ray beam trained on the sample for a longer period of time caused the strain to slowly relax, due to the silicon buffer layer. After a few extra minutes of X-rays, the sample was stable enough that they could utilize phase retrieval algorithms to accurately recover the 3D shape and size of the crystal.“No one had been able to do that before. Now that we can make this crystal, we can image electrochemical processes like corrosion in real time, watching the crystal fail in 3D under conditions that are very similar to inside a nuclear reactor. This has far-reaching impacts,” he says.They experimented with a different substrate, such as niobium doped strontium titanate, and found that only a silicon dioxide buffered silicon wafer created this unique effect.An unexpected resultAs they fine-tuned the experiment, the researchers discovered something else.They could also use the X-ray beam to precisely control the amount of strain in the material, which could have implications for the development of microelectronics.In the microelectronics community, engineers often introduce strain to deform a material’s crystal structure in a way that boosts its electrical or optical properties.“With our technique, engineers can use X-rays to tune the strain in microelectronics while they are manufacturing them. While this was not our goal with these experiments, it is like getting two results for the price of one,” he adds.In the future, the researchers want to apply this technique to more complex materials like steel and other metal alloys used in nuclear reactors and aerospace applications. They also want to see how changing the thickness of the silicon dioxide buffer layer impacts their ability to control the strain in a crystal sample.“This discovery is significant for two reasons. First, it provides fundamental insight into how nanoscale materials respond to radiation — a question of growing importance for energy technologies, microelectronics, and quantum materials. Second, it highlights the critical role of the substrate in strain relaxation, showing that the supporting surface can determine whether particles retain or release strain when exposed to focused X-ray beams,” says Edwin Fohtung, an associate professor at the Rensselaer Polytechnic Institute, who was not involved with this work.This work was funded, in part, by the MIT Faculty Startup Fund and the U.S. Department of Energy. The sample preparation was carried out, in part, at the MIT.nano facilities. More

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      in Energy

      Study sheds light on graphite’s lifespan in nuclear reactors

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      Graphite is a key structural component in some of the world’s oldest nuclear reactors and many of the next-generation designs being built today. But it also condenses and swells in response to radiation — and the mechanism behind those changes has proven difficult to study.Now, MIT researchers and collaborators have uncovered a link between properties of graphite and how the material behaves in response to radiation. The findings could lead to more accurate, less destructive ways of predicting the lifespan of graphite materials used in reactors around the world.“We did some basic science to understand what leads to swelling and, eventually, failure in graphite structures,” says MIT Research Scientist Boris Khaykovich, senior author of the new study. “More research will be needed to put this into practice, but the paper proposes an attractive idea for industry: that you might not need to break hundreds of irradiated samples to understand their failure point.”Specifically, the study shows a connection between the size of the pores within graphite and the way the material swells and shrinks in volume, leading to degradation.“The lifetime of nuclear graphite is limited by irradiation-induced swelling,” says co-author and MIT Research Scientist Lance Snead. “Porosity is a controlling factor in this swelling, and while graphite has been extensively studied for nuclear applications since the Manhattan Project, we still do not have a clear understanding of the porosity in both mechanical properties and swelling. This work addresses that.”The open-access paper appears this week in Interdisciplinary Materials. It is co-authored by Khaykovich, Snead, MIT Research Scientist Sean Fayfar, former MIT research fellow Durgesh Rai, Stony Brook University Assistant Professor David Sprouster, Oak Ridge National Laboratory Staff Scientist Anne Campbell, and Argonne National Laboratory Physicist Jan Ilavsky.A long-studied, complex materialEver since 1942, when physicists and engineers built the world’s first nuclear reactor on a converted squash court at the University of Chicago, graphite has played a central role in the generation of nuclear energy. That first reactor, dubbed the Chicago Pile, was constructed from about 40,000 graphite blocks, many of which contained nuggets of uranium.Today graphite is a vital component of many operating nuclear reactors and is expected to play a central role in next-generation reactor designs like molten-salt and high-temperature gas reactors. That’s because graphite is a good neutron moderator, slowing down the neutrons released by nuclear fission so they are more likely to create fissions themselves and sustain a chain reaction.“The simplicity of graphite makes it valuable,” Khaykovich explains. “It’s made of carbon, and it’s relatively well-known how to make it cleanly. Graphite is a very mature technology. It’s simple, stable, and we know it works.”But graphite also has its complexities.“We call graphite a composite even though it’s made up of only carbon atoms,” Khaykovich says. “It includes ‘filler particles’ that are more crystalline, then there is a matrix called a ‘binder’ that is less crystalline, then there are pores that span in length from nanometers to many microns.”Each graphite grade has its own composite structure, but they all contain fractals, or shapes that look the same at different scales.Those complexities have made it hard to predict how graphite will respond to radiation in microscopic detail, although it’s been known for decades that when graphite is irradiated, it first densifies, reducing its volume by up to 10 percent, before swelling and cracking. The volume fluctuation is caused by changes to graphite’s porosity and lattice stress.“Graphite deteriorates under radiation, as any material does,” Khaykovich says. “So, on the one hand we have a material that’s extremely well-known, and on the other hand, we have a material that is immensely complicated, with a behavior that’s impossible to predict through computer simulations.”For the study, the researchers received irradiated graphite samples from Oak Ridge National Laboratory. Co-authors Campbell and Snead were involved in irradiating the samples some 20 years ago. The samples are a grade of graphite known as G347A.The research team used an analysis technique known as X-ray scattering, which uses the scattered intensity of an X-ray beam to analyze the properties of material. Specifically, they looked at the distribution of sizes and surface areas of the sample’s pores, or what are known as the material’s fractal dimensions.“When you look at the scattering intensity, you see a large range of porosity,” Fayfar says. “Graphite has porosity over such large scales, and you have this fractal self-similarity: The pores in very small sizes look similar to pores spanning microns, so we used fractal models to relate different morphologies across length scales.”Fractal models had been used on graphite samples before, but not on irradiated samples to see how the material’s pore structures changed. The researchers found that when graphite is first exposed to radiation, its pores get filled as the material degrades.“But what was quite surprising to us is the [size distribution of the pores] turned back around,” Fayfar says. “We had this recovery process that matched our overall volume plots, which was quite odd. It seems like after graphite is irradiated for so long, it starts recovering. It’s sort of an annealing process where you create some new pores, then the pores smooth out and get slightly bigger. That was a big surprise.”The researchers found that the size distribution of the pores closely follows the volume change caused by radiation damage.“Finding a strong correlation between the [size distribution of pores] and the graphite’s volume changes is a new finding, and it helps connect to the failure of the material under irradiation,” Khaykovich says. “It’s important for people to know how graphite parts will fail when they are under stress and how failure probability changes under irradiation.”From research to reactorsThe researchers plan to study other graphite grades and explore further how pore sizes in irradiated graphite correlate with the probability of failure. They speculate that a statistical technique known as the Weibull Distribution could be used to predict graphite’s time until failure. The Weibull Distribution is already used to describe the probability of failure in ceramics and other porous materials like metal alloys.Khaykovich also speculated that the findings could contribute to our understanding of why materials densify and swell under irradiation.“There’s no quantitative model of densification that takes into account what’s happening at these tiny scales in graphite,” Khaykovich says. “Graphite irradiation densification reminds me of sand or sugar, where when you crush big pieces into smaller grains, they densify. For nuclear graphite, the crushing force is the energy that neutrons bring in, causing large pores to get filled with smaller, crushed pieces. But more energy and agitation create still more pores, and so graphite swells again. It’s not a perfect analogy, but I believe analogies bring progress for understanding these materials.”The researchers describe the paper as an important step toward informing graphite production and use in nuclear reactors of the future.“Graphite has been studied for a very long time, and we’ve developed a lot of strong intuitions about how it will respond in different environments, but when you’re building a nuclear reactor, details matter,” Khaykovich says. “People want numbers. They need to know how much thermal conductivity will change, how much cracking and volume change will happen. If components are changing volume, at some point you need to take that into account.”This work was supported, in part, by the U.S. Department of Energy. More

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      in Security

      Creeping crystals: Scientists observe “salt creep” at the single-crystal scale

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      Salt creeping, a phenomenon that occurs in both natural and industrial processes, describes the collection and migration of salt crystals from evaporating solutions onto surfaces. Once they start collecting, the crystals climb, spreading away from the solution. This creeping behavior, according to researchers, can cause damage or be harnessed for good, depending on the context. New research published June 30 in the journal Langmuir is the first to show salt creeping at a single-crystal scale and beneath a liquid’s meniscus.“The work not only explains how salt creeping begins, but why it begins and when it does,” says Joseph Phelim Mooney, a postdoc in the MIT Device Research Laboratory and one of the authors of the new study. “We hope this level of insight helps others, whether they’re tackling water scarcity, preserving ancient murals, or designing longer-lasting infrastructure.”The work is the first to directly visualize how salt crystals grow and interact with surfaces underneath a liquid meniscus, something that’s been theorized for decades but never actually imaged or confirmed at this level, and it offers fundamental insights that could impact a wide range of fields — from mineral extraction and desalination to anti-fouling coatings, membrane design for separation science, and even art conservation, where salt damage is a major threat to heritage materials.In civil engineering applications, for example, the research can help explain why and when salt crystals start growing across surfaces like concrete, stone, or building materials. “These crystals can exert pressure and cause cracking or flaking, reducing the long-term durability of structures,” says Mooney. “By pinpointing the moment when salt begins to creep, engineers can better design protective coatings or drainage systems to prevent this form of degradation.”For a field like art conservation, where salt can be devastating to murals, frescoes, and ancient artifacts, often forming beneath the surface before visible damage appears, the work can help identify the exact conditions that cause salt to start moving and spreading, allowing conservators to act earlier and more precisely to protect heritage objects.The work began during Mooney’s Marie Curie Fellowship at MIT. “I was focused on improving desalination systems and quickly ran into [salt buildup as] a major roadblock,” he says. “[Salt] was everywhere, coating surfaces, clogging flow paths, and undermining the efficiency of our designs. I realized we didn’t fully understand how or why salt starts creeping across surfaces in the first place.”That experience led Mooney to team up with colleagues to dig into the fundamentals of salt crystallization at the air–liquid–solid interface. “We wanted to zoom in, to really see the moment salt begins to move, so we turned to in situ X-ray microscopy,” he says. “What we found gave us a whole new way to think about surface fouling, material degradation, and controlled crystallization.”The new research may, in fact, allow better control of a crystallization processes required to remove salt from water in zero-liquid discharge systems. It can also be used to explain how and when scaling happens on equipment surfaces, and may support emerging climate technologies that depend on smart control of evaporation and crystallization.The work also supports mineral and salt extraction applications, where salt creeping can be both a bottleneck and an opportunity. In these applications, Mooney says, “by understanding the precise physics of salt formation at surfaces, operators can optimize crystal growth, improving recovery rates and reducing material losses.”Mooney’s co-authors on the paper include fellow MIT Device Lab researchers Omer Refet Caylan, Bachir El Fil (now an associate professor at Georgia Tech), and Lenan Zhang (now an associate professor at Cornell University); Jeff Punch and Vanessa Egan of the University of Limerick; and Jintong Gao of Cornell.The research was conducted using in situ X-ray microscopy. Mooney says the team’s big realization moment occurred when they were able to observe a single salt crystal pinning itself to the surface, which kicked off a cascading chain reaction of growth.“People had speculated about this, but we captured it on X-ray for the first time. It felt like watching the microscopic moment where everything tips, the ignition points of a self-propagating process,” says Mooney. “Even more surprising was what followed: The salt crystal didn’t just grow passively to fill the available space. It pierced through the liquid-air interface and reshaped the meniscus itself, setting up the perfect conditions for the next crystal. That subtle, recursive mechanism had never been visually documented before — and seeing it play out in real time completely changed how we thought about salt crystallization.”The paper, “In Situ X-ray Microscopy Unraveling the Onset of Salt Creeping at a Single-Crystal Level,” is available now in the journal Langmuir. Research was conducted in MIT.nano.  More

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      in Energy

      Theory-guided strategy expands the scope of measurable quantum interactions

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      A new theory-guided framework could help scientists probe the properties of new semiconductors for next-generation microelectronic devices, or discover materials that boost the performance of quantum computers.Research to develop new or better materials typically involves investigating properties that can be reliably measured with existing lab equipment, but this represents just a fraction of the properties that scientists could potentially probe in principle. Some properties remain effectively “invisible” because they are too difficult to capture directly with existing methods.Take electron-phonon interaction — this property plays a critical role in a material’s electrical, thermal, optical, and superconducting properties, but directly capturing it using existing techniques is notoriously challenging.Now, MIT researchers have proposed a theoretically justified approach that could turn this challenge into an opportunity. Their method reinterprets neutron scattering, an often-overlooked interference effect as a potential direct probe of electron-phonon coupling strength.The procedure creates two interaction effects in the material. The researchers show that, by deliberately designing their experiment to leverage the interference between the two interactions, they can capture the strength of a material’s electron-phonon interaction.The researchers’ theory-informed methodology could be used to shape the design of future experiments, opening the door to measuring new quantities that were previously out of reach.“Rather than discovering new spectroscopy techniques by pure accident, we can use theory to justify and inform the design of our experiments and our physical equipment,” says Mingda Li, the Class of 1947 Career Development Professor and an associate professor of nuclear science and engineering, and senior author of a paper on this experimental method.Li is joined on the paper by co-lead authors Chuliang Fu, an MIT postdoc; Phum Siriviboon and Artittaya Boonkird, both MIT graduate students; as well as others at MIT, the National Institute of Standards and Technology, the University of California at Riverside, Michigan State University, and Oak Ridge National Laboratory. The research appears this week in Materials Today Physics.Investigating interferenceNeutron scattering is a powerful measurement technique that involves aiming a beam of neutrons at a material and studying how the neutrons are scattered after they strike it. The method is ideal for measuring a material’s atomic structure and magnetic properties.When neutrons collide with the material sample, they interact with it through two different mechanisms, creating a nuclear interaction and a magnetic interaction. These interactions can interfere with each other.“The scientific community has known about this interference effect for a long time, but researchers tend to view it as a complication that can obscure measurement signals. So it hasn’t received much focused attention,” Fu says.The team and their collaborators took a conceptual “leap of faith” and decided to explore this oft-overlooked interference effect more deeply.They flipped the traditional materials research approach on its head by starting with a multifaceted theoretical analysis. They explored what happens inside a material when the nuclear interaction and magnetic interaction interfere with each other.Their analysis revealed that this interference pattern is directly proportional to the strength of the material’s electron-phonon interaction.“This makes the interference effect a probe we can use to detect this interaction,” explains Siriviboon.Electron-phonon interactions play a role in a wide range of material properties. They affect how heat flows through a material, impact a material’s ability to absorb and emit light, and can even lead to superconductivity.But the complexity of these interactions makes them hard to directly measure using existing experimental techniques. Instead, researchers often rely on less precise, indirect methods to capture electron-phonon interactions.However, leveraging this interference effect enables direct measurement of the electron-phonon interaction, a major advantage over other approaches.“Being able to directly measure the electron-phonon interaction opens the door to many new possibilities,” says Boonkird.Rethinking materials researchBased on their theoretical insights, the researchers designed an experimental setup to demonstrate their approach.Since the available equipment wasn’t powerful enough for this type of neutron scattering experiment, they were only able to capture a weak electron-phonon interaction signal — but the results were clear enough to support their theory.“These results justify the need for a new facility where the equipment might be 100 to 1,000 times more powerful, enabling scientists to clearly resolve the signal and measure the interaction,” adds Landry.With improved neutron scattering facilities, like those proposed for the upcoming Second Target Station at Oak Ridge National Laboratory, this experimental method could be an effective technique for measuring many crucial material properties.For instance, by helping scientists identify and harness better semiconductors, this approach could enable more energy-efficient appliances, faster wireless communication devices, and more reliable medical equipment like pacemakers and MRI scanners.   Ultimately, the team sees this work as a broader message about the need to rethink the materials research process.“Using theoretical insights to design experimental setups in advance can help us redefine the properties we can measure,” Fu says.To that end, the team and their collaborators are currently exploring other types of interactions they could leverage to investigate additional material properties.“This is a very interesting paper,” says Jon Taylor, director of the neutron scattering division at Oak Ridge National Laboratory, who was not involved with this research. “It would be interesting to have a neutron scattering method that is directly sensitive to charge lattice interactions or more generally electronic effects that were not just magnetic moments. It seems that such an effect is expectedly rather small, so facilities like STS could really help develop that fundamental understanding of the interaction and also leverage such effects routinely for research.”This work is funded, in part, by the U.S. Department of Energy and the National Science Foundation. More

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      in Environment

      AI stirs up the recipe for concrete in MIT study

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      For weeks, the whiteboard in the lab was crowded with scribbles, diagrams, and chemical formulas. A research team across the Olivetti Group and the MIT Concrete Sustainability Hub (CSHub) was working intensely on a key problem: How can we reduce the amount of cement in concrete to save on costs and emissions? The question was certainly not new; materials like fly ash, a byproduct of coal production, and slag, a byproduct of steelmaking, have long been used to replace some of the cement in concrete mixes. However, the demand for these products is outpacing supply as industry looks to reduce its climate impacts by expanding their use, making the search for alternatives urgent. The challenge that the team discovered wasn’t a lack of candidates; the problem was that there were too many to sort through.On May 17, the team, led by postdoc Soroush Mahjoubi, published an open-access paper in Nature’s Communications Materials outlining their solution. “We realized that AI was the key to moving forward,” notes Mahjoubi. “There is so much data out there on potential materials — hundreds of thousands of pages of scientific literature. Sorting through them would have taken many lifetimes of work, by which time more materials would have been discovered!”With large language models, like the chatbots many of us use daily, the team built a machine-learning framework that evaluates and sorts candidate materials based on their physical and chemical properties. “First, there is hydraulic reactivity. The reason that concrete is strong is that cement — the ‘glue’ that holds it together — hardens when exposed to water. So, if we replace this glue, we need to make sure the substitute reacts similarly,” explains Mahjoubi. “Second, there is pozzolanicity. This is when a material reacts with calcium hydroxide, a byproduct created when cement meets water, to make the concrete harder and stronger over time.  We need to balance the hydraulic and pozzolanic materials in the mix so the concrete performs at its best.”Analyzing scientific literature and over 1 million rock samples, the team used the framework to sort candidate materials into 19 types, ranging from biomass to mining byproducts to demolished construction materials. Mahjoubi and his team found that suitable materials were available globally — and, more impressively, many could be incorporated into concrete mixes just by grinding them. This means it’s possible to extract emissions and cost savings without much additional processing. “Some of the most interesting materials that could replace a portion of cement are ceramics,” notes Mahjoubi. “Old tiles, bricks, pottery — all these materials may have high reactivity. That’s something we’ve observed in ancient Roman concrete, where ceramics were added to help waterproof structures. I’ve had many interesting conversations on this with Professor Admir Masic, who leads a lot of the ancient concrete studies here at MIT.”The potential of everyday materials like ceramics and industrial materials like mine tailings is an example of how materials like concrete can help enable a circular economy. By identifying and repurposing materials that would otherwise end up in landfills, researchers and industry can help to give these materials a second life as part of our buildings and infrastructure.Looking ahead, the research team is planning to upgrade the framework to be capable of assessing even more materials, while experimentally validating some of the best candidates. “AI tools have gotten this research far in a short time, and we are excited to see how the latest developments in large language models enable the next steps,” says Professor Elsa Olivetti, senior author on the work and member of the MIT Department of Materials Science and Engineering. She serves as an MIT Climate Project mission director, a CSHub principal investigator, and the leader of the Olivetti Group.“Concrete is the backbone of the built environment,” says Randolph Kirchain, co-author and CSHub director. “By applying data science and AI tools to material design, we hope to support industry efforts to build more sustainably, without compromising on strength, safety, or durability.In addition to Mahjoubi, Olivetti, and Kirchain, co-authors on the work include MIT postdoc Vineeth Venugopal, Ipek Bensu Manav SM ’21, PhD ’24; and CSHub Deputy Director Hessam AzariJafari. More

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      in Energy

      New fuel cell could enable electric aviation

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      Batteries are nearing their limits in terms of how much power they can store for a given weight. That’s a serious obstacle for energy innovation and the search for new ways to power airplanes, trains, and ships. Now, researchers at MIT and elsewhere have come up with a solution that could help electrify these transportation systems.Instead of a battery, the new concept is a kind of fuel cell — which is similar to a battery but can be quickly refueled rather than recharged. In this case, the fuel is liquid sodium metal, an inexpensive and widely available commodity. The other side of the cell is just ordinary air, which serves as a source of oxygen atoms. In between, a layer of solid ceramic material serves as the electrolyte, allowing sodium ions to pass freely through, and a porous air-facing electrode helps the sodium to chemically react with oxygen and produce electricity.In a series of experiments with a prototype device, the researchers demonstrated that this cell could carry more than three times as much energy per unit of weight as the lithium-ion batteries used in virtually all electric vehicles today. Their findings are being published today in the journal Joule, in a paper by MIT doctoral students Karen Sugano, Sunil Mair, and Saahir Ganti-Agrawal; professor of materials science and engineering Yet-Ming Chiang; and five others.“We expect people to think that this is a totally crazy idea,” says Chiang, who is the Kyocera Professor of Ceramics. “If they didn’t, I’d be a bit disappointed because if people don’t think something is totally crazy at first, it probably isn’t going to be that revolutionary.”And this technology does appear to have the potential to be quite revolutionary, he suggests. In particular, for aviation, where weight is especially crucial, such an improvement in energy density could be the breakthrough that finally makes electrically powered flight practical at significant scale.“The threshold that you really need for realistic electric aviation is about 1,000 watt-hours per kilogram,” Chiang says. Today’s electric vehicle lithium-ion batteries top out at about 300 watt-hours per kilogram — nowhere near what’s needed. Even at 1,000 watt-hours per kilogram, he says, that wouldn’t be enough to enable transcontinental or trans-Atlantic flights.That’s still beyond reach for any known battery chemistry, but Chiang says that getting to 1,000 watts per kilogram would be an enabling technology for regional electric aviation, which accounts for about 80 percent of domestic flights and 30 percent of the emissions from aviation.The technology could be an enabler for other sectors as well, including marine and rail transportation. “They all require very high energy density, and they all require low cost,” he says. “And that’s what attracted us to sodium metal.”A great deal of research has gone into developing lithium-air or sodium-air batteries over the last three decades, but it has been hard to make them fully rechargeable. “People have been aware of the energy density you could get with metal-air batteries for a very long time, and it’s been hugely attractive, but it’s just never been realized in practice,” Chiang says.By using the same basic electrochemical concept, only making it a fuel cell instead of a battery, the researchers were able to get the advantages of the high energy density in a practical form. Unlike a battery, whose materials are assembled once and sealed in a container, with a fuel cell the energy-carrying materials go in and out.The team produced two different versions of a lab-scale prototype of the system. In one, called an H cell, two vertical glass tubes are connected by a tube across the middle, which contains a solid ceramic electrolyte material and a porous air electrode. Liquid sodium metal fills the tube on one side, and air flows through the other, providing the oxygen for the electrochemical reaction at the center, which ends up gradually consuming the sodium fuel. The other prototype uses a horizontal design, with a tray of the electrolyte material holding the liquid sodium fuel. The porous air electrode, which facilitates the reaction, is affixed to the bottom of the tray. Tests using an air stream with a carefully controlled humidity level produced a level of more than 1,500 watt-hours per kilogram at the level of an individual “stack,” which would translate to over 1,000 watt-hours at the full system level, Chiang says.The researchers envision that to use this system in an aircraft, fuel packs containing stacks of cells, like racks of food trays in a cafeteria, would be inserted into the fuel cells; the sodium metal inside these packs gets chemically transformed as it provides the power. A stream of its chemical byproduct is given off, and in the case of aircraft this would be emitted out the back, not unlike the exhaust from a jet engine.But there’s a very big difference: There would be no carbon dioxide emissions. Instead the emissions, consisting of sodium oxide, would actually soak up carbon dioxide from the atmosphere. This compound would quickly combine with moisture in the air to make sodium hydroxide — a material commonly used as a drain cleaner — which readily combines with carbon dioxide to form a solid material, sodium carbonate, which in turn forms sodium bicarbonate, otherwise known as baking soda.“There’s this natural cascade of reactions that happens when you start with sodium metal,” Chiang says. “It’s all spontaneous. We don’t have to do anything to make it happen, we just have to fly the airplane.”As an added benefit, if the final product, the sodium bicarbonate, ends up in the ocean, it could help to de-acidify the water, countering another of the damaging effects of greenhouse gases.Using sodium hydroxide to capture carbon dioxide has been proposed as a way of mitigating carbon emissions, but on its own, it’s not an economic solution because the compound is too expensive. “But here, it’s a byproduct,” Chiang explains, so it’s essentially free, producing environmental benefits at no cost.Importantly, the new fuel cell is inherently safer than many other batteries, he says. Sodium metal is extremely reactive and must be well-protected. As with lithium batteries, sodium can spontaneously ignite if exposed to moisture. “Whenever you have a very high energy density battery, safety is always a concern, because if there’s a rupture of the membrane that separates the two reactants, you can have a runaway reaction,” Chiang says. But in this fuel cell, one side is just air, “which is dilute and limited. So you don’t have two concentrated reactants right next to each other. If you’re pushing for really, really high energy density, you’d rather have a fuel cell than a battery for safety reasons.”While the device so far exists only as a small, single-cell prototype, Chiang says the system should be quite straightforward to scale up to practical sizes for commercialization. Members of the research team have already formed a company, Propel Aero, to develop the technology. The company is currently housed in MIT’s startup incubator, The Engine.Producing enough sodium metal to enable widespread, full-scale global implementation of this technology should be practical, since the material has been produced at large scale before. When leaded gasoline was the norm, before it was phased out, sodium metal was used to make the tetraethyl lead used as an additive, and it was being produced in the U.S. at a capacity of 200,000 tons a year. “It reminds us that sodium metal was once produced at large scale and safely handled and distributed around the U.S.,” Chiang says.What’s more, sodium primarily originates from sodium chloride, or salt, so it is abundant, widely distributed around the world, and easily extracted, unlike lithium and other materials used in today’s EV batteries.The system they envisage would use a refillable cartridge, which would be filled with liquid sodium metal and sealed. When it’s depleted, it would be returned to a refilling station and loaded with fresh sodium. Sodium melts at 98 degrees Celsius, just below the boiling point of water, so it is easy to heat to the melting point to refuel the cartridges.Initially, the plan is to produce a brick-sized fuel cell that can deliver about 1,000 watt-hours of energy, enough to power a large drone, in order to prove the concept in a practical form that could be used for agriculture, for example. The team hopes to have such a demonstration ready within the next year.Sugano, who conducted much of the experimental work as part of her doctoral thesis and will now work at the startup, says that a key insight was the importance of moisture in the process. As she tested the device with pure oxygen, and then with air, she found that the amount of humidity in the air was crucial to making the electrochemical reaction efficient. The humid air resulted in the sodium producing its discharge products in liquid rather than solid form, making it much easier for these to be removed by the flow of air through the system. “The key was that we can form this liquid discharge product and remove it easily, as opposed to the solid discharge that would form in dry conditions,” she says.Ganti-Agrawal notes that the team drew from a variety of different engineering subfields. For example, there has been much research on high-temperature sodium, but none with a system with controlled humidity. “We’re pulling from fuel cell research in terms of designing our electrode, we’re pulling from older high-temperature battery research as well as some nascent sodium-air battery research, and kind of mushing it together,” which led to the “the big bump in performance” the team has achieved, he says.The research team also included Alden Friesen, an MIT summer intern who attends Desert Mountain High School in Scottsdale, Arizona; Kailash Raman and William Woodford of Form Energy in Somerville, Massachusetts; Shashank Sripad of And Battery Aero in California, and Venkatasubramanian Viswanathan of the University of Michigan. The work was supported by ARPA-E, Breakthrough Energy Ventures, and the National Science Foundation, and used facilities at MIT.nano. More

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      in Energy

      How to solve a bottleneck for CO2 capture and conversion

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      Removing carbon dioxide from the atmosphere efficiently is often seen as a crucial need for combatting climate change, but systems for removing carbon dioxide suffer from a tradeoff. Chemical compounds that efficiently remove CO₂ from the air do not easily release it once captured, and compounds that release CO₂ efficiently are not very efficient at capturing it. Optimizing one part of the cycle tends to make the other part worse.Now, using nanoscale filtering membranes, researchers at MIT have added a simple intermediate step that facilitates both parts of the cycle. The new approach could improve the efficiency of electrochemical carbon dioxide capture and release by six times and cut costs by at least 20 percent, they say.The new findings are reported today in the journal ACS Energy Letters, in a paper by MIT doctoral students Simon Rufer, Tal Joseph, and Zara Aamer, and professor of mechanical engineering Kripa Varanasi.“We need to think about scale from the get-go when it comes to carbon capture, as making a meaningful impact requires processing gigatons of CO₂,” says Varanasi. “Having this mindset helps us pinpoint critical bottlenecks and design innovative solutions with real potential for impact. That’s the driving force behind our work.”Many carbon-capture systems work using chemicals called hydroxides, which readily combine with carbon dioxide to form carbonate. That carbonate is fed into an electrochemical cell, where the carbonate reacts with an acid to form water and release carbon dioxide. The process can take ordinary air with only about 400 parts per million of carbon dioxide and generate a stream of 100 percent pure carbon dioxide, which can then be used to make fuels or other products.Both the capture and release steps operate in the same water-based solution, but the first step needs a solution with a high concentration of hydroxide ions, and the second step needs one high in carbonate ions. “You can see how these two steps are at odds,” says Varanasi. “These two systems are circulating the same sorbent back and forth. They’re operating on the exact same liquid. But because they need two different types of liquids to operate optimally, it’s impossible to operate both systems at their most efficient points.”The team’s solution was to decouple the two parts of the system and introduce a third part in between. Essentially, after the hydroxide in the first step has been mostly chemically converted to carbonate, special nanofiltration membranes then separate ions in the solution based on their charge. Carbonate ions have a charge of 2, while hydroxide ions have a charge of 1. “The nanofiltration is able to separate these two pretty well,” Rufer says.Once separated, the hydroxide ions are fed back to the absorption side of the system, while the carbonates are sent ahead to the electrochemical release stage. That way, both ends of the system can operate at their more efficient ranges. Varanasi explains that in the electrochemical release step, protons are being added to the carbonate to cause the conversion to carbon dioxide and water, but if hydroxide ions are also present, the protons will react with those ions instead, producing just water.“If you don’t separate these hydroxides and carbonates,” Rufer says, “the way the system fails is you’ll add protons to hydroxide instead of carbonate, and so you’ll just be making water rather than extracting carbon dioxide. That’s where the efficiency is lost. Using nanofiltration to prevent this was something that we aren’t aware of anyone proposing before.”Testing showed that the nanofiltration could separate the carbonate from the hydroxide solution with about 95 percent efficiency, validating the concept under realistic conditions, Rufer says. The next step was to assess how much of an effect this would have on the overall efficiency and economics of the process. They created a techno-economic model, incorporating electrochemical efficiency, voltage, absorption rate, capital costs, nanofiltration efficiency, and other factors.The analysis showed that present systems cost at least $600 per ton of carbon dioxide captured, while with the nanofiltration component added, that drops to about $450 a ton. What’s more, the new system is much more stable, continuing to operate at high efficiency even under variations in the ion concentrations in the solution. “In the old system without nanofiltration, you’re sort of operating on a knife’s edge,” Rufer says; if the concentration varies even slightly in one direction or the other, efficiency drops off drastically. “But with our nanofiltration system, it kind of acts as a buffer where it becomes a lot more forgiving. You have a much broader operational regime, and you can achieve significantly lower costs.”He adds that this approach could apply not only to the direct air capture systems they studied specifically, but also to point-source systems — which are attached directly to the emissions sources such as power plant emissions — or to the next stage of the process, converting captured carbon dioxide into useful products such as fuel or chemical feedstocks.  Those conversion processes, he says, “are also bottlenecked in this carbonate and hydroxide tradeoff.”In addition, this technology could lead to safer alternative chemistries for carbon capture, Varanasi says. “A lot of these absorbents can at times be toxic, or damaging to the environment. By using a system like ours, you can improve the reaction rate, so you can choose chemistries that might not have the best absorption rate initially but can be improved to enable safety.”Varanasi adds that “the really nice thing about this is we’ve been able to do this with what’s commercially available,” and with a system that can easily be retrofitted to existing carbon-capture installations. If the costs can be further brought down to about $200 a ton, it could be viable for widespread adoption. With ongoing work, he says, “we’re confident that we’ll have something that can become economically viable” and that will ultimately produce valuable, saleable products.Rufer notes that even today, “people are buying carbon credits at a cost of over $500 per ton. So, at this cost we’re projecting, it is already commercially viable in that there are some buyers who are willing to pay that price.” But by bringing the price down further, that should increase the number of buyers who would consider buying the credit, he says. “It’s just a question of how widespread we can make it.” Recognizing this growing market demand, Varanasi says, “Our goal is to provide industry scalable, cost-effective, and reliable technologies and systems that enable them to directly meet their decarbonization targets.”The research was supported by Shell International Exploration and Production Inc. through the MIT Energy Initiative, and the U.S. National Science Foundation, and made use of the facilities at MIT.nano. More

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      in Environment

      Technology developed by MIT engineers makes pesticides stick to plant leaves

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      Reducing the amount of agricultural sprays used by farmers — including fertilizers, pesticides and herbicides — could cut down the amount of polluting runoff that ends up in the environment while at the same time reducing farmers’ costs and perhaps even enhancing their productivity. A classic win-win-win.A team of researchers at MIT and a spinoff company they launched has developed a system to do just that. Their technology adds a thin coating around droplets as they are being sprayed onto a field, greatly reducing their tendency to bounce off leaves and end up wasted on the ground. Instead, the coated droplets stick to the leaves as intended.The research is described today in the journal Soft Matter, in a paper by recent MIT alumni Vishnu Jayaprakash PhD ’22 and Sreedath Panat PhD ’23, graduate student Simon Rufer, and MIT professor of mechanical engineering Kripa Varanasi.A recent study found that if farmers didn’t use pesticides, they would lose 78 percent of fruit, 54 percent of vegetable, and 32 percent of cereal production. Despite their importance, a lack of technology that monitors and optimizes sprays has forced farmers to rely on personal experience and rules of thumb to decide how to apply these chemicals. As a result, these chemicals tend to be over-sprayed, leading to runoff and chemicals ending up in waterways or building up in the soil.Pesticides take a significant toll on global health and the environment, the researchers point out. A recent study found that 31 percent of agricultural soils around the world were at high risk from pesticide pollution. And agricultural chemicals are a major expense for farmers: In the U.S., they spend $16 billion a year just on pesticides.Making spraying more efficient is one of the best ways to make food production more sustainable and economical. Agricultural spraying essentially boils down to mixing chemicals into water and spraying water droplets onto plant leaves, which are often inherently water-repellent. “Over more than a decade of research in my lab at MIT, we have developed fundamental understandings of spraying and the interaction between droplets and plants — studying when they bounce and all the ways we have to make them stick better and enhance coverage,” Varanasi says.The team had previously found a way to reduce the amount of sprayed liquid that bounces away from the leaves it strikes, which involved using two spray nozzles instead of one and spraying mixtures with opposite electrical charges. But they found that farmers were reluctant to take on the expense and effort of converting their spraying equipment to a two-nozzle system. So, the team looked for a simpler alternative.They discovered they could achieve the same improvement in droplet retention using a single-nozzle system that can be easily adapted to existing sprayers. Instead of giving the droplets of pesticide an electric charge, they coat each droplet with a vanishingly thin layer of an oily material.In their new study, they conducted lab experiments with high-speed cameras. When they sprayed droplets with no special treatment onto a water-repelling (hydrophobic) surface similar to that of many plant leaves, the droplets initially spread out into a pancake-like disk, then rebounded back into a ball and bounced away. But when the researchers coated the surface of the droplets with a tiny amount of oil — making up less than 1 percent of the droplet’s liquid — the droplets spread out and then stayed put. The treatment improved the droplets’ “stickiness” by as much as a hundredfold.“When these droplets are hitting the surface and as they expand, they form this oil ring that essentially pins the droplet to the surface,” Rufer says. The researchers tried a wide variety of conditions, he says, explaining that they conducted hundreds of experiments, “with different impact velocities, different droplet sizes, different angles of inclination, all the things that fully characterize this phenomenon.” Though different oils varied in their effectiveness, all of them were effective. “Regardless of the impact velocity and the oils, we saw that the rebound height was significantly lower,” he says.The effect works with remarkably small amounts of oil. In their initial tests they used 1 percent oil compared to the water, then they tried a 0.1 percent, and even .01. The improvement in droplets sticking to the surface continued at a 0.1 percent, but began to break down beyond that. “Basically, this oil film acts as a way to trap that droplet on the surface, because oil is very attracted to the surface and sort of holds the water in place,” Rufer says.In the researchers’ initial tests they used soybean oil for the coating, figuring this would be a familiar material for the farmers they were working with, many of whom were growing soybeans. But it turned out that though they were producing the beans, the oil was not part of their usual supply chain for use on the farm. In further tests, the researchers found that several chemicals that farmers were already routinely using in their spraying, called surfactants and adjuvants, could be used instead, and that some of these provided the same benefits in keeping the droplets stuck on the leaves.“That way,” Varanasi says, “we’re not introducing a new chemical or changed chemistries into their field, but they’re using things they’ve known for a long time.”Varanasi and Jayaprakash formed a company called AgZen to commercialize the system. In order to prove how much their coating system improves the amount of spray that stays on the plant, they first had to develop a system to monitor spraying in real time. That system, which they call RealCoverage, has been deployed on farms ranging in size from a few dozen acres to hundreds of thousands of acres, and many different crop types, and has saved farmers 30 to 50 percent on their pesticide expenditures, just by improving the controls on the existing sprays. That system is being deployed to 920,000 acres of crops in 2025, the company says, including some in California, Texas, the Midwest, France and Italy. Adding the cloaking system using new nozzles, the researchers say, should yield at least another doubling of efficiency.“You could give back a billion dollars to U.S. growers if you just saved 6 percent of their pesticide budget,” says Jayaprakash, lead author of the research paper and CEO of AgZen. “In the lab we got 300 percent of extra product on the plant. So that means we could get orders of magnitude reductions in the amount of pesticides that farmers are spraying.”Farmers had already been using these surfactant and adjuvant chemicals as a way to enhance spraying effectiveness, but they were mixing it with a water solution. For it to have any effect, they had to use much more of these materials, risking causing burns to the plants. The new coating system reduces the amount of these materials needed, while improving their effectiveness.In field tests conducted by AgZen, “we doubled the amount of product on kale and soybeans just by changing where the adjuvant was,” from mixed in to being a coating, Jayaprakash says. It’s convenient for farmers because “all they’re doing is changing their nozzle. They’re getting all their existing chemicals to work better, and they’re getting more product on the plant.”And it’s not just for pesticides. “The really cool thing is this is useful for every chemistry that’s going on the leaf, be it an insecticide, a herbicide, a fungicide, or foliar nutrition,” Varanasi says. This year, they plan to introduce the new spray system on about 30,000 acres of cropland.Varanasi says that with projected world population growth, “the amount of food production has got to double, and we are limited in so many resources, for example we cannot double the arable land. … This means that every acre we currently farm must become more efficient and able to do more with less.” These improved spraying technologies, for both monitoring the spraying and coating the droplets, Varanasi says, “I think is fundamentally changing agriculture.”AgZen has recently raised $10 million in venture financing to support rapid commercial deployment of these technologies that can improve the control of chemical inputs into agriculture. “The knowledge we are gathering from every leaf, combined with our expertise in interfacial science and fluid mechanics, is giving us unparalleled insights into how chemicals are used and developed — and it’s clear that we can deliver value across the entire agrochemical supply chain,” Varanasi says  “Our mission is to use these technologies to deliver improved outcomes and reduced costs for the ag industry.”  More