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      in Energy

      MIT engineers design surfaces that make water boil more efficiently

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      The boiling of water or other fluids is an energy-intensive step at the heart of a wide range of industrial processes, including most electricity generating plants, many chemical production systems, and even cooling systems for electronics.

      Improving the efficiency of systems that heat and evaporate water could significantly reduce their energy use. Now, researchers at MIT have found a way to do just that, with a specially tailored surface treatment for the materials used in these systems.

      The improved efficiency comes from a combination of three different kinds of surface modifications, at different size scales. The new findings are described in the journal Advanced Materials in a paper by recent MIT graduate Youngsup Song PhD ’21, Ford Professor of Engineering Evelyn Wang, and four others at MIT. The researchers note that this initial finding is still at a laboratory scale, and more work is needed to develop a practical, industrial-scale process.

      There are two key parameters that describe the boiling process: the heat transfer coefficient (HTC) and the critical heat flux (CHF). In materials design, there’s generally a tradeoff between the two, so anything that improves one of these parameters tends to make the other worse. But both are important for the efficiency of the system, and now, after years of work, the team has achieved a way of significantly improving both properties at the same time, through their combination of different textures added to a material’s surface.

      “Both parameters are important,” Song says, “but enhancing both parameters together is kind of tricky because they have intrinsic trade off.” The reason for that, he explains, is “because if we have lots of bubbles on the boiling surface, that means boiling is very efficient, but if we have too many bubbles on the surface, they can coalesce together, which can form a vapor film over the boiling surface.” That film introduces resistance to the heat transfer from the hot surface to the water. “If we have vapor in between the surface and water, that prevents the heat transfer efficiency and lowers the CHF value,” he says.

      Song, who is now a postdoc at Lawrence Berkeley National Laboratory, carried out much of the research as part of his doctoral thesis work at MIT. While the various components of the new surface treatment he developed had been previously studied, the researchers say this work is the first to show that these methods could be combined to overcome the tradeoff between the two competing parameters.

      Adding a series of microscale cavities, or dents, to a surface is a way of controlling the way bubbles form on that surface, keeping them effectively pinned to the locations of the dents and preventing them from spreading out into a heat-resisting film. In this work, the researchers created an array of 10-micrometer-wide dents separated by about 2 millimeters to prevent film formation. But that separation also reduces the concentration of bubbles at the surface, which can reduce the boiling efficiency. To compensate for that, the team introduced a much smaller-scale surface treatment, creating tiny bumps and ridges at the nanometer scale, which increases the surface area and promotes the rate of evaporation under the bubbles.

      In these experiments, the cavities were made in the centers of a series of pillars on the material’s surface. These pillars, combined with nanostructures, promote wicking of liquid from the base to their tops, and this enhances the boiling process by providing more surface area exposed to the water. In combination, the three “tiers” of the surface texture — the cavity separation, the posts, and the nanoscale texturing — provide a greatly enhanced efficiency for the boiling process, Song says.

      “Those micro cavities define the position where bubbles come up,” he says. “But by separating those cavities by 2 millimeters, we separate the bubbles and minimize the coalescence of bubbles.” At the same time, the nanostructures promote evaporation under the bubbles, and the capillary action induced by the pillars supplies liquid to the bubble base. That maintains a layer of liquid water between the boiling surface and the bubbles of vapor, which enhances the maximum heat flux.

      Although their work has confirmed that the combination of these kinds of surface treatments can work and achieve the desired effects, this work was done under small-scale laboratory conditions that could not easily be scaled up to practical devices, Wang says. “These kinds of structures we’re making are not meant to be scaled in its current form,” she says, but rather were used to prove that such a system can work. One next step will be to find alternative ways of creating these kinds of surface textures so these methods could more easily be scaled up to practical dimensions.

      “Showing that we can control the surface in this way to get enhancement is a first step,” she says. “Then the next step is to think about more scalable approaches.” For example, though the pillars on the surface in these experiments were created using clean-room methods commonly used to produce semiconductor chips, there are other, less demanding ways of creating such structures, such as electrodeposition. There are also a number of different ways to produce the surface nanostructure textures, some of which may be more easily scalable.

      There may be some significant small-scale applications that could use this process in its present form, such as the thermal management of electronic devices, an area that is becoming more important as semiconductor devices get smaller and managing their heat output becomes ever more important. “There’s definitely a space there where this is really important,” Wang says.

      Even those kinds of applications will take some time to develop because typically thermal management systems for electronics use liquids other than water, known as dielectric liquids. These liquids have different surface tension and other properties than water, so the dimensions of the surface features would have to be adjusted accordingly. Work on these differences is one of the next steps for the ongoing research, Wang says.

      This same multiscale structuring technique could also be applied to different liquids, Song says, by adjusting the dimensions to account for the different properties of the liquids. “Those kinds of details can be changed, and that can be our next step,” he says.

      The team also included Carlos Diaz-Martin, Lenan Zhang, Hyeongyun Cha, and Yajing Zhao, all at MIT. The work was supported by the Advanced Research Projects Agency-Energy (ARPA-E), the Air Force Office of Scientific Research, and the Singapore-MIT Alliance for Research and Technology, and made use of the MIT.nano facilities. More

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      in Energy

      Donald Sadoway wins European Inventor Award for liquid metal batteries

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      MIT Professor Donald Sadoway has won the 2022 European Inventor Award, in the category for Non-European Patent Office Countries, for his work on liquid metal batteries that could enable the long-term storage of renewable energy.

      Sadoway is the John F. Elliott Professor of Materials Chemistry in MIT’s Department of Materials Science and Engineering, and a longtime supporter and friend of the Materials Research Laboratory.

      “By enabling the large-scale storage of renewable energy, Donald Sadoway’s invention is a huge step towards the deployment of carbon-free electricity generation,” says António Campinos, president of the European Patent Office. “He has spent his career studying electrochemistry and has transformed this expertise into an invention that represents a huge step forward in the transition to green energy.”

      Sadoway was honored at the 2022 European Inventor Award ceremony on June 21. The award is one of Europe’s most prestigious innovation prizes and is presented annually to outstanding inventors from Europe and beyond who have made an exceptional contribution to society, technological progress, and economic growth.

      When accepting the award in Munich, Sadoway told the audience:

      “I am astonished. When I look at all the patented technologies that are represented at this event I see an abundance of excellence, all of them solutions to pressing problems. I wonder if the judges are assessing not only degrees of excellence but degrees of urgency. The liquid metal battery addresses an existential threat to the health of our atmosphere which is related to climate change.

      “By hosting this event the EPO celebrates invention. The thread that connects all the inventors is their efforts to make the world a better place. In my judgment there is no nobler pursuit. So perhaps this is a celebration of nobility.”

      Sadoway’s liquid metal batteries consist of three liquid layers of different densities, which naturally separate in the same way as oil and vinegar do in a salad dressing. The top and bottom layers are made from molten metals, with a middle layer of molten liquid salt.

      To keep the metals liquid, the batteries need to operate at extremely high temperatures, so Sadoway designed a system that is self-heating and insulated, requiring no external heating or cooling. They have a lifespan of more than 20 years, can maintain 99 percent of their capacity over 5,000 charging cycles, and have no combustible materials, meaning there is no fire risk.

      In 2010, with a patent for his invention and support from Bill Gates, Sadoway co-founded Ambri, based in Marlborough, Massachusetts just outside Boston, to develop a commercial product. The company will soon install a unit on a 3,700-acre development for a data center in Nevada. This battery will store energy from a reported 500 megawatts of on-site renewable generation, the same output as a natural gas power plant.

      Born in 1950 into a family of Ukrainian immigrants in Canada, Sadoway studied chemical metallurgy specializing in what he calls “extreme electrochemistry” — chemical reactions in molten salts and liquid metals that have been heated to over 500 degrees Celsius. After earning his BASc, MASc, and PhD, all from the University of Toronto, he joined the faculty at MIT in 1978. More

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      in Energy

      Using excess heat to improve electrolyzers and fuel cells

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      Reducing the use of fossil fuels will have unintended consequences for the power-generation industry and beyond. For example, many industrial chemical processes use fossil-fuel byproducts as precursors to things like asphalt, glycerine, and other important chemicals. One solution to reduce the impact of the loss of fossil fuels on industrial chemical processes is to store and use the heat that nuclear fission produces. New MIT research has dramatically improved a way to put that heat toward generating chemicals through a process called electrolysis. 

      Electrolyzers are devices that use electricity to split water (H2O) and generate molecules of hydrogen (H2) and oxygen (O2). Hydrogen is used in fuel cells to generate electricity and drive electric cars or drones or in industrial operations like the production of steel, ammonia, and polymers. Electrolyzers can also take in water and carbon dioxide (CO2) and produce oxygen and ethylene (C2H4), a chemical used in polymers and elsewhere.

      There are three main types of electrolyzers. One type works at room temperature, but has downsides; they’re inefficient and require rare metals, such as platinum. A second type is more efficient but runs at high temperatures, above 700 degrees Celsius. But metals corrode at that temperature, and the devices need expensive sealing and insulation. The third type would be a Goldilocks solution for nuclear heat if it were perfected, running at 300-600 C and requiring mostly cheap materials like stainless steel. These cells have never been operated as efficiently as theory says they should. The new work, published this month in Nature, both illuminates the problem and offers a solution.

      A sandwich mystery

      The intermediate-temperature devices use what are called protonic ceramic electrochemical cells. Each cell is a sandwich, with a dense electrolyte layered between two porous electrodes. Water vapor is pumped into the top electrode. A wire on the side connects the two electrodes, and externally generated electricity runs from the top to the bottom. The voltage pulls electrons out of the water, which splits the molecule, releasing oxygen. A hydrogen atom without an electron is just a proton. The protons get pulled through the electrolyte to rejoin with the electrons at the bottom electrode and form H2 molecules, which are then collected.

      On its own, the electrolyte in the middle, made mainly of barium, cerium, and zirconium, conducts protons very well. “But when we put the same material into this three-layer device, the proton conductivity of the full cell is pretty bad,” says Yanhao Dong, a postdoc in MIT’s Department of Nuclear Science and Engineering and a paper co-author. “Its conductivity is only about 50 percent of the bulk form’s. We wondered why there’s an inconsistency here.”

      A couple of clues pointed them in the right direction. First, if they don’t prepare the cell very carefully, the top layer, only about 20 microns (.02 millimeters) thick, doesn’t stay attached. “Sometimes if you use just Scotch tape, it will peel off,” Dong says. Second, when they looked at a cross section of a device using a scanning electron microscope, they saw that the top surface of the electrolyte layer was flat, whereas the bottom surface of the porous electrode sitting on it was bumpy, and the two came into contact in only a few places. They didn’t bond well. That precarious interface leads to both structural de-lamination and poor proton passage from the electrode to the electrolyte.

      Acidic solution

      The solution turned out to be simple: researchers roughed up the top of the electrolyte. Specifically, they applied acid for 10 minutes, which etched grooves into the surface. Ju Li, the Battelle Energy Alliance Professor in Nuclear Engineering and professor of materials science and engineering at MIT, and a paper co-author, likens it to sandblasting a surface before applying paint to increase adhesion. Their acid-treated cells produced about 200 percent more hydrogen per area at 1.5 volts at 600 C than did any previous cell of its type, and worked well down to 350 C with very little performance decay over extended operation. 

      “The authors reported a surprisingly simple yet highly effective surface treatment to dramatically improve the interface,” says Liangbing Hu, the director of the Center for Materials Innovation at the Maryland Energy Innovation Institute, who was not involved in the work. He calls the cell performance “exceptional.”

      “We are excited and surprised” by the results, Dong says. “The engineering solution seems quite simple. And that’s actually good, because it makes it very applicable to real applications.” In a practical product, many such cells would be stacked together to form a module. MIT’s partner in the project, Idaho National Laboratory, is very strong in engineering and prototyping, so Li expects to see electrolyzers based on this technology at scale before too long. “At the materials level, this is a breakthrough that shows that at a real-device scale you can work at this sweet spot of temperature of 350 to 600 degrees Celsius for nuclear fission and fusion reactors,” he says.

      “Reduced operating temperature enables cheaper materials for the large-scale assembly, including the stack,” says Idaho National Laboratory researcher and paper co-author Dong Ding. “The technology operates within the same temperature range as several important, current industrial processes, including ammonia production and CO2 reduction. Matching these temperatures will expedite the technology’s adoption within the existing industry.”

      “This is very significant for both Idaho National Lab and us,” Li adds, “because it bridges nuclear energy and renewable electricity.” He notes that the technology could also help fuel cells, which are basically electrolyzers run in reverse, using green hydrogen or hydrocarbons to generate electricity. According to Wei Wu, a materials scientist at Idaho National Laboratory and a paper co-author, “this technique is quite universal and compatible with other solid electrochemical devices.”

      Dong says it’s rare for a paper to advance both science and engineering to such a degree. “We are happy to combine those together and get both very good scientific understanding and also very good real-world performance.”

      This work, done in collaboration with Idaho National Laboratory, New Mexico State University, and the University of Nebraska–Lincoln, was funded, in part, by the U.S. Department of Energy. More

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      in Environment

      Strengthening students’ knowledge and experience in climate and sustainability

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      Tackling the climate crisis is central to MIT. Critical to this mission is harnessing the innovation, passion, and expertise of MIT’s talented students, from a variety of disciplines and backgrounds. To help raise this student involvement to the next level, the MIT Climate and Sustainability Consortium (MCSC) recently launched a program that will engage MIT undergraduates in a unique, year-long, interdisciplinary experience both developing and implementing climate and sustainability research projects.

      The MCSC Climate and Sustainability Scholars Program is a way for students to dive deeply and directly into climate and sustainability research, strengthen their skill sets in a variety of climate and sustainability-related areas, build their networks, and continue to embrace and grow their passion.The MCSC Climate and Sustainability Scholars Program is representative of MIT’s ambitious and bold initiatives on climate and sustainability — bringing together faculty and students across MIT to collaborate with industry on developing climate and sustainability solutions in the context of undergraduate education and research.

      The program, open to rising juniors and seniors from all majors and departments, is inspired by MIT’s SuperUROP program. Students will enroll in a year-long class while simultaneously engaging in research. Research projects will be climate- and sustainability-focused and can be on or off campus. The course will be initially facilitated by Desiree Plata, the Gilbert W. Winslow Career Development Professor in Civil and Environmental Engineering, and Elsa Olivetti, the Esther and Harold E. Edgerton Associate Professor in Materials Science and Engineering and MCSC co-director.“Climate and sustainability challenges face real barriers in science, technology, policy, and beyond,” says Plata, who also serves on the MCSC’s Faculty Steering Committee. “We need to motivate an all-hands effort to bring MIT talent to bear on these challenges, and we need to give our students the tools to make tangible benefits within and between their disciplines. This was our goal in designing the MCSC Scholars Program, and it’s what I’m most excited about.”

      The Climate and Sustainability Scholars Program has relevance across all five schools, and the number of places the course is cross-listed continues to grow. As is the broader goal of the MCSC, the Climate and Sustainability Scholars Program aims to amplify and extend MIT’s expertise — through engaging students of all backgrounds and majors, bringing in faculty mentors and instructors from around the Institute, and identifying research opportunities and principal investigators that span disciplines. The student cohort model will also build off of the successful community-building endeavors by the MIT Energy Initiative and Environmental Solutions Initiative, among others, to bring students with similar interests together into an interdisciplinary, problem-solving space.The program’s fall semester will focus on key climate and sustainability topics, such as decarbonization strategies, policy, environmental justice, and quantitative methods for evaluating social and environmental impacts, and humanities-based communication of climate topics, all while students engage in research. Students will simultaneously develop project proposals, participate in a project through MIT’s Undergraduate Research Opportunities Program, and communicate their work using written and oral media. The spring semester’s course will focus on research and experiential activities, and help students communicate their outputs in entrepreneurial or policy activities that would enable the research outcomes to be rapidly scaled for impact.Throughout the program, students will engage with their research mentors, additional mentors drawn from MCSC-affiliated faculty, postdoctoral Impact Fellows, and graduate students — and there will also be opportunities for interaction with representatives of MCSC member companies.“Providing opportunities for students to sharpen the skills and knowledge needed to pioneer solutions for climate change mitigation and adaptation is critical,” says Olivetti. “We are excited that the Climate and Sustainability Scholars Program can contribute to that important mission.” More

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      in Security

      MIT engineers introduce the Oreometer

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      When you twist open an Oreo cookie to get to the creamy center, you’re mimicking a standard test in rheology — the study of how a non-Newtonian material flows when twisted, pressed, or otherwise stressed. MIT engineers have now subjected the sandwich cookie to rigorous materials tests to get to the center of a tantalizing question: Why does the cookie’s cream stick to just one wafer when twisted apart?

      “There’s the fascinating problem of trying to get the cream to distribute evenly between the two wafers, which turns out to be really hard,” says Max Fan, an undergraduate in MIT’s Department of Mechanical Engineering.

      In pursuit of an answer, the team subjected cookies to standard rheology tests in the lab and found that no matter the flavor or amount of stuffing, the cream at the center of an Oreo almost always sticks to one wafer when twisted open. Only for older boxes of cookies does the cream sometimes separate more evenly between both wafers.

      The researchers also measured the torque required to twist open an Oreo, and found it to be similar to the torque required to turn a doorknob and about 1/10th what’s needed to twist open a bottlecap. The cream’s failure stress — i.e. the force per area required to get the cream to flow, or deform — is twice that of cream cheese and peanut butter, and about the same magnitude as mozzarella cheese. Judging from the cream’s response to stress, the team classifies its texture as “mushy,” rather than brittle, tough, or rubbery.

      So, why does the cookie’s cream glom to one side rather than splitting evenly between both? The manufacturing process may be to blame.

      “Videos of the manufacturing process show that they put the first wafer down, then dispense a ball of cream onto that wafer before putting the second wafer on top,” says Crystal Owens, an MIT mechanical engineering PhD candidate who studies the properties of complex fluids. “Apparently that little time delay may make the cream stick better to the first wafer.”

      The team’s study isn’t simply a sweet diversion from bread-and-butter research; it’s also an opportunity to make the science of rheology accessible to others. To that end, the researchers have designed a 3D-printable “Oreometer” — a simple device that firmly grasps an Oreo cookie and uses pennies and rubber bands to control the twisting force that progressively twists the cookie open. Instructions for the tabletop device can be found here.

      The new study, “On Oreology, the fracture and flow of ‘milk’s favorite cookie,’” appears today in Kitchen Flows, a special issue of the journal Physics of Fluids. It was conceived of early in the Covid-19 pandemic, when many scientists’ labs were closed or difficult to access. In addition to Owens and Fan, co-authors are mechanical engineering professors Gareth McKinley and A. John Hart.

      Confection connection

      A standard test in rheology places a fluid, slurry, or other flowable material onto the base of an instrument known as a rheometer. A parallel plate above the base can be lowered onto the test material. The plate is then twisted as sensors track the applied rotation and torque.

      Owens, who regularly uses a laboratory rheometer to test fluid materials such as 3D-printable inks, couldn’t help noting a similarity with sandwich cookies. As she writes in the new study:

      “Scientifically, sandwich cookies present a paradigmatic model of parallel plate rheometry in which a fluid sample, the cream, is held between two parallel plates, the wafers. When the wafers are counter-rotated, the cream deforms, flows, and ultimately fractures, leading to separation of the cookie into two pieces.”

      While Oreo cream may not appear to possess fluid-like properties, it is considered a “yield stress fluid” — a soft solid when unperturbed that can start to flow under enough stress, the way toothpaste, frosting, certain cosmetics, and concrete do.

      Curious as to whether others had explored the connection between Oreos and rheology, Owens found mention of a 2016 Princeton University study in which physicists first reported that indeed, when twisting Oreos by hand, the cream almost always came off on one wafer.

      “We wanted to build on this to see what actually causes this effect and if we could control it if we mounted the Oreos carefully onto our rheometer,” she says.

      Play video

      Cookie twist

      In an experiment that they would repeat for multiple cookies of various fillings and flavors, the researchers glued an Oreo to both the top and bottom plates of a rheometer and applied varying degrees of torque and angular rotation, noting the values  that successfully twisted each cookie apart. They plugged the measurements into equations to calculate the cream’s viscoelasticity, or flowability. For each experiment, they also noted the cream’s “post-mortem distribution,” or where the cream ended up after twisting open.

      In all, the team went through about 20 boxes of Oreos, including regular, Double Stuf, and Mega Stuf levels of filling, and regular, dark chocolate, and “golden” wafer flavors. Surprisingly, they found that no matter the amount of cream filling or flavor, the cream almost always separated onto one wafer.

      “We had expected an effect based on size,” Owens says. “If there was more cream between layers, it should be easier to deform. But that’s not actually the case.”

      Curiously, when they mapped each cookie’s result to its original position in the box, they noticed the cream tended to stick to the inward-facing wafer: Cookies on the left side of the box twisted such that the cream ended up on the right wafer, whereas cookies on the right side separated with cream mostly on the left wafer. They suspect this box distribution may be a result of post-manufacturing environmental effects, such as heating or jostling that may cause cream to peel slightly away from the outer wafers, even before twisting.

      The understanding gained from the properties of Oreo cream could potentially be applied to the design of other complex fluid materials.

      “My 3D printing fluids are in the same class of materials as Oreo cream,” she says. “So, this new understanding can help me better design ink when I’m trying to print flexible electronics from a slurry of carbon nanotubes, because they deform in almost exactly the same way.”

      As for the cookie itself, she suggests that if the inside of Oreo wafers were more textured, the cream might grip better onto both sides and split more evenly when twisted.

      “As they are now, we found there’s no trick to twisting that would split the cream evenly,” Owens concludes.

      This research was supported, in part, by the MIT UROP program and by the National Defense Science and Engineering Graduate Fellowship Program. More

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      in Energy

      A new heat engine with no moving parts is as efficient as a steam turbine

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      Engineers at MIT and the National Renewable Energy Laboratory (NREL) have designed a heat engine with no moving parts. Their new demonstrations show that it converts heat to electricity with over 40 percent efficiency — a performance better than that of traditional steam turbines.

      The heat engine is a thermophotovoltaic (TPV) cell, similar to a solar panel’s photovoltaic cells, that passively captures high-energy photons from a white-hot heat source and converts them into electricity. The team’s design can generate electricity from a heat source of between 1,900 to 2,400 degrees Celsius, or up to about 4,300 degrees Fahrenheit.

      The researchers plan to incorporate the TPV cell into a grid-scale thermal battery. The system would absorb excess energy from renewable sources such as the sun and store that energy in heavily insulated banks of hot graphite. When the energy is needed, such as on overcast days, TPV cells would convert the heat into electricity, and dispatch the energy to a power grid.

      With the new TPV cell, the team has now successfully demonstrated the main parts of the system in separate, small-scale experiments. They are working to integrate the parts to demonstrate a fully operational system. From there, they hope to scale up the system to replace fossil-fuel-driven power plants and enable a fully decarbonized power grid, supplied entirely by renewable energy.

      “Thermophotovoltaic cells were the last key step toward demonstrating that thermal batteries are a viable concept,” says Asegun Henry, the Robert N. Noyce Career Development Professor in MIT’s Department of Mechanical Engineering. “This is an absolutely critical step on the path to proliferate renewable energy and get to a fully decarbonized grid.”

      Henry and his collaborators have published their results today in the journal Nature. Co-authors at MIT include Alina LaPotin, Kevin Schulte, Kyle Buznitsky, Colin Kelsall, Andrew Rohskopf, and Evelyn Wang, the Ford Professor of Engineering and head of the Department of Mechanical Engineering, along with collaborators at NREL in Golden, Colorado.

      Jumping the gap

      More than 90 percent of the world’s electricity comes from sources of heat such as coal, natural gas, nuclear energy, and concentrated solar energy. For a century, steam turbines have been the industrial standard for converting such heat sources into electricity.

      On average, steam turbines reliably convert about 35 percent of a heat source into electricity, with about 60 percent representing the highest efficiency of any heat engine to date. But the machinery depends on moving parts that are temperature- limited. Heat sources higher than 2,000 degrees Celsius, such as Henry’s proposed thermal battery system, would be too hot for turbines.

      In recent years, scientists have looked into solid-state alternatives — heat engines with no moving parts, that could potentially work efficiently at higher temperatures.

      “One of the advantages of solid-state energy converters are that they can operate at higher temperatures with lower maintenance costs because they have no moving parts,” Henry says. “They just sit there and reliably generate electricity.”

      Thermophotovoltaic cells offered one exploratory route toward solid-state heat engines. Much like solar cells, TPV cells could be made from semiconducting materials with a particular bandgap — the gap between a material’s valence band and its conduction band. If a photon with a high enough energy is absorbed by the material, it can kick an electron across the bandgap, where the electron can then conduct, and thereby generate electricity — doing so without moving rotors or blades.

      To date, most TPV cells have only reached efficiencies of around 20 percent, with the record at 32 percent, as they have been made of relatively low-bandgap materials that convert lower-temperature, low-energy photons, and therefore convert energy less efficiently.

      Catching light

      In their new TPV design, Henry and his colleagues looked to capture higher-energy photons from a higher-temperature heat source, thereby converting energy more efficiently. The team’s new cell does so with higher-bandgap materials and multiple junctions, or material layers, compared with existing TPV designs.

      The cell is fabricated from three main regions: a high-bandgap alloy, which sits over a slightly lower-bandgap alloy, underneath which is a mirror-like layer of gold. The first layer captures a heat source’s highest-energy photons and converts them into electricity, while lower-energy photons that pass through the first layer are captured by the second and converted to add to the generated voltage. Any photons that pass through this second layer are then reflected by the mirror, back to the heat source, rather than being absorbed as wasted heat.

      The team tested the cell’s efficiency by placing it over a heat flux sensor — a device that directly measures the heat absorbed from the cell. They exposed the cell to a high-temperature lamp and concentrated the light onto the cell. They then varied the bulb’s intensity, or temperature, and observed how the cell’s power efficiency — the amount of power it produced, compared with the heat it absorbed — changed with temperature. Over a range of 1,900 to 2,400 degrees Celsius, the new TPV cell maintained an efficiency of around 40 percent.

      “We can get a high efficiency over a broad range of temperatures relevant for thermal batteries,” Henry says.

      The cell in the experiments is about a square centimeter. For a grid-scale thermal battery system, Henry envisions the TPV cells would have to scale up to about 10,000 square feet (about a quarter of a football field), and would operate in climate-controlled warehouses to draw power from huge banks of stored solar energy. He points out that an infrastructure exists for making large-scale photovoltaic cells, which could also be adapted to manufacture TPVs.

      “There’s definitely a huge net positive here in terms of sustainability,” Henry says. “The technology is safe, environmentally benign in its life cycle, and can have a tremendous impact on abating carbon dioxide emissions from electricity production.”

      This research was supported, in part, by the U.S. Department of Energy. More

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      in Energy

      Engineers enlist AI to help scale up advanced solar cell manufacturing

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      Perovskites are a family of materials that are currently the leading contender to potentially replace today’s silicon-based solar photovoltaics. They hold the promise of panels that are far thinner and lighter, that could be made with ultra-high throughput at room temperature instead of at hundreds of degrees, and that are cheaper and easier to transport and install. But bringing these materials from controlled laboratory experiments into a product that can be manufactured competitively has been a long struggle.

      Manufacturing perovskite-based solar cells involves optimizing at least a dozen or so variables at once, even within one particular manufacturing approach among many possibilities. But a new system based on a novel approach to machine learning could speed up the development of optimized production methods and help make the next generation of solar power a reality.

      The system, developed by researchers at MIT and Stanford University over the last few years, makes it possible to integrate data from prior experiments, and information based on personal observations by experienced workers, into the machine learning process. This makes the outcomes more accurate and has already led to the manufacturing of perovskite cells with an energy conversion efficiency of 18.5 percent, a competitive level for today’s market.

      The research is reported today in the journal Joule, in a paper by MIT professor of mechanical engineering Tonio Buonassisi, Stanford professor of materials science and engineering Reinhold Dauskardt, recent MIT research assistant Zhe Liu, Stanford doctoral graduate Nicholas Rolston, and three others.

      Perovskites are a group of layered crystalline compounds defined by the configuration of the atoms in their crystal lattice. There are thousands of such possible compounds and many different ways of making them. While most lab-scale development of perovskite materials uses a spin-coating technique, that’s not practical for larger-scale manufacturing, so companies and labs around the world have been searching for ways of translating these lab materials into a practical, manufacturable product.

      “There’s always a big challenge when you’re trying to take a lab-scale process and then transfer it to something like a startup or a manufacturing line,” says Rolston, who is now an assistant professor at Arizona State University. The team looked at a process that they felt had the greatest potential, a method called rapid spray plasma processing, or RSPP.

      The manufacturing process would involve a moving roll-to-roll surface, or series of sheets, on which the precursor solutions for the perovskite compound would be sprayed or ink-jetted as the sheet rolled by. The material would then move on to a curing stage, providing a rapid and continuous output “with throughputs that are higher than for any other photovoltaic technology,” Rolston says.

      “The real breakthrough with this platform is that it would allow us to scale in a way that no other material has allowed us to do,” he adds. “Even materials like silicon require a much longer timeframe because of the processing that’s done. Whereas you can think of [this approach as more] like spray painting.”

      Within that process, at least a dozen variables may affect the outcome, some of them more controllable than others. These include the composition of the starting materials, the temperature, the humidity, the speed of the processing path, the distance of the nozzle used to spray the material onto a substrate, and the methods of curing the material. Many of these factors can interact with each other, and if the process is in open air, then humidity, for example, may be uncontrolled. Evaluating all possible combinations of these variables through experimentation is impossible, so machine learning was needed to help guide the experimental process.

      But while most machine-learning systems use raw data such as measurements of the electrical and other properties of test samples, they don’t typically incorporate human experience such as qualitative observations made by the experimenters of the visual and other properties of the test samples, or information from other experiments reported by other researchers. So, the team found a way to incorporate such outside information into the machine learning model, using a probability factor based on a mathematical technique called Bayesian Optimization.

      Using the system, he says, “having a model that comes from experimental data, we can find out trends that we weren’t able to see before.” For example, they initially had trouble adjusting for uncontrolled variations in humidity in their ambient setting. But the model showed them “that we could overcome our humidity challenges by changing the temperature, for instance, and by changing some of the other knobs.”

      The system now allows experimenters to much more rapidly guide their process in order to optimize it for a given set of conditions or required outcomes. In their experiments, the team focused on optimizing the power output, but the system could also be used to simultaneously incorporate other criteria, such as cost and durability — something members of the team are continuing to work on, Buonassisi says.

      The researchers were encouraged by the Department of Energy, which sponsored the work, to commercialize the technology, and they’re currently focusing on tech transfer to existing perovskite manufacturers. “We are reaching out to companies now,” Buonassisi says, and the code they developed has been made freely available through an open-source server. “It’s now on GitHub, anyone can download it, anyone can run it,” he says. “We’re happy to help companies get started in using our code.”

      Already, several companies are gearing up to produce perovskite-based solar panels, even though they are still working out the details of how to produce them, says Liu, who is now at the Northwestern Polytechnical University in Xi’an, China. He says companies there are not yet doing large-scale manufacturing, but instead starting with smaller, high-value applications such as building-integrated solar tiles where appearance is important. Three of these companies “are on track or are being pushed by investors to manufacture 1 meter by 2-meter rectangular modules [comparable to today’s most common solar panels], within two years,” he says.

      ‘The problem is, they don’t have a consensus on what manufacturing technology to use,” Liu says. The RSPP method, developed at Stanford, “still has a good chance” to be competitive, he says. And the machine learning system the team developed could prove to be important in guiding the optimization of whatever process ends up being used.

      “The primary goal was to accelerate the process, so it required less time, less experiments, and less human hours to develop something that is usable right away, for free, for industry,” he says.

      “Existing work on machine-learning-driven perovskite PV fabrication largely focuses on spin-coating, a lab-scale technique,” says Ted Sargent, University Professor at the University of Toronto, who was not associated with this work, which he says demonstrates “a workflow that is readily adapted to the deposition techniques that dominate the thin-film industry. Only a handful of groups have the simultaneous expertise in engineering and computation to drive such advances.” Sargent adds that this approach “could be an exciting advance for the manufacture of a broader family of materials” including LEDs, other PV technologies, and graphene, “in short, any industry that uses some form of vapor or vacuum deposition.” 

      The team also included Austin Flick and Thomas Colburn at Stanford and Zekun Ren at the Singapore-MIT Alliance for Science and Technology (SMART). In addition to the Department of Energy, the work was supported by a fellowship from the MIT Energy Initiative, the Graduate Research Fellowship Program from the National Science Foundation, and the SMART program. More

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      in Energy

      Embracing ancient materials and 21st-century challenges

      by

      When Sophia Mittman was 10 years old, she wanted to be an artist. But instead of using paint, she preferred the mud in her backyard. She sculpted it into pots and bowls like the ones she had seen at the archaeological museums, transforming the earthly material into something beautiful.

      Now an MIT senior studying materials science and engineering, Mittman seeks modern applications for sustainable materials in ways that benefit the community around her.

      Growing up in San Diego, California, Mittman was homeschooled, and enjoyed the process of teaching herself new things. After taking a pottery class in seventh grade, she became interested in sculpture, teaching herself how to make fused glass. From there, Mittman began making pottery and jewelry. This passion to create new things out of sustainable materials led her to pursue materials science, a subject she didn’t even know was originally offered at the Institute.

      “I didn’t know the science behind why those materials had the properties they did. And materials science explained it,” she says.

      During her first year at MIT, Mittman took 2.00b (Toy Product Design), which she considers one of her most memorable classes at the Institute. She remembers learning about the mechanical side of building, using drill presses and sanding machines to create things. However, her favorite part was the seminars on the weekends, where she learned how to make things such as stuffed animals or rolling wooden toys. She appreciated the opportunity to learn how to use everyday materials like wood to construct new and exciting gadgets.

      From there, Mittman got involved in the Glass Club, using blowtorches to melt rods of glass to make things like marbles and little fish decorations. She also took a few pottery and ceramics classes on campus, learning how to hone her skills to craft new things. Understanding MIT’s hands-on approach to learning, Mittman was excited to use her newly curated skills in the various workshops on campus to apply them to the real world.

      In the summer after her first year, Mittman became an undergraduate field and conservation science researcher for the Department of Civil and Environmental Engineering. She traveled to various cities across Italy to collaborate with international art restorers, conservation scientists, and museum curators to study archaeological materials and their applications to modern sustainability. One of her favorite parts was restoring the Roman baths, and studying the mosaics on the ground. She did a research project on Egyptian Blue, one of the first synthetic pigments, which has modern applications because of its infrared luminescence, which can be used for detecting fingerprints in crime scenes. The experience was eye-opening for Mittman; she got to directly experience what she had been learning in the classroom about sustainable materials and how she could preserve and use them for modern applications.

      The next year, upon returning to campus, Mittman joined Incredible Foods as a polymeric food science and technology intern. She learned how to create and apply a polymer coating to natural fruit snacks to replicate real berries. “It was fun to see the breadth of material science because I had learned about polymers in my material science classes, but then never thought that it could be applied to making something as fun as fruit snacks,” she says.

      Venturing into yet another new area of materials science, Mittman last year pursued an internship with Phoenix Tailings, which aims to be the world’s first “clean” mining company. In the lab, she helped develop and analyze chemical reactions to physically and chemically extract rare earth metals and oxides from mining waste. She also worked to engineer bright-colored, high-performance pigments using nontoxic chemicals. Mittman enjoyed the opportunity to explore a mineralogically sustainable method for mining, something she hadn’t previously explored as a branch of materials science research.

      “I’m still able to contribute to environmental sustainability and to try to make a greener world, but it doesn’t solely have to be through energy because I’m dealing with dirt and mud,” she says.

      Outside of her academic work, Mittman is involved with the Tech Catholic Community (TCC) on campus. She has held roles as the music director, prayer chair, and social committee chair, organizing and managing social events for over 150 club members. She says the TCC is the most supportive community in her campus life, as she can meet people who have similar interests as her, though are in different majors. “There are a lot of emotional aspects of being at MIT, and there’s a spiritual part that so many students wrestle with. The TCC is where I’ve been able to find so much comfort, support, and encouragement; the closest friends I have are in the Tech Catholic Community,” she says.

      Mittman is also passionate about teaching, which allows her to connect to students and teach them material in new and exciting ways. In the fall of her junior and senior years, she was a teaching assistant for 3.091 (Introduction to Solid State Chemistry), where she taught two recitations of 20 students and offered weekly private tutoring. She enjoyed helping students tackle difficult course material in ways that are enthusiastic and encouraging, as she appreciated receiving the same help in her introductory courses.

      Looking ahead, Mittman plans to work fulltime at Phoenix Tailings as a materials scientist following her graduation. In this way, she feels like she has come full circle: from playing in the mud as a kid to working with it as a materials scientist to extract materials to help build a sustainable future for nearby and international communities.

      “I want to be able to apply what I’m enthusiastic about, which is materials science, by way of mineralogical sustainability, so that it can help mines here in America but also mines in Brazil, Austria, Jamaica — all over the world, because ultimately, I think that will help more people live better lives,” she says. More