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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Examining Performance Loss Mechanisms in Lithium-Ion Batteries with the High-Voltage Mn-Rich Spinel Positive Electrodes

The high-voltage spinel, with the nominal composition of LiNi 0.5-x Mn 1.5+x O 4 (LNMO), could be a sustainable alternative to the layered-oxide positive electrodes used in lithium-ion batteries. However, commercial acceptance has been limited as LNMO cells display rapid performance loss during cycling. To examine reasons for this loss we prepared cells with LNMO-based positive and either graphite or lithium titanate (LTO) based negative electrodes. Our initial cells displayed high impedance and rapid impedance rise during cycling. Adding single walled carbon nanotubes in the positive lowered initial cell impedance but impedance increased during cycling because of coating delamination from the Al foil. Using a primed Al current collector solved the delamination problem: cells with this current collector showed only a small impedance rise. Regarding capacity, cells with the LTO negative showed higher initial capacities and smaller fade. Our data indicate that cell capacity retention is determined by reduction reactions at the negative electrode that lower capacity and oxidation reactions at the positive electrode that increase capacity: both types of reactions deplete the cell electrolyte during extended cycling. All things considered, species generated at high voltages, either in the electrolyte or at the LNMO electrode, drive cell capacity fade.

25 ENERGY STORAGE↗
DOE OSTI2022

Solvent-Free Manufacturing of Lithium-Ion Battery Electrodes via Cold Plasma

Slurry casting has been used to fabricate lithium-ion battery electrodes for decades, which involves toxic and expensive organic solvents followed by high-cost vacuum drying and electrode calendering. This work presents a new manufacturing method using a nonthermal plasma to create inter-particle binding without using any polymeric binding materials, enabling solvent-free manufacturing electrodes with any electrochemistry of choice. The cold-plasma-coating technique enables fabricating electrodes with thickness (>200 μm), high mass loading (>30 mg cm -2 ), high peel strength, and the ability to print lithium-ion batteries in an arbitrary geometry. This crosscutting, chemistry agnostic, platform technology would increase energy density, eliminate the use of solvents, vacuum drying, and calendering processes during production, and reduce manufacturing cost for current and future cell designs. Here, lithium iron phosphate and lithium cobalt oxide were used as examples to demonstrate the efficacy of the cold-plasma-coating technique. It is found that the mechanical peel strength of cold-plasma-coating-manufactured lithium iron phosphate is over an order of magnitude higher than that of slurry-casted lithium iron phosphate electrodes. Full cells assembled with a graphite anode and the cold-plasma-coating-lithium iron phosphate cathode offer highly reversible cycling performance with a capacity retention of 81.6% over 500 cycles. For the highly conductive cathode material lithium cobalt oxide, an areal capacity of 4.2 mAh cm -2 at 0.2 C is attained. We anticipate that this new, highly scalable manufacturing technique will redefine global lithium-ion battery manufacturing providing significantly reduced plant footprints and material costs.

25 ENERGY STORAGE↗
DOE OSTI2020

A disordered rock salt anode for fast-charging lithium-ion batteries

Rechargeable lithium-ion batteries with high energy density that can be safely charged and discharged at high rates are desirable for electrified transportation and other applications. However, the sub-optimal intercalation potentials of current anodes result in a trade-off between energy density, power and safety. In this paper we report that disordered rock salt Li 3+ x V 2 O 5 can be used as a fast-charging anode that can reversibly cycle two lithium ions at an average voltage of about 0.6 volts versus a Li/Li + reference electrode. The increased potential compared to graphite reduces the likelihood of lithium metal plating if proper charging controls are used, alleviating a major safety concern (short-circuiting related to Li dendrite growth). In addition, a lithium-ion battery with a disordered rock salt Li 3 V 2 O 5 anode yields a cell voltage much higher than does a battery using a commercial fast-charging lithium titanate anode or other intercalation anode candidates (Li 3 VO 4 and LiV 0.5 Ti 0.5 S 2 ). Further, disordered rock salt Li 3 V 2 O 5 can perform over 1,000 charge–discharge cycles with negligible capacity decay and exhibits exceptional rate capability, delivering over 40 per cent of its capacity in 20 seconds. We attribute the low voltage and high rate capability of disordered rock salt Li 3 V 2 O 5 to a redistributive lithium intercalation mechanism with low energy barriers revealed via ab initio calculations. This low-potential, high-rate intercalation reaction can be used to identify other metal oxide anodes for fast-charging, long-life lithium-ion batteries.

25 ENERGY STORAGE↗
NASA NTRS1978

Lightweight electrodes

The fabrication of a lightweight composite nickel hydroxide electrode based on nickel-coated graphite is described and its effect on the load to failure and electrical resistivity of nickel cadmium and nickel zinc systems was evaluated. The use pure lead in lead acid batteries for submarines is also discussed.

Sutula, R.↗
DOE OSTI2023

High-throughput and high-performance lithium-ion batteries via dry processing

A scalable powder-to-electrode dry processing strategy mainly based on powder dry mixing and rolling/calendering is rationally designed. The dry processed electrodes show lower tortuosity compared to that of conventional slurry-based electrodes. The dry-processed high-loading graphite anodes (6.6 mAh cm -2 ) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 cathodes (6.0 mAh cm -2 ) exhibit promising electrochemical performance in half-cells and full-cells. The full-cells with both electrodes from dry processing demonstrates superb rate performance to their counterpart with conventional slurry-based electrodes and delivers of capacity retentions of 74.1 % and 63.6 % over 400 and 800 cycles, respectively. Notably, the initial Coulombic efficiency of the dry processed graphite anodes is low ascribed to polytetrafluoroethylene binder. Finally, the results suggest that dry processing is promising for future lithium-ion battery manufacturing and also pinpoint the needs of modification for the polytetrafluoroethylene binder in the graphite anodes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Enabling Ether-Based Electrolytes for Long Cycle Life of Lithium-Ion Batteries at High Charge Voltage

Lithium-ion batteries (LIBs) with high-nickel (Ni) content LiNi x Mn y Co z O 2 ( x + y + z = 1) (NMC with Ni ≥ 0.6) cathodes operated at high charge voltages have been considered as one of the most promising candidates for addressing the challenge of increasing energy density demand. Conventional LiPF 6 –organocarbonate electrolytes exhibit incompatibility with such cell chemistries under certain testing conditions because of the instability of electrode/electrolyte interphases. In response to this challenge, ether-based electrolytes with finely tuned structure and composition of solvation sheaths were developed and evaluated in graphite (Gr)∥NMC811 cell chemistry in 2.5–4.4 V, despite ethers being conventionally considered to be unfavorable electrolyte solvents for LIBs because of their anodic instability above 4.0 V and cointercalation into Gr electrodes. Furthermore, the functional ether-based electrolytes in this work enable both excellent cycle life and high rate capability of Gr∥NMC811 cells. Mechanistic studies reveal that the unique structure and composition of the solvation sheath of the functional ether electrolytes are the main reasons behind their excellent anodic stability and effective protection of the Gr electrode and, consequently, the extraordinary cell performances when operated at high charge cutoff voltages. This work also provides a feasible approach in developing highly stable functional electrolytes for high-energy density LIBs.

25 ENERGY STORAGE↗
DOE OSTI2020

Hierarchical porous silicon structures with extraordinary mechanical strength as high-performance lithium-ion battery anodes

Abstract Porous structured silicon has been regarded as a promising candidate to overcome pulverization of silicon-based anodes. However, poor mechanical strength of these porous particles has limited their volumetric energy density towards practical applications. Here we design and synthesize hierarchical carbon-nanotube@silicon@carbon microspheres with both high porosity and extraordinary mechanical strength (>200 MPa) and a low apparent particle expansion of ~40% upon full lithiation. The composite electrodes of carbon-nanotube@silicon@carbon-graphite with a practical loading (3 mAh cm −2 ) deliver ~750 mAh g −1 specific capacity, <20% initial swelling at 100% state-of-charge, and ~92% capacity retention over 500 cycles. Calendered electrodes achieve ~980 mAh cm −3 volumetric capacity density and <50% end-of-life swell after 120 cycles. Full cells with LiNi 1/3 Mn 1/3 Co 1/3 O 2 cathodes demonstrate >92% capacity retention over 500 cycles. This work is a leap in silicon anode development and provides insights into the design of electrode materials for other batteries.

25 ENERGY STORAGE↗
NASA NTRS1981

Analytical investigation of critical MHD phenomena

Development and analysis of schemes for suppression of the startup overvoltage transient in the AEDC High Performance Demonstration Experiment (HPDE), analysis of performance enhancement due to electrode voltage drop reduction by use of pyrolytic graphites in the HPDE, prediction of optimal loading schemes for the HPDE, prediction of PHDE performance with a diagonal electrical connection, and predictions of the likelihood and effects of axial current leakage between adjacent electrodes in the HPDE are reviewed. Simulations of tests at the AEDC/HPDE with STD Research Corporation multidimensional and time dependent computer codes provided additional validation for the computer codes and shed light on physical mechanisms which govern performance and durability of MHD power generators. The magnetoaerothermal effect was predicted by STD Research Corporation to have a significant effect on the HPDE/MHD generator performance at high interaction.

Source record↗
NASA NTRS1978

Solubility, stability, and electrochemical studies of sulfur-sulfide solutions in organic solvents

A preliminary study of the sulfur electrode in organic solvents suggests that the system warrants further investigation for use in a low temperature (100 deg to 120 C) Na-S secondary battery. A qualitative screening was undertaken at 120 C to determine the solubilities and stabilities of Na2S and Na2S2 in representatives of many classes of organic solvents. From the screening and quantitative studies, two classes of solvents were selected for work; amides and cyclic polyalcohols. Voltammetric and Na-S cell charge discharge studies of sulfide solutions in organic solvents (e.g., N, N-dimethylformamide) at 120 C suggested that the reversibilities of the reactions on Pt or high density graphite were moderately poor. However, the sulfur electrode was indeed reducible (and oxidizable) through the range of elemental sulfur to Na2S. Reactions and mechanisms are proposed for the oxidation reduction processes occurring at the sulfur electrode.

Fielder, W. L.↗
DOE OSTI2022

Laser ablation for structuring Li-ion electrodes for fast charging and its impact on material properties, rate capability, Li plating, and wetting

Laser ablation is a scalable technique for decreasing the effective tortuosity of electrodes by selectively removing material with high precision. Applied to ≈ 110 um thick electrode coatings, this work focuses on understanding the impact of laser ablation on electrode material properties at the beginning of life and synergistic impacts of ablated channels on cell performance throughout their cycle life. Post laser ablation, local changes in chemistry, crystallography, and morphology of the laser-impacted electrode regions are investigated. It is shown that femtosecond pulsed laser ablation can achieve high-rate material removal with minor material damage locally at the interface of the impacted zones. The capacity achieved during a 6C (10 min) constant-current constant-voltage charge to 4.2 V improved from 1 mAh cm -2 for the non-ablated electrodes to almost 2 mAh cm -2 for the ablated electrodes. This benefit is attributed to a synergistic effect of enhanced wetting and decreased electrode tortuosity. The benefit was maintained for over 120 cycles, and upon disassembly decreased Li-plating on the graphite anode was observed. Finally, multi-physics modeling in conjunction with wetting analyses showed that laser ablating either one of the electrodes led to substantial improvements in wetting and rate capability, indicating that substantial performance benefits can be achieved by ablating only the graphite anode as apposed to both electrodes.

25 ENERGY STORAGE↗
DOE OSTI2021

Review—The Lithiation/Delithiation Behavior of Si-Based Electrodes: A Connection between Electrochemistry and Mechanics

Silicon is a promising alternative anode material to graphite because of its high gravimetric and volumetric energy densities. However, severe capacity fading is observed in Si electrodes, and it is a result of mechanical changes of Si, such as volume changes, stress or fracture. Furthermore, these mechanical behaviors are strongly coupled with the electrochemistry of the Li-Si alloying reaction in Si-based electrodes, including both thermodynamics and kinetics. Therefore, the electrochemical properties of Si-based electrodes are strongly dependent on the control of the mechanics of Si during lithiation/delithiation. As such, it is very important to understand the correlation between electrochemistry and mechanics. Here, we review lithiation/delithiation behaviors of various types of Si-based electrodes, applying a fundamental understanding of electrochemistry and mechanics and the correlation between them.

25 ENERGY STORAGE↗
DOE OSTI2022

Capacity and Coulombic Efficiency Measurements Underestimate the Rate of SEI Growth in Silicon Anodes

Capacity measurements and related quantities are the first layer of information acquired during testing of Li-ion cells. It is generally considered that elevated values of coulombic efficiency and capacity retention are absolute indicators of the existence of a stable solid electrolyte interphase (SEI). Here, we challenge this notion by analyzing how the effect of side reactions on cell capacity depends on the choice of electrodes. More specifically, we demonstrate that the extent of measurable capacity fade due to SEI growth is modulated by the shape of the voltage profile of the cathode and anode at the end of charge and discharge half-cycles. This shape-dependency creates a mismatch between SEI growth and cell capacity loss, which is relatively small for graphite anodes but sizable for silicon-containing electrodes. We illustrate this point by showing that, at the same coulombic efficiency and capacity retention, cells containing silicon-based materials could actually exhibit rates of SEI growth that are as much as ≥ 40% higher than graphite cells. The main implication of this behavior is that, for certain systems, capacity measurements may be an unreliable source of information about the extent of reactions at the SEI, allowing other consequences of these side reactions (such as electrolyte depletion) to proceed unchecked while the cell appears to be stable.

25 ENERGY STORAGE↗
DOE OSTI2025

Comparative Analysis via CFD Simulation on the Impact of Graphite Anode Morphologies on the Discharge of a Lithium-Ion Battery

The morphology of electrode materials plays a crucial role in determining the performance of lithium-ion batteries. Traditional computational models often simplify graphite flakes as uniformly sized spheres, which limits their predictive accuracy. In this study, we present a computational workflow that overcomes these limitations by incorporating a more realistic representation of graphite morphologies. This workflow is designed to be flexible and reproducible, enabling efficient evaluation of electrochemical performance across diverse material structures. By exploring different graphite morphologies, our approach accelerates the optimization of material preparation techniques and processing conditions. Our findings reveal that incorporating greater morphological complexity leads to significant deviations from classical model predictions. Instead, our refined model offers a more accurate representation of battery discharge behavior, closely aligning with experimental data. This improvement underscores the importance of detailed morphological descriptions in advancing battery design and performance assessments. To promote accessibility and reproducibility, we provide the developed code for seamless integration with the COMSOL API, allowing researchers to implement and adapt it easily. This computational framework serves as a valuable tool for investigating the impact of graphite morphology on battery performance, bridging the gap between theoretical modeling and experimental validation to enhance lithium-ion battery technology.

25 ENERGY STORAGE↗
NASA NTRS1988

Performance of lightweight nickel electrodes

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art (SOA) sintered nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber and felt, nickel plated plastic and graphite) are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C 1.37C, 2.0C and 2.74C. The electrodes that pass the initial tests are life cycle tested in a low Earth orbit regime at 80 percent depth of discharge. Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. One particular lightweight fiber mat electrode has accumulated over 3000 cycles to date, with stable capacity and voltage. Life and performance data of this electrode were investigated and presented. Good dimensional stability and active material adherence have been demonstrated in electrodes made from this lightweight plaque.

Britton, Doris L.↗
NASA NTRS1988

Performance of lightweight nickel electrodes

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) batteries. These electrodes are lighter in weight and have higher energy densities than the heavier state-of-the-art (SOA) sintered nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber and felt, nickel plated plastic and graphite) are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. Evaluation is performed in half cells structured in the bipolar configuration. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C and 2.74C. The electrodes that pass the initial tests are life cycle tested in a low earth orbit regime at 80 percent depth of discharge. Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. One particular lightweight fiber mat electrode has accumulated over 3000 cycles to date, with stable capacity and voltage. Life and performance data of this electrode were investigated and presented. Good dimensional stability and active material adherence have been demonstrated in electrodes made from this lightweight plaque.

Britton, Doris L.↗
DOE OSTI2023

Progresses and Perspectives of All‐Iron Aqueous Redox Flow Batteries

Abstract Redox flow batteries (RFBs) are a promising option for long‐duration energy storage (LDES) due to their stability, scalability, and potential reversibility. However, solid‐state and non‐aqueous flow batteries have low safety and low conductivity, while aqueous systems using vanadium and zinc are expensive and have low power and energy densities, limiting their industrial application. An approach to lower capital cost and improve scalability is to utilize cheap Earth‐abundant metals such as iron (Fe). Nevertheless, all‐iron RFBs have many complications, involving voltage loss from ohmic resistance, side reactions such as hydrogen evolution, oxidation, and most significantly electrode plating, and dendrite growth. To address these issues, researchers have begun to examine the effects of various alterations to all‐iron RFBs, such as adding organic ligands to form Fe complexes and using a slurry electrode instead of common materials such as graphite or platinum rods. Overall, progress in improving aqueous all‐iron RFBs is at its infant stage, and new strategies must be introduced, such as the utilization of nanoparticles, which can limit dendrite growth while increasing storage capacity. This review provides an in‐depth overview of current research and offers perspectives on how to design the next generation of all‐iron aqueous RFBs.

Belongia, Shawn↗
DOE OSTI2025

Elucidating the Origins of High Capacity in Iron-Based Conversion Materials: Benefit of Complementary Advanced Characterization toward Mechanistic Understanding

Lithium-ion batteries are recognized as an important electrochemical energy storage technology due to their superior volumetric and gravimetric energy densities. Graphite is widely used as the negative electrode, and its adoption enabled much of the modern portable electronics technology landscape. However, developing markets, such as electric vehicles and grid-scale storage, have increased demands, including higher energy content and a diverse materials supply chain. Alternatives that provide the opportunity to increase capacity and address supply chain concerns are of interest. Understanding the fundamental mechanisms that govern battery function is crucial to driving further improvements in the field. Advanced characterization techniques, such as those enabled by synchrotron light sources and high-resolution electron microscopes, that can uncover these mechanisms have become a necessity for elucidating structural evolution upon electrochemical conversion at the nano- to mesoscales. Performing these experiments with relevant electrochemistry using in situ and operando experiments imparts the ability to identify critical reaction pathways and capture intermediate (dis)charge products not discernible by traditional experiments.

36 MATERIALS SCIENCE↗