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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Phase Stability of Garnet Solid-Electrolyte Interfacing with Various Cathodes in All Solid-State Batteries

Garnet-structured Li 6.75 La 3 Zr 1.75 Ta 0.25 O 12 (LLZTO) is one of the most promising electrolyte materials for solid-state Li batteries (SS-LiB). The design and fabrication of a good cathode/electrolyte interface is an important criterion for the SS-LiB. In this work, we performed a systematic study on the impact of cathode crystal structure and chemical compositions on their chemical stabilities against the LLZTO at elevated temperatures, which are required for their adhesion during cell fabrication processes. X-ray Diffraction (XRD) and Rietveld refinement analyses revealed the chemical stabilities of various cathode materials in contact with the LLZTO. While layered LiCoO 2 cathode showed good stability in contact with LLZTO to 900 °C, LiNiO 2 or Ni-rich LiNi x Mn y Co 1–x–y O 2 (NMC) cathodes suffered from the formation of La 4 NiLiO 8 due to La-diffusion from LLZTO. Furthermore, Mn-rich LiMn 2 O 4 spinel and layered LiNi 1/3 Mn 1/3 Co 1/3 O 2 cathodes suffered from the formation of La 2 Zr 2 O 7 due to Li-diffusion and production of Li 2 MnO 3 . As a result, LiNi 0.6 Mn 0.2 Co 0.2 O 2 , having an ideal balance of Ni/Mn/Co composition, or Li 2 MnO 3 containing cathodes such as Li 1.2 Ni 0.15 Mn 0.55 Co 0.1 O 2 were found to have excellent phase stability as the cathodes for LLZTO-based SS-LiBs.

25 ENERGY STORAGE↗
DOE OSTI2022

Across-Depth Heterogeneity and Irreversibility of Fast-Charge-Driven Lithium Plating

Enabling fast charging in lithium-ion batteries (LIBs) is a key factor for resolving consumers’ “range anxiety” concerns in choosing an electric vehicle over a gasoline-powered one. The best-known issue in the fast charging of current LIBs (based on LiNi x Mn y Co 1–x–y O 2 /graphite) is lithium plating, which is barely reversible and is accompanied by capacity loss over time. Therefore, understanding the reasons for the irreversibility of lithium plating driven by fast charging is critical to enhancing the fast-charging capability of LIBs. Here, a study of the irreversibility and heterogeneity of lithium plating is carried out by using electrochemical analyses, inductively coupled plasma mass spectroscopy, and X-ray photoelectron spectroscopy. Further, the study shows that the majority of the lithium plated during fast charging remains inactive even with very slow discharging rates, implying that most of the plated lithium is irreversibly lost. The study also reveals that chemical compounds such as LiF, Li 2 O and Li 2 (CO 3 ) are formed heterogeneously within the lithium plating and are responsible for some of the irreversibility of the plated lithium.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Nanosecond Laser Annealing of NMC 811 Cathodes for Enhanced Performance

Improved performance of lithium-ion batteries (LIBs) plays a critical role in the future of next- generation battery applications. Nickel-rich layered oxides such as LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC 811), are popular cathodes due to their high energy densities. However, they suffer from high surface reactivity, which results in the formation of Li 2 CO 3 passive layer. Herein, we show the role of nanosecond pulsed laser annealing (PLA) in improving the current capacity and cycling stability of LIBs by reducing the carbonate layer, in addition to forming a protective LiF layer and manipulating the NMC 811 microstructures. We use high-power nanosecond laser pulses in a controlled way to create nanostructured surface topography which has a positive impact on the capacity retention and current capacity by providing an increased active surface area, which influences the diffusion kinetics of lithium-ions in the electrode materials during the battery cycling process. Advanced characterizations show that the PLA treatment results in the thinning of the passive Li 2 CO 3 layer, which is formed on as-received NMC811 samples, along with the decomposition of excess polyvinylidene fluoride (PVDF) binder. The high-power laser interacts with the decomposed binder and surface Li + to form LiF phase, which acts as a protective layer to prevent surface reactive sites from initiating parasitic reactions. As a result, the laser treated cathodes show relative increase of the current capacity of up to 50%, which is consistent with electrochemical measurements of LiB cells.

25 ENERGY STORAGE↗
DOE OSTI2024

High Throughput Electrochemical Screening of Phosphate-Rich Nonflammable Electrolytes in Lithium-Ion Batteries

Frequent fires and explosions in lithium-ion batteries (LIBs) used in grid energy storage systems (ESS) highlight the necessity of revisiting nonflammable phosphate electrolytes as alternatives to the currently used flammable carbonates. However, previous studies have shown the difficulty of integrating phosphate solvents into LIB electrolytes due to compatibility issues with graphite. In this work, we developed a high-throughput (HTP) electrochemical characterization method, akin to pH test paper, to rapidly screen potential phosphate electrolytes and graphite materials. Through HTP screening, we identified 101 promising combinations out of 1,740. This number was reduced to 26 after testing in Li/Graphite half cells. The optimized phosphate-rich electrolyte (60 v% phosphate) with cosolvents demonstrated 300 stable cycles at 0.1 C in Graphite/LiFePO 4 (LFP) full cells with thick electrodes (∼3.0 mAh cm −2 ), surpassing prior research findings. This unique HTP method provides a powerful tool to expedite the development of safe LIBs for ESS applications.

25 ENERGY STORAGE↗
DOE OSTI2025

Physics-Based Analysis of Cell Imbalances and Aging in Lithium-Ion Battery Modules and Packs

Lithium-ion battery (LIB) packs are a key solution for grid-scale energy storage, enabling grid resilience and supporting critical infrastructure. LIB modules and packs experience current imbalances and uneven cell aging due to various design and operational factors, and require a battery management system (BMS) to continuously monitor and control. In this context, a physics-based modeling framework for LIB modules and packs (liionpack) was enhanced to identify design and control strategies that minimize current imbalance and improve module/pack operation. Simulations of an 8-cell parallel-connected module demonstrate that reducing current imbalance leads to more uniform cell aging and improved module/pack-level degradation predictions. The analysis shows that current imbalance are affected by the electrical resistances. Terminal location significantly affects imbalance, with opposite-end terminal connections at intermediate branches minimizing the imbalance, and the pack circuit construction influences the accuracy of physics-based analysis at the pack scale. This framework enables design optimization of modules and packs through a fast and easy evaluation of pack performance and aging, and supports the development of aging-informed balancing strategies compatible with BMS implementation. Thereby, offering practical pathways to improve reliability and cycle life predictions in large-scale battery energy storage systems.

Ayalasomayajula, Surya Mitra [Oak Ridge National L↗
DOE OSTI2025

Neutron-Friendly Li-Ion Battery Coin Cell for In Situ 3D Visualization of Li Plating

Advanced battery characterization using in situ/operando neutron imaging is critical for uncovering degradation modes such as lithium (Li) plating in Li-ion batteries (LIBs). However, conventional LIBs hinder operando neutron radiography (NR) and in situ neutron micro-computed tomography (N-μCT) for visualizing Li plating near the graphite-separator interface due to strong attenuation from hydrogen-rich components like PP–PE–PP separators, electrolyte, and Fe-based spacers. In this work, we designed and tested a neutron-friendly battery (NFB) optimized for in situ Li detection during extreme fast charging (XFC). Guided by neutron attenuation cross-sections and material transmission, the NFB enables clear visualization at the graphite–separator interface, which is typically opaque in standard LIBs. Electrochemical tests show the NFB exhibits voltage/current responses like standard cells for up to 50 XFC cycles. However, its lower reversibility and capacity are likely due to Cu-coated Al spacer degradation from delamination or corrosion. We propose titanium spacers as a more stable alternative, albeit requiring custom machining. Using this optimized cell, we achieved simultaneous neutron tomography of multiple cells, capturing in situ 3D images of dead Li accumulation, particularly near graphite edges. These heterogeneous deposits and disconnected Li clusters suggest localized current density hotspots during XFC.

25 ENERGY STORAGE↗
DOE OSTI2022

American Made Challenges Battery Voucher Program Cooperative Research and Development Agreement (Cooperative Research and Development Final Report, CRADA Number CRD-21-17533)

Renewance is a Phase II winner of the U.S. Department of Energy Lithium-ion Battery Recycling Prize. The Prize is designed to incentivize American entrepreneurs to develop and demonstrate processes that, when scaled, have the potential to profitably capture 90% of all discarded or spent lithium-based batteries (LIB) in the Unites States for eventual recovery of key materials for re-introductions into the U.S. supply chain. The objective of this work is to enable a more efficient evaluation of battery sources for second life applications prior to ultimately being recycled, through evaluation of chemistry characteristics, projected battery lifetime, and application history. This work will develop the capability to identify groups of batteries that may be useful for second life and reduce the cost of end-of-life (EOL) LIB evaluation and repurposing. To meet the objective, NREL will use existing and new data to create a refined algorithm that could be used to evaluate batches of batteries for potential reuse based on manufacturing date and historical use characteristics. Based on current battery market prices and compiled literature data, a starting-point estimate of the market value of the batteries for reuse based on expected lifetime will be included in the algorithm. With the projected surge in LIB demand, battery second life is a new area ripe for development and investment from companies like Renewance. With so few large format batteries reaching EOL to date, this is a new market with a variety of areas for optimization and adding value. This work with Renewance is an example of how existing expertise in battery degradation at NREL can be used to reduce the cost of shifting a battery into a second life application. With these cost reductions, this work is also facilitating the development of a battery circular economy in the United States. A robust circular economy can maximize the utilization of critical metals demanded by battery technology such as nickel and cobalt while also reducing the costs of batteries in the marketplace for the many end-uses needed for the green energy transition. The supply of these metals is limited, and we face a supply chain shortage both domestically and globally unless we can ensure they are being used to their maximum potential. This research can improve the economics of a battery circular economy to make it a more likely path for EOL batteries with critical metals. CRADA benefit to DOE, Participant, and US Taxpayer: assists laboratory in achieving programmatic scope competencies, uses the laboratory's core competencies.

25 ENERGY STORAGE↗
DOE OSTI2022

High Energy Aqueous Lithium-Ion Batteries (Final Report)

Lithium-ion batteries (LIBs) are a widely used energy storage device. For decades, researchers have been studying aqueous electrolytes due to their non-flammability and environmental friendless. However, the hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) of water greatly limit the voltage window of the aqueous electrolyte. The recent concept of ‘solvent-in-salt’ electrolytes, namely ‘water-in-salt’ electrolytes (WISE) for aqueous batteries and ‘super-concentrated’ electrolytes for non-aqueous batteries, greatly expands the electrochemical window of these battery systems and consequently their energy density. This expansion occurs because the large number of salt aggregates in ‘solvent-in-salt’ electrolytes enables preferential salt decomposition over solvent decomposition to form robust interphase layers on electrodes, thus enhancing their stability in a wide range of operating voltages. However, even when the salt concentration reached 63m, regardless of cost, the cathodic potential of the WISE expanded only to 1.75V with an overall electrochemical stability window of <3.25V. To design the next generation of high energy aqueous LIBs, electrolytes that possess a wider electrochemical stability window and lower cost but still maintain the merit of non-flammability are much needed. In this project, we designed the aqueous LIBs with widened voltage window. We reported a cheap and non-flammable ternary eutectic electrolyte that can form a robust solid electrolyte interface (SEI)so that the cathodic limiting potential can be decreased to <1.5 V for Li 4 Ti 5 O 12 anodes, while maintaining both a high ionic conductivity of >10 -3 S cm –1 and a low viscosity. We demonstrated the super-stable2.5V LiMn 2 O 4 ||Li 4 Ti 5 O 12 pouch cell with mass loading of 2.5 mAh/cm. Further, LiCl-LiBr-Graphite/Li full cells were designed with high energy density. Finally, we use a bi-layer design to enlarge the voltage window of aqueous electrolyte, which can endow the stable cycling of aqueous Lithium metal batteries.

25 ENERGY STORAGE↗
DOE OSTI2023

Establishing Isotopic Measurement Capabilities using Laser-Induced Breakdown Spectroscopy for the Molten Salt Reactor Campaign

Proof-of-principle H isotope ratios of aqueous aerosol systems and liquid droplets on filter paper have been measured using laser-induced breakdown spectroscopy (LIBS) with root mean square error of prediction values down to 1.9%. Molten salt reactors (MSRs) will consist of a complex chemical and radiological system consistently producing new fission products as the reactor operates. Some of these fission products and/or their daughter species will leave the salt in the reactor off-gas. Monitoring the composition of the off-gas, as well as the salt itself, is important for monitoring reactor performance, including burnup, corrosion, and the concentration of impurities. Tritium is of concern for MSRs because it will be produced from the irradiation of key salt constituents, including Li and Be. LIBS offers an avenue for in situ salt and off-gas monitoring by firing a laser onto or into the sample stream to generate a plasma. The plasma light can be monitored to measure an elemental fingerprint of the sample. Extending this analysis to include isotopic ratios offers a critical expansion of the in situ monitoring capabilities being developed. This study demonstrates the expansion of Oak Ridge National Laboratory’s LIBS capabilities to monitor isotopes and shows how simple calibrations may provide rapid semiquantitative models.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2024

A Review on Solid State Batteries: Life Cycle Perspectives

This report briefly reviews the characteristics of solid-state batteries (SSBs) and the life-cycle analysis (LCA) studies that have been completed for SSBs. Compared with conventional lithium-ion batteries (LIBs), SSBs offer improved safety and potentially higher energy density — both enabled by replacing liquid electrolytes with solid electrolytes and using lithium metal anodes. Several challenges impede the commercialization of SSBs, primarily related to the stability of the interface between the solid electrolyte and the electrodes. Several options are under consideration for SSB electrolyte and cathode chemistries. As a result, the production processes for these components and the corresponding battery packs are still under development and can differ significantly from those used for conventional LIB pack production. A robust comparison of SSBs with LIBs through LCA is important to analyze the environmental benefits and challenges associated with this alternative battery system. While the literature provides only a few LCA studies focused on SSBs, with significant uncertainty in their life-cycle inventories (LCIs), those studies collectively suggest that solid electrolyte manufacturing is the major environmental hotspot, followed by cathode and anode production.

25 ENERGY STORAGE↗
DOE OSTI2025

ElementLIBS User's Guide: An operational aid for use and development

Laser-Induced Breakdown Spectroscopy or LIBS is a rapid, in-situ analytical technique where a laser of known energy is pulsed at the surface of an analyte. The laser pulse rapidly heats a localized area to many thousand degrees Kelvin, ablating part of the analyte and turning it into a plasma. As the plasma cools, excited atoms return to a ground state with known emission energies. This emitted energy is captured by various spectrometers and provides a spectrum of the emitted energies and intensities. This spectrum can be analyzed to provide the elemental composition of a sample by using known emission lines and relative abundance. ElementLIBS was developed for the SciAps hand-held LIBS model Z300 but will work with any model that provides a LIBS spectrum of similar resolution. The Z300 has an integrated resolution of 1/30 nm with a range of approximately 180nm – 960nm, providing an output spectrum of 23431 pixels across three spectrometers. These criteria are only provided as a reference, as the software was designed to work with any size spectrum, provided the input file is of the correct format and the models were developed using the same framework. If spectra of varying dimensions are used, the software will fail without warning and unusual events could occur.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Recycling of Lithium-Ion Batteries via Electrochemical Recovery: A Mini-Review

With the rising demand for lithium-ion batteries (LIBs), it is crucial to develop recycling methods that minimize environmental impacts and ensure resource sustainability. The focus of this short review is on the electrochemical techniques used in LIB recycling, particularly electrochemical leaching and electrodeposition. Our summary covers the latest research, highlighting the principles, progress, and challenges tied to these methods. By examining the current state of electrochemical recovery, this review intends to provide guidance for future advancements and enhance LIB recycling efficiency.

25 ENERGY STORAGE↗
DOE OSTI2024

North America’s Potential for an Environmentally Sustainable Nickel, Manganese, and Cobalt Battery Value Chain

The Detroit Big Three General Motors (GMs), Ford, and Stellantis predict that electric vehicle (EV) sales will comprise 40–50% of the annual vehicle sales by 2030. Among the key components of LIBs, the LiNixMnyCo1−x−yO2 cathode, which comprises nickel, manganese, and cobalt (NMC) in various stoichiometric ratios, is widely used in EV batteries. This review reveals NMC cathodes from laboratory research. Furthermore, this study examines the environmental effect of NMC cathode production for EV batteries (including coating technologies), encompassing aspects such as energy consumption, water usage, and air emissions. Although gaps persist in NMC cathode environmental assessments (NMC111, NMC532, NMC622, and NMC811), limited life cycle assessments “(LCA)” have been conducted. Most available data originate from Asia (primarily China), accounting for 85% of the production of EV LIB cathode materials. The concept of battery passports for data collection on LIB components has been proposed to facilitate material traceability as a system for ensuring a sustainable supply chain for critical minerals. The automotive industry’s shift to electrification necessitates a sustainable supply chain from mine to vehicle end-of-life. As the critical mineral supply moves from Asia to North America, environmentally friendly industrial methods must be studied to provide this supply chain direction.

25 ENERGY STORAGE↗
DOE OSTI2026

Quantitative Analysis of Fission-Product Surrogates in Molten Salt Chloride Aerosols

This work demonstrates laser-induced breakdown spectroscopy (LIBS) applied to a stream of aerosolized salt from molten eutectic LiCl-KCl. We demonstrate analytical capabilities to track fission-product surrogates of Cs, Sr, Pr, and Nd simultaneously, with application to monitor salts in pyroprocessing schemes and molten salt reactors. This work demonstrates limits of detection using LIBS on the order of 100 μg/g, which proves potentially applicable to monitoring fission-product concentrations in pyroprocessing applications. Additionally, this work explores fundamental aspects of plasma temperature and plasma electron density of the aerosolized species during LIBS with a specific focus on potential non-uniform plasma conditions in the aerosol.

74 - ATOMIC AND MOLECULAR PHYSICS↗
NASA NTRS2004

New Lithium-ion Polymer Battery for the Extravehicular Mobility Unit Suit

The Extravehicular Mobility Unit (EMU) suit currently has a silver-zinc battery that is 20.5 V and 45 Ah capacity. The EMU's portable life support system (PLSS) will draw power from the battery during the entire period of an EVA. Due to the disadvantages of using the silver-zinc battery in terms of cost and performance, a new high energy density battery is being developed for future use, The new battery (Lithium-ion battery or LIB) will consist of Li-ion polymer cells that will provide power to the EMU suit. The battery design consists of five 8 Ah cells in parallel to form a single module of 40 Ah and five such modules will be placed in series to give a 20.5 V, 40 Ah battery. Charging will be accomplished on the Shuttle or Station using the new LIB charger or the existing ALPS (Air Lock Power Supply) charger. The LIB delivers a maximum of 3.8 A on the average, for seven continuous hours, at voltages ranging from 20.5 V to 16.0 V and it should be capable of supporting transient pulses during start up and once every hour to support PLSS fan and pump operation. Figure 1 shows the placement of the battery in the backpack area of the EMU suit. The battery and cells will undergo testing under different conditions to understand its performance and safety characteristics.

Jeevarajan, J. A.↗
NASA NTRS2010

Multivariate Methods for Prediction of Geologic Sample Composition with Laser-Induced Breakdown Spectroscopy

Laser-induced breakdown spectroscopy (LIBS) uses pulses of laser light to ablate a material from the surface of a sample and produce an expanding plasma. The optical emission from the plasma produces a spectrum which can be used to classify target materials and estimate their composition. The ChemCam instrument on the Mars Science Laboratory (MSL) mission will use LIBS to rapidly analyze targets remotely, allowing more resource- and time-intensive in-situ analyses to be reserved for targets of particular interest. ChemCam will also be used to analyze samples that are not reachable by the rover's in-situ instruments. Due to these tactical and scientific roles, it is important that ChemCam-derived sample compositions are as accurate as possible. We have compared the results of partial least squares (PLS), multilayer perceptron (MLP) artificial neural networks (ANNs), and cascade correlation (CC) ANNs to determine which technique yields better estimates of quantitative element abundances in rock and mineral samples. The number of hidden nodes in the MLP ANNs was optimized using a genetic algorithm. The influence of two data preprocessing techniques were also investigated: genetic algorithm feature selection and averaging the spectra for each training sample prior to training the PLS and ANN algorithms. We used a ChemCam-like laboratory stand-off LIBS system to collect spectra of 30 pressed powder geostandards and a diverse suite of 196 geologic slab samples of known bulk composition. We tested the performance of PLS and ANNs on a subset of these samples, choosing to focus on silicate rocks and minerals with a loss on ignition of less than 2 percent. This resulted in a set of 22 pressed powder geostandards and 80 geologic samples. Four of the geostandards were used as a validation set and 18 were used as the training set for the algorithms. We found that PLS typically resulted in the lowest average absolute error in its predictions, but that the optimized MLP ANN and the CC ANN often gave results comparable to PLS. Averaging the spectra for each training sample and/or using feature selection to choose a small subset of wavelengths to use for predictions gave mixed results, with degraded performance in some cases and similar or slightly improved performance in other cases. However, training time was significantly reduced for both PLS and ANN methods by implementing feature selection, making this a potentially appealing method for initial, rapid-turn-around analyses necessary for Chemcam's tactical role on MSL. Choice of training samples has a strong influence on the accuracy of predictions. We are currently investigating the use of clustering algorithms (e.g. k-means, neural gas, etc.) to identify training sets that are spectrally similar to the unknown samples that are being predicted, and therefore result in improved predictions

Morris, Richard↗
NASA NTRS2011

A Comparison of Multivariate and Pre-Processing Methods for Quantitative Laser-Induced Breakdown Spectroscopy of Geologic Samples

The ChemCam instrument selected for the Curiosity rover is capable of remote laser-induced breakdown spectroscopy (LIBS).[1] We used a remote LIBS instrument similar to ChemCam to analyze 197 geologic slab samples and 32 pressed-powder geostandards. The slab samples are well-characterized and have been used to validate the calibration of previous instruments on Mars missions, including CRISM [2], OMEGA [3], the MER Pancam [4], Mini-TES [5], and Moessbauer [6] instruments and the Phoenix SSI [7]. The resulting dataset was used to compare multivariate methods for quantitative LIBS and to determine the effect of grain size on calculations. Three multivariate methods - partial least squares (PLS), multilayer perceptron artificial neural networks (MLP ANNs) and cascade correlation (CC) ANNs - were used to generate models and extract the quantitative composition of unknown samples. PLS can be used to predict one element (PLS1) or multiple elements (PLS2) at a time, as can the neural network methods. Although MLP and CC ANNs were successful in some cases, PLS generally produced the most accurate and precise results.

Anderson, R. B.↗
NASA NTRS2014

Volume Measurements of Laser-generated Pits for In Situ Geochronology using KArLE (Potassium-Argon Laser Experiment)

The Potassium-Argon Laser Experiment( KArLE), is composed of two main instruments: a spectrometer as part of the Laser-Induced Breakdown Spectroscopy (LIBS) method and a Mass Spectrometer (MS). The LIBS laser ablates a sample and creates a plasma cloud, generating a pit in the sample. The LIBS plasma is measured for K abundance in weight percent and the released gas is measured using the MS, which calculates Ar abundance in mols. To relate the K and Ar measurements, total mass of the ablated sample is needed but can be difficult to directly measure. Instead, density and volume are used to calculate mass, where density is calculated based on the elemental composition of the rock (from the emission spectrum) and volume is determined by pit morphology. This study aims to reduce the uncertainty for KArLE by analyzing pit volume relationships in several analog materials and comparing methods of pit volume measurements and their associated uncertainties.

French, R. A.↗