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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Hybrid Doping Strategy with High‐Entropy Cu/Fe Surface Modification and Zr Bulk Incorporation for Ni‐Rich Cathodes

A hybrid doping strategy combining Zr 4+ bulk doping with high-entropy Cu 2+ /Fe 3+ surface doping is developed to enhance the structural and interfacial stability of Ni-rich layered oxide cathodes. Cu and Fe are selectively introduced at the particle surface via a surface-selective ion-exchange process, forming a ≈15 nm Fe-rich layer while preserving the layered framework. Compared to the pristine cathode, the hybrid sample exhibits significantly improved electrochemical performance in both half-cell and full-cell configurations. In half-cells, the hybrid retains 88.5% and 90.2% after 100 cycles at 1C under 4.6 and 4.5 V, respectively. During high-voltage full-cell cycling, the hybrid cathode maintains over 80% capacity retention, whereas the pristine counterpart retains less than 10% under identical conditions over the same cycling period. XPS, EELS, and DEMS analyses confirm improved oxygen retention, suppressed gas evolution, and stable surface chemistry, while DFT calculations indicate enhanced Me–O bonding in the selected Fe 0.75 Cu 0.25 (Mn 1/16 Co 2/16 Ni 13/16 )O 2 surface composition, which is identified through DFT-calculated mixing energy reaching a minimum at this ratio, indicating the most thermodynamically favorable configuration. In conclusion, these results demonstrate the effectiveness of this hybrid doping strategy in mitigating coupled degradation pathways in Ni-rich cathodes.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Chromium Tolerant, Highly Active and Stable Electrocatalytic Internal Surface Coating for Cathode of Commercial SOFCs (Final Report)

This project is aimed to develop a chromium (Cr) tolerant, highly active, and stable coating layer on the internal surfaces of the porous composite cathode from commercially available SOFCs. Such coating layer was developed using the additive manufacturing process of Atomic Layer Deposition (ALD) and has been applied on the cathode consisting of either an electronic conductor of LaxSr 1-x MnyO 3-δ (LSM) or mixed ionic and electronic conducting La x Sr 1-x Co y Fe 1-y O 3-δ (LSCF). PI's work has demonstrated that the internal surface of cathode from the commercial cells, can be further tailored using ALD coating to dramatically enhance the cell performance. For instance, ALD layer consisting heterostructured nano composite of nano-Pt and nano-(Mn 0.8 Co 0.2 ) 3 O 4 oxide on the internal surface of porous LSM/YSZ cathode from SOFCs, has resulted in the large reduction of the cell polarizations resistance by up to 53%, and enormous increase of power density over 370%. For the cells with LSCF/Sm 2 O 3 doped CeO 2 (SDC) cathode, the conformal layer of nano-composite consisting of superjacent CoOx and subjacent minimum amount of Pt nano-grains has resulted in the power density enhancement by 126% for the large scale industry tubular cells at 750°C, and both the performance enhancement and nanostructure of the ALD layer are stable over ~ 2000 h continuous operation performed at industry test station. In the meanwhile, those ALD coating layer developed by PI's work is also inherently Cr-tolerant, and could act as physical barrier for preventing Cr diffusion into the cathode backbone, so as to mitigate the Cr poisoning effect on the cathode. In this project, the impact of Cr on the performance of those ALD coated commercial cells has been evaluated. Based on evolution of the cell performance, the ALD coating layer chemistry and ALD coating layer thickness has been optimized to maximize the overall Cr tolerance, cell power density and cell longevity. Different ALD coating has been applied onto the internal surface of LSM/YSZ and LSCF/SDC backbone respectively. The architecture/scaffold structures on the internal surface of different cathode, designed by this project, was catalogued and analyzed using High Resolution Transmission Electron Microscopy (HRTEM), and cell power/durability performance are assured via comprehensive electrochemical performance testing in the industry operation relevant conditions. The impact of the electrochemical operation current density, the water humidity, the cell operation temperature, and cell operation duration on the Cr tolerance of ALD coated cells has been systematically investigated. There is completely different nanostructure degradation mechanisms between LSM and LSCF cells induced by Cr contamination. For the LSCF/SDC baseline cell, With the Cr source, there is no apparent Sr surface segregation phase even for the baseline cell operated for 3000 h at 750 °C. With the Cr source, there is significant amorphous (SrCr)Ox phase accumulated in the original pore region. For the commercial baseline cells, Cr contaminants on the LSM electrode severely impacted the entire cell's electrochemical performance and nanostructure degradation. Those degradations include (1). Peak power density loss of 64 % after 109 h of operation. The dramatic increase in Rp (2). They are cracking at LSM/SSZ interface, LSM grains. SSZ remains intact but with (CrMn)Ox. By contrast, ALD coating (MnCo)Ox/Pt dramatically improves the Cr resistance, as follows (1). ALD-coated cell with a power density is 280-380 % of the baseline cell, depending on the ALD layer thickness. (2). For a cell with a 20 nm thick ALD layer, there is a large performance enhancement (> 200 % power density) induced by ALD coating of Cr-tolerant Mn 0.8 Co 0.2 Ox. (3). For a cell with a 20 nm thick ALD layer, after 168 h at 750 °C power density of the ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination for 109 h. The ALD coating on the internal surface of cathode developed by this project integrated multi-functions. Those multi-functions include (1). Dramatically improving the cell power density for the commercial cells; (2). Dramatically improving contamination resistance of the cathode, for being an excellent protection coating layer sealing off Cr contamination. (3). Dramatically increasing the cell longevity by potentially preventing the microstructure evolution and grain coarsening of the cathode. Overall, this project will provide a simple solution to simultaneously enhance power density and increase the reliability, robustness, and endurance of commercial SOFCs, over the entire operating temperature range of 650-800 °C. For the inherently functional SOFC, the ALD coating of LSM based cathode mitigate the Cr-contamination. Power density of ALD-coated cell is ~ 600% of that baseline cell upon operation with Cr contamination. In addition to SOFCs, the novel on-demand design approach and creation of multifunctional heterogeneous architecture on the electrode surface presented in this work opens further research for their application in other types of fuel cells, batteries, and sensors for which electrochemical reactions on the surface are similarly critical.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal-healing of lattice defects for high-energy single-crystalline battery cathodes

Abstract Single-crystalline nickel-rich cathodes are a rising candidate with great potential for high-energy lithium-ion batteries due to their superior structural and chemical robustness in comparison with polycrystalline counterparts. Within the single-crystalline cathode materials, the lattice strain and defects have significant impacts on the intercalation chemistry and, therefore, play a key role in determining the macroscopic electrochemical performance. Guided by our predictive theoretical model, we have systematically evaluated the effectiveness of regaining lost capacity by modulating the lattice deformation via an energy-efficient thermal treatment at different chemical states. We demonstrate that the lattice structure recoverability is highly dependent on both the cathode composition and the state of charge, providing clues to relieving the fatigued cathode crystal for sustainable lithium-ion batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Hierarchical nickel valence gradient stabilizes high-nickel content layered cathode materials

High-nickel content cathode materials offer high energy density. However, the structural and surface instability may cause poor capacity retention and thermal stability of them. To circumvent this problem, nickel concentration-gradient materials have been developed to enhance high-nickel content cathode materials’ thermal and cycling stability. Even though promising, the fundamental mechanism of the nickel concentration gradient’s stabilization effect remains elusive because it is inseparable from nickel’s valence gradient effect. To isolate nickel’s valence gradient effect and understand its fundamental stabilization mechanism, we design and synthesize a LiNi 0.8 Mn 0.1 Co 0.1 O 2 material that is compositionally uniform and has a hierarchical valence gradient. The nickel valence gradient material shows superior cycling and thermal stability than the conventional one. The result suggests creating an oxidation state gradient that hides the more capacitive but less stable Ni 3+ away from the secondary particle surfaces is a viable principle towards the optimization of high-nickel content cathode materials.

25 ENERGY STORAGE↗
DOE OSTI2022

Polyanionic insertion hosts for aqueous rechargeable batteries

Safety concerns and costs of present-day lithium-ion batteries (LIBs) are prompting the development of alternate battery technologies with different types of electrolyte ( e.g. , solid-state, gel-polymer, aqueous, etc. ); notably, systems based on aqueous electrolytes have emerged as a promising alternative, especially for grid storage applications. The last decade has witnessed a considerable spike in the research carried out on aqueous batteries. However, the narrow operating voltage window of aqueous electrolytes and the structural instability of materials in aqueous media demand proper selection of cathode materials to achieve desirable energy density. Polyanionic materials can be an ideal choice as they are structurally more stable and exhibit tunable redox potentials. This class of materials is considered as a storehouse in which many materials can be realized by substituting different polyanionic subunits. Here, this review highlights some of the recent advances made in the polyanionic class of cathode materials for rechargeable aqueous batteries (Li-, Na- and Zn-ion batteries). The challenges facing the field, possible remedies to overcome them and future perspectives are also presented.

25 ENERGY STORAGE↗
DOE OSTI2024

Integrated rocksalt–polyanion cathodes with excess lithium and stabilized cycling

Co- and Ni-free disordered rocksalt cathodes utilize oxygen redox to increase the energy density of lithium-ion batteries, but it is challenging to achieve good cycle life at high voltages >4.5 V (versus Li/Li + ). Here, in this study, we report a family of Li-excess Mn-rich cathodes that integrates rocksalt- and polyanion-type structures. Following design rules for cation filling and ordering, we demonstrate the bulk incorporation of polyanion groups into the rocksalt lattice. This integration bridges the two primary families of lithium-ion battery cathodes—layered/spinel and phosphate oxides—dramatically enhancing the cycling stability of disordered rocksalt cathodes with 4.8 V upper cut-off voltage. The cathode exhibits high gravimetric energy densities above 1,100 Wh kg -1 and >70% retention over 100 cycles. This study opens up a broad compositional space for developing battery cathodes using earth-abundant elements such as Mn and Fe.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Screening and Development of Sacrificial Cathode Additives for Lithium‐Ion Batteries

Abstract This work presents a computational screening approach to identify Li‐rich transition‐metal oxide sacrificial cathode additives and provides experimental validation of antifluorite‐structured Li 6 MnO 4 as a potential candidate. Initial attempts to synthesize this compound result in low purity (≤40% by weight) owing to close thermodynamic competition with Li 2 O and MnO at low temperature. However, it is shown that a much higher purity of 85% by weight can be achieved by combining Li excess with rapid cooling from high temperature, which effectively stabilizes the Li 6 MnO 4 phase. The synthesized product delivers a high irreversible Li release capacity that exceeds 700 mAh g −1 by utilizing combined Mn oxidation (Mn 2+/3+ and Mn 3+/4+ ) and O oxidation. These results demonstrate that Li 6 MnO 4 may therefore be useful as a potential sacrificial cathode additive in Li‐ion batteries and motivate further investigation of other structurally‐related compounds. While attempts were made to synthesize two additional compounds among computationally screened candidates, it was not successful to experimentally realize the two candidates. The difficulty of experimental realization of the newly predicted materials remains a challenge and it is suggested that more efforts need to be devoted to developing computational techniques to precisely predict synthesizability and propose potential synthetic routes of the predicted materials.

Kim, Haegyeom↗
DOE OSTI2025

Etching-assisted upcycling of Ni-lean to Ni-rich cathode materials

Upcycling is recognized as a sustainable recycling approach for spent lithium-ion batteries. However, existing upcycling methods typically involve intricate pretreatment or post-treatment steps, complicating their practical application. Here, in this study, we propose a straightforward, etching-assisted upcycling method that effectively transforms polycrystalline Ni-lean cathodes into high-performance single crystal Ni-rich cathodes. During the etching step, nickel acetate was dissolved into acetic acid and then polycrystalline NMC111 are etched in the solution. Finally, polycrystalline NMC111 are converted into single crystal particles coated with amorphous nickel acetate. This significantly enhances elemental diffusion during subsequent sintering by minimizing both particle size and the contact distance between NMC111 and nickel acetate. As elemental diffusion is improved and acetate ions decompose completely during sintering, the process requires neither additional pretreatment nor post-treatment. The resulting cathode materials (Etched-UP622) exhibit superior structural and electrochemical properties compared to the Control622, achieving an energy density of 719.7 Wh/kg, approximately 56.7 mAh/g higher than Control622 and 125.5 Wh/kg higher than NMC111. Etched-UP622 also delivers higher discharge capacity, improved rate performance and cycling stability, surpassing Control622 and NMC111. Meanwhile, NMC811 also can be synthesized by the proposed strategy, and the discharge capacity can reach 166.9 mAh/g at 1C, similar to 14 mAh/g higher than Control811. Overall, this etching-assisted strategy simplifies the upcycling process and offers a scalable, sustainable route for producing high-quality cathode materials.

Acid etching↗
DOE OSTI2020

Synthesis of LiNiO 2 at Moderate Oxygen Pressure and Long-Term Cyclability in Lithium-Ion Full Cells

The widespread adoption of electric vehicles necessitates higher-energy-density and longer-life cathode materials for Li-ion batteries. LiNiO 2 offers a higher energy density at a lower cost than other high-Ni-content cathodes containing additional transition-metal ions. However, detrimental phase transformations and impedance growth, resulting from structural defects formed during synthesis, lead to poor cyclability and limit the practical viability of LiNiO 2 . Herein, we demonstrate a considerably improved cycle life for LiNiO 2 by synthesizing it under a pressurized oxygen environment. The capacity retention in pouch-type full cells with a graphite anode after 1000 cycles is increased from 59 to 76% by applying a mere 1.7 atm of oxygen pressure during the synthesis of LiNiO 2 . With iodometric titration and inductively coupled plasma optical emission spectroscopy analysis, we provide clear evidence that oxygen pressure during synthesis reduces the occurrence of lattice oxygen vacancies and increases the content of Ni 3+ in LiNiO 2 , improving its structural integrity and cyclability. Post-mortem analysis of the cycled cathodes provides insights into the sources of degradation occurring during long-term cycling. Here, this work demonstrates a practically viable, synthetic approach combined with doping and coating to achieve improved performance with high-Ni layered oxide materials. Furthermore, this work represents the first report of extended cycling of LiNiO 2 in pouch full cells with graphite anode and will, therefore, serves as an important benchmark for future research on LiNiO 2 .

25 ENERGY STORAGE↗
DOE OSTI2022

Investigation of Ca Insertion into α-MoO 3 Nanoparticles for High Capacity Ca-Ion Cathodes

Calcium-ion batteries (CIBs) are a promising alternative to lithium-ion batteries (LIBs) due to the low redox potential of calcium metal and high abundance of calcium compounds. Due to its layered structure, α-MoO 3 is regarded as a promising cathode host lattice. While studies have reported that α-MoO 3 can reversibly intercalate Ca ions, limited electrochemical activity has been noted, and its reaction mechanism remains unclear. Here, we re-examine Ca insertion into α-MoO 3 nanoparticles with a goal to improve reaction kinetics and clarify the storage mechanism. The α-MoO 3 electrodes demonstrated a specific capacity of 165 mA h g –1 centered near 2.7 V vs Ca 2+ /Ca, stable long-term cycling, and good rate performance at room temperature. Furthermore, this work demonstrates that, under the correct conditions, layered oxides can be a promising host material for CIBs and renews prospects for CIBs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Insights into Layered Oxide Cathodes for Rechargeable Batteries

Layered intercalation compounds are the dominant cathode materials for rechargeable Li-ion batteries. In this article we summarize in a pedagogical way our work in understanding how the structure’s topology, electronic structure, and chemistry interact to determine its electrochemical performance. We discuss how alkali–alkali interactions within the Li layer influence the voltage profile, the role of the transition metal electronic structure in dictating O3-structural stability, and the mechanism for alkali diffusion. We then briefly delve into emerging, next-generation Li-ion cathodes that move beyond layered intercalation hosts by discussing disordered rocksalt Li-excess structures, a class of materials which may be essential in circumventing impending resource limitations in our era of clean energy technology.

25 ENERGY STORAGE↗
DOE OSTI2023

Porous bipolar polymers as organic cathodes for sustainable sodium/potassium-ion batteries

Redox-active porous polymers are becoming promising organic electrode materials for alkali-ion batteries because of their tunable pore size, flexible chemical structure, and high thermal stability. This work presents various porous bipolar polymers as cathodes in Na-ion batteries (NIBs) and K-ion batteries (KIBs). Two structural units containing carbonyl and amine active centers, respectively, were introduced into the repeating units of the polymers by the polycondensation of N,N,N',N'-tetrakis(4-aminophenyl)-1,4-phenylenediamine (TAP) and various dianhydrides. Here, the resulting bipolar polymers undergo multi-electron redox reactions involving both cations and anions during battery charge and discharge. The impacts of extended conjugation structures and porosity on the electrochemical performances were investigated by tuning the conjugation structures in the dianhydride monomers. The bipolar polymers with extended conjugation structures and small pore size exhibit superior electrochemical performance in NIBs and KIBs in terms of high redox potentials, long cycle life, and fast-charging capability, demonstrating great promise as organic cathode materials for alkali-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Microstrain screening towards defect-less layered transition metal oxide cathodes

Microstrain and the associated surface-to-bulk propagation of structural defects are known to be major roadblocks to developing high-energy and long-life batteries. However, the origin and effects of microstrain during the synthesis of battery materials remain largely unknown. Here, in this study, we perform microstrain screening during real-time and realistic synthesis of sodium layered oxide cathodes. Evidence gathered from multiscale in situ synchrotron X-ray diffraction and microscopy characterization collectively reveals that the spatial distribution of transition metals within individual precursor particles strongly governs the nanoscale phase transformation, local charge heterogeneity and accumulation of microstrain during synthesis. This unexpected dominance of transition metals results in a counterintuitive outward propagation of defect nucleation and growth. These insights direct a more rational synthesis route to reduce the microstrain and crystallographic defects within the bulk lattice, leading to significantly improved structural stability. The present work on microstrain screening represents a critical step towards synthesis-by-design of defect-less battery materials.

25 ENERGY STORAGE↗
DOE OSTI2021

Direct Cathode Recycling of End-Of-Life Li-Ion Batteries Enabled by Redox Mediation

The ongoing surge of electric vehicle (EV) adoption forecasts an unprecedented amount of lithium-ion battery wastes in the near future. Since cathode materials have the highest economic and engineering values, it is essential to recycle and reuse the end-of-life (EOL) cathode materials. Here, we show that redox mediators can deliver lithium ions and electrons from a lithium source to the cathode, efficiently relithiate the EOL cathode materials, and make them ready for new battery production after a postheat treatment. We have found that some quinone-based redox mediators, especially 3,5-di-tert-butyl-o-benzoquinone (DTBQ), can shuttle the charges very fast between Li metal and EOL cathode. Reduction of DTBQ on lithium is evidenced by chemical changes of Li metal and DTBQ, and successful relithiation of the EOL cathode by the subsequent oxidation of DTBQ is verified by electrochemical and structural evaluations.

battery recycling↗
DOE OSTI2021

In situ inorganic conductive network formation in high-voltage single-crystal Ni-rich cathodes

High nickel content in LiNi x Co y Mn z O 2 (NCM, x ≥ 0.8, x + y + z = 1) layered cathode material allows high specific energy density in lithium-ion batteries (LIBs). However, Ni-rich NCM cathodes suffer from performance degradation, mechanical and structural instability upon prolonged cell cycling. Although the use of single-crystal Ni-rich NCM can mitigate these drawbacks, the ion-diffusion in large single-crystal particles hamper its rate capability. Herein, we report a strategy to construct an in situ Li 1.4 Y 0.4 Ti 1.6 (PO 4 ) 3 (LYTP) ion/electron conductive network which interconnects single-crystal LiNi 0.88 Co 0.09 Mn 0.03 O 2 (SC-NCM88) particles. The LYTP network facilitates the lithium-ion transport between SC-NCM88 particles, mitigates mechanical instability and prevents detrimental crystalline phase transformation. When used in combination with a Li metal anode, the LYTP-containing SC-NCM88-based cathode enables a coin cell capacity of 130 mAh g -1 after 500 cycles at 5 C rate in the 2.75-4.4 V range at 25 °C. Tests in Li-ion pouch cell configuration (i.e., graphite used as negative electrode active material) demonstrate capacity retention of 85% after 1000 cycles at 0.5 C in the 2.75-4.4 V range at 25 °C for the LYTP-containing SC-NCM88-based positive electrode.

25 ENERGY STORAGE↗
DOE OSTI2021

Conditioning the Surface and Bulk of High-Nickel Cathodes with a Nb Coating: An In Situ X-ray Study

Surface coating is commonly employed by industries to improve the cycling and thermal stability of high-nickel (Ni) transition metal (TM) layered cathodes for their practical use in lithium-ion batteries. Niobium (Nb) coating or substitution has been shown to be effective in stabilizing LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathodes; in addition, the electrochemical performance of the final products varies depending on the postprocessing. In this follow-up study, we use in situ synchrotron X-ray diffraction to investigate the kinetic processes and the involved structural evolution in Nb-coated NMC811 upon heat treatment. Furthermore, quantitative structure analysis reveals thermally driven concurrent changes in the bulk and surface, in particular, the phase evolution of the coating layer and Nb/TM interdiffusion that facilitates penetration of Nb into the bulk and particle growth at the increased temperatures. Findings from this study highlight the new opportunities for the intended control of the structure and surface properties of high-Ni cathodes through surface coating in conjunction with postprocessing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High Nickel and No Cobalt - The Pursuit of Next-Generation Layered Oxide Cathodes

The prosperity of the electric vehicle industry is driving the research and development of lithium-ion batteries. As one of the core components in the entire battery system, cathode materials are currently facing major challenges in pushing higher capacity up to their theoretical limits and transitioning away from the unaffordable metals. To meet these requirements, the search for next-generation cathode materials has shifted to high-nickel and cobalt-free cathodes. In this review, we distinctly pointed out the shortcomings of cobalt in stabilizing layered structures, and systematically summarized the recent efforts to eliminate cobalt and achieve higher nickel content in layered cathode materials. Lastly, a reasonable prospect is put forward for further development of layered cathode materials and other promising candidates, which is likely to spur a wave of efforts toward developing high-performance and low-cost Li-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2021

Rational design of mechanically robust Ni-rich cathode materials via concentration gradient strategy

Mechanical integrity issues such as particle cracking are considered one of the leading causes of structural deterioration and limited long-term cycle stability for Ni-rich cathode materials of Li-ion batteries. Indeed, the detrimental effects generated from the crack formation are not yet entirely addressed. Here, applying physicochemical and electrochemical ex situ and in situ characterizations, the effect of Co and Mn on the mechanical properties of the Ni-rich material are thoroughly investigated. As a result, we successfully mitigate the particle cracking issue in Ni-rich cathodes via rational concentration gradient design without sacrificing the electrode capacity. Our result reveals that the Co-enriched surface design in Ni-rich particles benefits from its low stiffness, which can effectively suppress the formation of particle cracking. Meanwhile, the Mn-enriched core limits internal expansion and improve structural integrity. The concentration gradient design also promotes morphological stability and cycling performances in Li metal coin cell configuration.

36 MATERIALS SCIENCE↗