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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Building-to-Grid Modeling Framework with a Case Study of Battery Systems

Coordinating electricity load shifting operations of multiple buildings has the potential to achieve significant benefits for both building owners and grid operation. In support of this research, this paper develops a novel building-to-grid modeling framework, which uses EnergyPlus to develop physics-based building energy models and GridLAB-D to develop distribution-level grid models. The data exchanges between buildings and distribution-level grid are conducted using Python script and HELICS co-simulation platform. Then, by using this modeling framework, this paper conducts a case study of battery systems in a connected community, which consists of 10 multi-family buildings with appropriately sized batteries. The three scenarios, baseline operation, tolerant to price fluctuations, and opportune usage, are studied. The result displays that, by adopting onsite batteries, both electricity costs for building owners and aggregated peak power demands are reduced.

Building-to-grid, connected community, co-simulati↗
DOE OSTI2022

Joint routing of conventional and range-extended electric vehicles in a large metropolitan network

Range-extended electric vehicles combine the higher efficiency and environmental benefits of battery-powered electric motors with the longer mileage and autonomy of conventional internal combustion engines. This combination is particularly advantageous for time-constrained delivery routing in dense urban areas, where battery recharging along routes can be too time-consuming to economically justify the use of all-electric vehicles. However, switching from electric to conventional fossil fuel modes also results in higher costs and emissions and lower efficiency. This paper analyzes this heterogeneous vehicle routing problem and describes two solution methods: an exact branch-price-and-cut algorithm and an iterated tabu search metaheuristic. From a methodological perspective, we find that the exact algorithm consistently obtains tight lower bounds that also serve to certify the metaheuristic solutions as near-optimal. From a policy standpoint, we examine a large-scale real-world case study concerning parcel deliveries in the Chicago metropolitan area and quantify various operational metrics including energy costs and vehicle miles traveled. We find that by deploying roughly 20% of range -extended vehicles with a modest all-electric range of 33 miles, parcel distributors can save energy costs by up to 17% while incurring less than 0.5% increase in vehicle miles traveled. Increasing the range to 60 miles further reduces costs by only 4%, which can alternatively be achieved by decreasing the average service time by 1 minute or increasing driver working time by 1 hour. In conclusion, our study reveals several key areas of improvement on which vehicle manufacturers, distributors, and policy makers can focus their attention.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1984

Charge Efficiency Tests of Lead/Acid Batteries

Current, voltage, and gas evolution measured during charge/discharge cycles. Series of standarized tests for evaluating charging efficiency of lead/acid storage batteries described in report. Purpose of tests to provide information for design of battery charger that allows maximum recharge efficiency for electric-vehicle batteries consistent with other operating parameters, such as range, water loss, and cycle life.

Rowlette, J. J.↗
DOE OSTI2026

Understanding Electric Vehicle Range and Charging Needs: Interactions Between Ambient Temperature, Commute Patterns, and State-of-Charge Usage

Electric vehicle (EV) performance can vary substantially under real-world operating conditions, particularly due to ambient temperature effects on energy consumption, battery behavior, and thermal management requirements. This study quantifies how weather conditions, daily driving patterns, and State-of-Charge (SOC) usage strategies jointly influence EV driving range, charging frequency, and overall energy efficiency. A detailed and experimentally validated Autonomie vehicle model is developed, integrating a powertrain, a mono-zonal cabin model, and a battery electro-thermal model. Three battery sizes (200-, 300-, and 400-mile homologated ranges) are assessed across five commute profiles (20–200 miles) and six ambient temperatures (−18 °C to 50 °C), including scenarios with and without preconditioning. Results show that extreme temperatures could significantly decrease the maximum achievable range by up to 55% in cold conditions (−18 °C) and 40% in hot conditions (50 °C), relative to moderate conditions. Larger battery packs retain a greater fraction of their nominal range under thermal stress, while smaller packs experience sharper relative penalties due to the higher contribution of thermal loads to total energy demand. The analysis further demonstrates that limiting operation to partial SOC windows (e.g., 80–20%), a common real-world practice, significantly reduces achievable range and increases charging frequency, particularly in cold weather. Thermal preconditioning while plugged in is shown to mitigate these effects for short trips, reducing energy consumption by up to 31% in hot conditions and 7% in cold conditions. The findings demonstrate how climate, SOC usage behavior, and thermal management jointly shape the practical driving capability of EVs, highlighting the importance of efficient thermal management and realistic user charging strategies for ensuring reliable EV operation across diverse climatic scenarios.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRSDate not supplied

Aerothermal Shape Optimization of Actively-Cooled Battery Packs using Conjugate Heat Transfer

Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.

thermal management↗
NASA NTRSDate not supplied

Aerothermal Shape Optimization of Actively-Cooled Battery Packs Using Conjugate Heat Transfer

Thermal management for battery is important for electric aircraft because battery temperature is critically important to vehicle safety, and it also has direct impact on the efficiency of the battery system. Because ambient air is a readily available resource for aircraft, this paper considers an active cooling concept with forced convection of ambient air through the battery pack. Conjugate heat transfer analysis is used to solve the coupled aero-thermal problem, which consists of a finite-volume computational fluid dynamics solver for the fluid domain, and a conduction heat transfer solver for the solid domain. A mixed Neumann and Dirichlet boundary condition is developed for the fluid-solid interface, which allows the solid domain to completely submerge in the fluid domain. A gradient-based optimization method is adopted, and the discrete adjoint approach implemented in DAFoam is used to efficiently compute the gradients. The aero-thermal coupling for primal analysis and gradient computation is handled using the OpenMDAO-based MPhys framework. A constant heat source is prescribed for the battery cells, and the battery shape (design variable) is optimized to minimize cooling pump power and battery weight (composite objective function) while keeping the battery temperature below a threshold (constraint). The optimized design achieves a 44.6% and 1.5% reduction in the cooling pump power and battery weight, respectively, and the maximal temperature constraint is satisfied. This work has the potential to reduce battery-pack weight, improve performance, and reduce the weight of thermal management systems for electric vertical take-off and landing aircraft.

heat transfer↗
NASA NTRS2020

Feasibility of a Solid Oxide Fuel Cell System Applied to Hybrid-Electric Regional Aircraft

NASA’s vision for the future of flight includes highly energy efficient aircraft that are environmentally friendly and have positive national economic impact. Although battery-powered electric aircraft are a viable alternative to reduce environmental impact, purely electric aircraft have drawbacks such as the low specific energy of batteries, which translates to an unfavorable weight scaling. Solid oxide fuel cell (SOFC) systems also have promise in providing environmentally friendly electrical power for new aircraft configurations at a higher efficiency than current methods, such as electrical generators. This study explores the use of the Fostering Ultra-Efficient, Low Emitting Aviation Power (FUELEAP) power system architecture for hybrid-electric regional aircraft. The FUELEAP power system utilizes a SOFC as part of a hybrid-electric power system architecture, enabling higher efficiency and specific power with a reduction in carbon and NOx emissions compared to state-of-the-art hybrid-electric SOFC architectures. The study includes comparisons of hybrid-electric power architectures and integration of the FUELEAP power system for two regional-sized passenger aircraft concepts. Results suggest that use of the FUELEAP power system as a replacement for onboard batteries may provide up to a 50% reduction in the weight of the electric d energy system for a typical regional aircraft mission.

Geuther, Steven↗
DOE OSTI2022

U.S. Federal Policy Considerations for the Management of Retired Large-Format Batteries

The global demand for large-format batteries used in electric vehicles (EV) and battery energy storage is expected to continue as governments call for zero emission policies. Total installed large-scale stationary battery energy storage is expected to increase almost 20-fold in the coming years - from 17 GW installed globally in 2020 to 358 GW projected in 2030. Similarly, light duty EVs sales globally are expected to increase more than 8-fold from 2020 to 2030 - from 3 million units to 25 million units. The expected demand for large-format batteries brings supply chain concerns, and economic opportunities. Domestic reuse and recycling is one potential circular economy solution for large-format batteries. This presentation discusses current U.S. law and regulatory landscape for the reuse and recycling of large-format batteries, and how certain policy frameworks impact reuse and end-of-life management decisions for large-format battery materials.

battery↗
DOE OSTI2021

Supporting the Li-Ion Battery Supply Chain via PEV Battery Reuse

The electric vehicle market is growing rapidly and there is significant need for lithium ion batteries and their materials. There is growing concern about the supply chain issues of lithium ion batteries in the US as most of the materials and components come from overseas. The concern about supply chain would be even more of a concern as more lithium ion systems will be installed in the renewable grid. By 2025, it is estimated that 3.5 million used PEVs may be retiring worldwide with commutative capacity of around 150 GWh. The question is what the is best way to deal with these batteries: recycle them right away for re-introduction of valuable materials into the battery supply chain or reused and then recycle them. These batteries usually have between 70-80% of their original capacity and studies have shown second use of these batteries are technically and environmentally – the question has been the economic viability. Most of LIBs has been going into the growing electric vehicle market. Rather than using new LIBs in the future grid, the second-life batteries is a significant resource and could alleviate supply chain issues.

47 OTHER INSTRUMENTATION↗
NASA NTRS1997

SSTI- Lewis Spacecraft Nickel-Hydrogen Battery

Topics considered include: NASA-Small Spacecraft Technology Initiative (SSTI) objectives, SSTI-Lewis overview, battery requirement, two cells Common Pressure Vessel (CPV) design summary, CPV electric performance, battery design summary, battery functional description, battery performance.

Tobias, R. F.↗
DOE OSTI2026

EVs@Scale: NextGen Profiles EVSE Characterization 2025

As part of the U.S. DOE EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles [NGP]) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. Electric Vehicle Service Equipment (EVSE) characterization involves testing over a wide range of DC charging currents and voltages during nominal and off-nominal conditions. This testing allows for a better understanding of the impact that high-power charging will have on the electric grid. A common set of standard test plans, procedures, and data requirements were applied to the characterization in this document with minor updates and improvements. This report covers all conductive characterization activities performed between October 2024 and September 2025 on the Delta Electronics 350KW Electric Vehicle Charging System, consisting of power cabinet model EIDN-U350KTA01 and dispenser model EIDD-U350SSUUAEG-350.Key Findings include: Output regulation, Efficiency and power factor, Load management, Grid Resilience, Smart Charge Management (SCM) performance, Thermal control system performance, Multi-port simultaneous charging performance, and Selected performance comparisons with other EVSEs characterized in the NextGen Profiles project. Hot and cold temperature testing was not conducted on the Delta 350KW due to laboratory limitations. Future research could include continued testing the Delta hardware under off-nominal temperature conditions including multi-port/multi-session simultaneous charge testing, in addition to collecting data on other high-power conductive chargers to augment.

25 ENERGY STORAGE↗
DOE OSTI2023

Energy and Power Evolution Over the Lifetime of a Battery

Li-ion batteries currently are dominant energy storage devices for electric vehicles. Rechargeable batteries with lower cost, longer lifetime, and higher safety are desired in support of building of a green grid infrastructure. The continued investment in new battery materials, novel battery structures, advanced manufacturing processes, and accelerated testing/validation of battery performance has led to significant progress in battery development and deployment. Battery safety/reliability, which is essential to the success of a battery technology in the real world, naturally becomes the next big topic in battery research. Recently, the increasing interest in long-duration storage, fast charging, battery secondary use, and material recycling to build a circular industry and sustainable material supply chain has compelled further attention to understand the energy/power evolution and safety over the lifetime of a battery. Here, in this short Viewpoint, we discuss some high-level analyses on the energy/power evolution of rechargeable batteries over their life cycles aiming to inspire more discussion on the safety and sustainability of some representative and emerging battery technologies.

25 ENERGY STORAGE↗
DOE OSTI2024

Grid-Constrained Electric Vehicle Fast Charging Sites: Battery-Buffered Options

This case study summarizes recent Joint Office of Energy and Transportation technical assistance work performed by the National Renewable Energy Laboratory which involved helping a state department of transportation analyze the feasibility of a battery energy storage system solution at a grid-constrained EV charging location.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Chapter 11: Renewable Microgrids as a Foundation of the Future Sustainable Electrical Energy System

Renewable microgrids are an integral part of the future sustainable energy system. This chapter focuses on the role of renewable energy-based microgrids in the electricity system transformation. It is seen as a foundation that complements large-scale generation plants and high-voltage transmission lines by providing additional flexibility and resilience. This flexibility and resilience are crucial for balancing the energy system and ensuring its long-term sustainability, given the changing supply and demand patterns due to rooftop solar photovoltaics (PV), battery storage, electric mobility, and heat pumps. It is also an opportunity for residential and commercial consumers to become active participants in the energy market. Innovation, new technologies and business models will act as the key enabler for this transformation. The regulatory restructuring of the energy market will be crucial for successful integration of prosumers and aggregated energy communities. The chapter presents the vision of a sustainable, decentralized, and digitized energy future including market potential, most innovative case study projects and start-up companies, and the shifts needed in the regulatory landscape.

battery storage↗
NASA NTRS1989

Energy storage and thermal control system design status

The Space Station Freedom electric power system (EPS) will initially rely on photovoltaics for power generation and Ni/H2 batteries for electrical energy storage. The current design for the development status of two major subsystems in the PV Power Module is discussed. The energy storage subsystem comprised of high capacity Ni/H2 batteries and the single-phase thermal control system that rejects the excess heat generated by the batteries and other components associated with power generation andstorage is described.

Simons, Stephen N.↗
NASA NTRS1989

Energy storage and thermal control system design status

The Space Station Freedom electric power system (EPS) will initially rely on photovoltaics for power generation and Ni/H2 batteries for electrical energy storage. The current design for and the development status of two major subsystems in the PV Power Module is discussed. The energy storage subsystem comprised of high capacity Ni/H2 batteries and the single-phase thermal control system that rejects the excess heat generated by the batteries and other components associated with power generation and storage is described.

Simons, Stephen N.↗
DOE OSTI2023

Long-life lithium-ion batteries realized by low-Ni, Co-free cathode chemistry

The increasing demand for lithium-ion battery-powered electric vehicles (EVs) has led to a surge in recent prices of strategic battery materials such as cobalt (Co) and nickel (Ni). While all EV makers are eager to eliminate Co usage, Ni has rapidly become another ‘pain point’ for the industry, as its price is nearing half that of Co. The sustainability issue facing both Ni and Co puts forward a grand materials challenge, that is, to reduce Ni content and eliminate Co while maintaining high specific energy and stability. Here in this work, a complex concentrated doping strategy is used to eliminate Co in a commercial NMC-532 cathode. The LiNi 0.5 Mn 0.43 Ti 0.02 Mg 0.02 Nb 0.01 Mo 0.02 O 2 cathode shows potential cost advantage with relatively high specific energy and significantly improved overall performance (~95% capacity retained after 1,000 cycles in pouch-type cells, 2.8–4.3 V vs graphite, at 1 C, 1.5 mA cm -2 ). Combining X-ray techniques and electron microscopy, we uncover the origins of the superior stability.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Heterogeneity of the Dominant Causes of Performance Loss in End-of-Life Cathodes and Their Consequences for Direct Recycling

Recycling Li-ion batteries from electric vehicles is critical for reducing costs and supporting the development of a domestic battery supply chain. Direct recycling of cathodes, like LiNixMnyCozO2 (NMC), is attractive due to its low cost, energy use, and emissions compared to traditional recycling techniques. However, a comprehensive understanding of the active material properties at end-of-life is needed to guide direct recycling processes and the performance-dependent reuse applications. Here, NMC material from an end-of-life commercial pouch cell is characterized and bench-marked against pristine non-cycled counterparts with respect to capacity, impedance, crystallography, morphology, and microstructure to identify major degradation modes and understand variability in the end-of-life material. The spatial heterogeneity of each property throughout the cell is also quantified. While the degraded material demonstrated similar capacity as the pristine, its impedance and rate capability are severely diminished. Furthermore, samples from the periphery of the electrode layers showed more severe performance loss compared to samples extracted from central regions. The dominant culprit of performance loss is the material microstructure, where the magnitude of particle cracking showed the strongest correlation to the impedance components that are most unfavorably impacted. This work suggests severe cracks in cathode active materials are the primary challenge that direct recycling methods must overcome.

25 ENERGY STORAGE↗