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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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Propagation of thermal events from one damaged cell in a battery module to adjacent cells is a safety concern. A team of researchers from Sandia National Laboratories (SNL) and the National Renewable Energy Laboratory (NREL) have developed a “safety-map” to evaluate propensity for failure propagation. The model results were used to evaluate passive thermal management designs for Li-ion battery modules.
Clean and sustainable energy is becoming increasingly crucial to tackle the current energy crisis. However, the intermittent nature of renewable energy sources presents a challenge for their effective implementation. Redox flow batteries (RFBs) have emerged as a promising solution to this problem, as they can help enhance the stability of grid networks and promote the use of renewable energy sources. RFBs are highly modular and scalable systems that can be customized to meet the power and energy requirements of different renewable energy plants. Moreover, they offer several advantages over conventional battery technologies, including cost and safety concerns. However, conventional RFBs have limited energy densities due to the low solubility of their active species in electrolyte. To overcome this limitation, semi-solid (SSRFBs) and redox targeting (RTFBs) flow batteries have been proposed. These systems feature high concentrations of active species and impressive energy densities, making them highly attractive for renewable energy applications. LiFePO4 (LFP) is a highly promising active material for semi-solid and targeting flow batteries. One of the key advantages of LFP is its low raw materials cost, as it is composed of Earth-abundant elements such as iron and phosphorus. This makes it an attractive option for large-scale battery production. The recent developments in SSRFBs and RTFBs using LFP as catholyte hold great promise for the future of sustainable energy storage. The combination of LFP's low cost, safety, durability, and high energy density with the modularity and scalability of flow battery systems make for a compelling solution to the challenges of intermittent renewable energy sources. Ongoing research and development in this area will likely yield even further improvements in the performance and efficiency of LFP-based flow batteries, opening exciting new possibilities for sustainable energy storage.
Lithium metal batteries (LMBs) are prime candidates for next-generation energy storage devices characterized by their remarkable energy storage capabilities. Despite the importance of understating the calendar aging impacts in LMBs, cycle life and calendar life have received inconsistent attention across various research and development stages. For acceptance into an application, especially electric vehicles, batteries are required to have sufficient calendar life to ensure performance over the life of vehicles which often experience extended periods of inactivity. In this study, an in-depth exploration into the calendar aging of LMB (Li/ Li[Ni 0.8 Mn 0.1 Co 0.1 ]O 2 in pouch cell format) is conducted. Specifically, the impact of calendar aging factors, state-of-charge (SOC), temperature, pressure, and operating conditions (open-circuit voltage, OCV and constant voltage, CV) on the surface morphology and thickness change rate in lithium metal anode is investigated. Notably, the results show that storing LMB pouch cells at an OCV, 80 % SOC, 25 °C, and 10 psi external pressure leads to a <1% reduction in capacity over 18 months. The results also suggest routes which can be utilized in the future for accelerated aging without altering the primary degradation modes. The results also show an accelerated calendar aging at high temperatures (45 °C), 100 % SOC, and CV suggesting they may serve as key accelerated aging methods for future studies. During calendar aging, pressure mitigates dendrite growth and extends calendar life. In conclusion, the insights from this study reinforce the viability of LMBs as a compelling solution for addressing increased energy storage needs in real-world applications.
The SUbsonic Single Aft eNgine (SUSAN) program is being developed as a sustainable subsonic regional aircraft. NASA is conducting trade studies for this future hybrid single aisle passenger aircraft. The goal of reducing emission levels by 50% will be enabled through an advanced design. An aft mounted single turbine engine provides thrust and electric power to drive 16 wing mounted electric engines. Using the 16 counter-rotating electric fans will create an efficient, very high bypass ratio, engine. Electric engines allow for distributed thrust, reducing control surfaces and provide a greater dynamic response. Batteries provide boost for takeoff and climb, allowing a smaller, more efficient, turbine engine. As part of the SUSAN effort, two pilot-in-the-loop studies were conducted at NASA Langley Research Center in Virginia to explore flight deck design issues. In particular: how many throttles are required/desired for a 17-engine aircraft, does the hybrid electric design change the answer, what are the requirements for electric engine displays, what system pages are required, and what information is required to monitor the batteries. Objective and subjective data were collected after each scenario and at the end of the day with a guided set of questionnaires from sixteen crews paired by airline. Data along with pilot comments were used to improve the throttle and engine displays between the studies and used to make the final recommendations on flight deck configurations. This paper provides final design recommendations for the SUSAN flight deck and justification for each recommendation.
Highlights Zn-MnO 2 batteries promise safe, reliable energy storage, and this roadmap outlines a combination of manufacturing strategies and technical innovations that could make this goal achievable. Approaches such as improved efficiency of manufacturing and increasing active material utilization will be important to getting costs as low as $100/kWh, but key materials innovations that facilitate the full 2-electron capacity utilization of MnO 2 , the use of high energy density 3D electrodes, and the promise of a separator-free battery with greater than 2V potential offer a route to batteries at $50/kWh or less. Abstract Large-scale energy storage is certain to play a significant, enabling role in the evolution of the emerging electrical grid. Battery-based storage, while not a dominant form of storage today, has opportunity to expand its utility through safe, reliable, and cost-effective technologies. Here, secondary Zn–MnO 2 batteries are highlighted as a promising extension of ubiquitous primary alkaline batteries, offering a safe, environmentally friendly chemistry in a scalable and practical energy dense technology. Importantly, there is a very realistic pathway to also making such batteries cost-effective at price points of $50/kWh or lower. By examining manufacturing examples at the Zn–MnO 2 battery manufacturer Urban Electric Power, a roadmap has been created to realize such low-cost systems. By focusing on manufacturing optimization through reduced materials waste, scalable manufacturing, and effective materials selection, costs can be significantly reduced. Ultimately, though, coupling these approaches with emerging research and development advances to enable full capacity active materials utilization and battery voltages greater than 2V are likely needed to drive costs below a target of $50/kWh. Reaching this commercially important goal, especially with a chemistry that is safe, well-known, and reliably effective stands to inject Zn–MnO 2 batteries in the storage landscape at a critical time in energy storage development and deployment. Graphical abstract
Automated/autonomous vehicle fleet operations within automated mobility districts have been studied over the past five years by the National Renewable Energy Laboratory, a US Department of Energy federally funded research and development center. This paper extends the analysis in this third phase of research underway to include considerations for electric vehicle operations and charging within a fleet of right-sized automated vehicles providing on-demand public mobility services. The current focus of research is on the operational complexities and associated challenges for automated/autonomous vehicles employing electric drivetrains and the resultant need for an efficient battery charging process while vehicles are operating in an "on-demand" mode of service. The blossoming of microtransit with shared-ride and point-to-point dispatching of each vehicle instills complex operations, with multiple mobility-on-demand transit operating sites being deployed, studied, and analyzed across North America. As a starting point, the authors' experience over the past 20 years with the analysis of automated transit network systems operating on and within dedicated and protected transitways provides initial insights into the system-level operational implications for maintaining a sufficient battery charge for a fleet of automated vehicles. Lessons learned through the prior analyses of automated transit network systems operating in on-demand service are identified, along with the capital cost implications for the requisite operating fleet size and charging station infrastructure for various approaches. These costs are summarized in juxtaposition with the benefits of realizing the higher goals of reducing environmental impacts and energy use within automated mobility districts as automated/autonomous vehicle technology matures. Finally, the discussion addresses key aspects of battery-electric propulsion for managed fleets in fully automated operation that will be studied as the third phase of research continues.
As the electric-vehicle market continues to expand, LiFePO 4 (LFP) batteries, valued for their intrinsic safety and cost-effectiveness, are being increasingly utilized. However, this widespread adoption highlights the urgent need for innovative and environmentally friendly recycling methods for spent LFP batteries due to their relatively low material value and the environmental challenges associated with traditional recycling processes. Here, in this study, we present a novel selective lithium leaching technique that involves a gas–solid reaction with chlorine gas. This method achieves a remarkable leaching efficiency of 99.8 % and a selectivity of 98.8 % at 200 °C within just 10 min, without generating acidic wastewater. The resulting LiCl solution was successfully converted into Li 2 CO 3 with an excellent purity of 99.5 %, while producing NaCl solution as the only byproduct. Notably, the olivine structure of the LFP was preserved as FePO 4 after lithium leaching. The regenerated LFP demonstrated excellent performance, retaining 94.1 % of its capacity after 150 cycles, while the lithium-leached FePO 4 delivered a reversible capacity exceeding 150 mAh/g. This approach not only enhances the efficiency of LFP recycling but also paves the way for more sustainable battery technologies.
The Explorer Platform/Extreme Ultraviolet Explorer (EP/EUVE) spacecraft power is provided by the Modular Power Subsystems (MPS) which contains three 50 ampere-hour Nickel Cadmium (NiCd) batteries. The batteries were fabricated by McDonnell Douglas Electronics Systems Company, with the cells fabricated by Gates Aerospace Batteries (GAB), Gainesville, Florida. Shortly following launch, the battery performance characteristics showed similar signatures as the anomalous performance observed on both the Upper Atmosphere Research Satellite (UARS) and the Compton Gamma Ray Observatory (CGRO). This prompted the development and implementation of alternate charging profiles to optimize the spacecraft battery performance. The Flight Operations Team (FOT), under the direction of Goddard Space Flight Center's (GSFC) EP/EUVE Project and Space Power Applications Branch have monitored and managed battery performance through control of the battery Charge to Discharge (C/D) ratio and implementation of a Solar Array (SA) offset. This paper provides a brief overview of the EP/EUVE mission, the MPS, the FOT's battery management for achieving the alternate charging profile, and the observed spacecraft battery performance.
Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.
Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.
Urban Air Mobility (UAM) promises to revolutionize transportation in major cities, offering passenger travel, cargo delivery, and emergency medical services through a network of electric vertical takeoff and landing (eVTOL) aircraft. However, the limited range of current eVTOLs, due to the low specific energy of lithium-ion batteries along with a possibility of thermal runaway conditions poses significant safety concerns, leading to potentially compromising operational safety. To address this critical challenge, researchers are actively evaluating the impact of flight and environmental conditions on onboard lithium-ion battery health. This involves carefully assessing the performance of battery packs under laboratory and operational conditions for developing models to estimate future health using prognostics framework. This study examines the effectiveness of evaluating battery degradation leading to catastrophic failures under varying operational conditions in laboratory. These are captured using physics based models of underlying phenomenons and integrated into the prognostics framework. A fully charged battery undergoes controlled discharge cycles at varying C-rates based on the simulated power draw profile, with current and voltage, temperature data recorded throughout the experiment. The observed data provides valuable insights into how different operating conditions and mission profiles affect battery performance. This information is crucial for developing strategies to optimize battery systems, enhance range, and ultimately ensure the safe and reliable operation of UAM vehicles.
Lithium (Li) metal is the ultimate anode material for Li batteries because of its highest capacity among all candidates. Recent research has focused on stable interphase and host materials to address its low stability and reversibility. Here, we discover that tortuosity is a critical parameter affecting the morphology and electrochemical performances of hosted Li anodes. In three types of hosts—vertically aligned, horizontally aligned, and random reduced graphene oxide (rGO) electrodes with tortuosities of 1.25, 4.46, and 1.76, respectively—we show that high electrode tortuosity causes locally higher current density on the top surface of electrodes, resulting in thick Li deposition on the surface and degraded cycling performance. Low electrode tortuosity in the vertically aligned rGO host enables homogeneous Li transport and uniform Li deposition across the host, realizing greatly improved cycling stability. Furthermore, using this principle of low tortuosity, the designed electrode shows through-electrode uniform morphology with anodic Coulombic efficiency of ~99.1% under high current and capacity cycling conditions.
Lithium-ion batteries (LIBs) have revolutionized our society in many respects, and we are expecting even more favorable changes in our lifestyles with newer battery technologies. In pursuing such eligible batteries, nanophase materials play some important roles in LIBs and beyond technologies. Here, stimulated by their beneficial effects of nanophase materials, we initiated this Focus. Excitingly, this Focus collects 13 excellent original research and review articles related to the applications of nanophase materials in various rechargeable batteries, ranging from nanostructured electrode materials, nanoscale interface tailoring, novel separators, computational calculations, and advanced characterizations.
The majority of new satellites generate electrical power using photovoltaic solar arrays and store energy in batteries for use during eclipse periods. Careful regulation of battery charging during insolation can greatly increase the expected lifetime of the satellite. The battery charge regulator is usually custom designed for each satellite and its specific mission. Economic competition in the small satellite market requires battery charge regulators that are lightweight, efficient, inexpensive, and modular enough to be used in a wide variety of satellites. A new battery charge regulator topology has been developed at the NASA Lewis Research Center to address these needs. The new regulator topology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. A transformer-isolated buck converter is connected such that the high input line is connected in series with the output. This "bypass connection" biases the converter's output onto the solar array voltage. Because of this biasing, the converter only processes the fraction of power necessary to charge the battery above the solar array voltage. Likewise, the same converter hookup can be used to regulate the battery output to the spacecraft power bus with similar fractional power processing. The advantages of this scheme are: 1) Because only a fraction of the power is processed through the dc-dc converter, the single- stage conversion efficiency is 94 to 98 percent; 2) Costly, high-efficiency dc-dc converters are not necessary for high end-to-end system efficiency; 3) The system is highly fault tolerant because the bypass connection will still deliver power if the dc-dc converter fails; and 4) The converters can easily be connected in parallel, allowing higher power systems to be built from a common building block. This new technology will be spaceflight tested in the Photovoltaic Regulator Kit Experiment (PRKE) on TRW's Small Spacecraft Technology Initiative (SSTI) satellite scheduled for launch in 1996. This experiment uses commercial dc-dc converters (28 to 15 Vdc) and additional control circuitry to regulate current to a battery load. The 60-W, 87- percent efficiency converters can control 180 W of power at an efficiency of 94 percent in the new configuration. The power density of the Photovoltaic Regulator Kit Experiment is about 200 W/kg.
The majority of new satellites generate electrical power using photovoltaic solar arrays and store energy in batteries for use during eclipse periods. Careful regulation of battery charging during insolation can greatly increase the expected lifetime of the satellite. The battery charge regulator is usually custom designed for each satellite and its specific mission. Economic competition in the small satellite market requires battery charge regulators that are lightweight, efficient, inexpensive, and modular enough to be used in a wide variety of satellites. A new battery charge regulator topology has been developed at the NASA Lewis Research Center to address these needs. The new regulator topology uses industry-standard dc-dc converters and a unique interconnection to provide size, weight, efficiency, fault tolerance, and modularity benefits over existing systems. A transformer-isolated buck converter is connected such that the high input line is connected in series with the output. This "bypass connection" biases the converter's output onto the solar array voltage. Because of this biasing, the converter only processes the fraction of power necessary to charge the battery above the solar array voltage. Likewise, the same converter hookup can be used to regulate the battery output to the spacecraft power bus with similar fractional power processing.
Nonaqueous conversion-reaction sulfur chemistry has been attracting increasing attention over the past decade for the development of next-generation lithium-based batteries. Li–S batteries are currently approaching a nexus stage from lab-scale experiments to possible pragmatic applications. Inspired by the success of Li–S chemistry, other metal–sulfur batteries with a variety of metallic anodes, such as sodium, potassium, magnesium, calcium, and aluminum, have also started to attract attention. In comparison to lithium, Na, Mg, Al, K, and Ca are naturally more abundant and affordable. The Na-S, Mg-S, Al-S, K-S, and Ca-S battery systems provide a great potential for improving the volumetric energy density of sulfur-based batteries. The multivalent metal-sulfur systems, Mg-S, Al-S, and Ca-S, offer better safety features as well. However, the research and development on Na-S, Mg-S, Al-S, K-S, and Ca-S batteries is far behind the Li–S system due to many critical challenges. In this progress report, the fundamental principles of various metal–sulfur chemistries are first presented and compared. Then, the historical progress, recent advances, and key challenges of the Li–S, Na-S, Mg-S, Al-S, K-S, and Ca-S systems are summarized and discussed. Finally, future efforts and directions for both the fundamental and practical research are prospected.
With the electric vehicle (EV) market expansion and the energy sector's shift towards electrification, the demand for battery metals, including lithium (Li), cobalt (Co), and nickel (Ni), is set to surpass supply. A critical knowledge gap exists in the purity standards for battery precursors and the impact of impurities on battery performance. Addressing this, our study employs a Deep Machine Learning (DL) based multi-objective optimization approach to interpret the relationship between metal impurities in domestic battery resources and their effects on battery performance. We analyze experimental data from Li-ion batteries with NMC (Nickel-Manganese-Cobalt oxide) cathodes over 1000 cycles, representing approximately ~6-8 months of operation, to establish a baseline of performance without impurities. Leveraging this data, we develop a Physics-Informed Deep Learning (PIDL) framework to extend our findings to cases that include metal impurities (e.g., Fe, Cu, Al) ranging from (0.001 - 0.01) %, respectively. By incorporating physics-based features, our PIDL model can accurately estimate the performance of NMC cathodes doped with various metal impurities to provide rapid design decisions. This research paves the way for informed decisions in Li-ion battery material design and optimization, ensuring the sustainable growth of the EV market and the broader energy sector.
The lithium–sulfur (Li–S) battery is a promising next-generation energy storage technology because of its high theoretical energy and low cost. Extensive research efforts have been made on new materials and advanced characterization techniques for mechanistic studies. However, it is uncertain how discoveries made on the material level apply to realistic batteries due to limited analysis and characterization of real high-energy cells, such as pouch cells. Evaluation of pouch cells (>1 A h) (instead of coin cells) that are scalable to practical cells provides a critical understanding of current limitations which enables the proposal of strategies and solutions for further performance improvement. Herein, we design and fabricate pouch cells over 300 W h kg -1 , compare the cell parameters required for high-energy pouch cells, and investigate the reaction processes and their correlation to cell cycling behavior and failure mechanisms. Spatially resolved characterization techniques and fluid-flow simulation reveal the impacts of the liquid electrolyte diffusion within the pouch cells. We found that catastrophic failure of high-energy Li–S pouch cells results from uneven sulfur/polysulfide reactions and electrolyte depletion for the first tens of cycles, rather than sulfur dissolution as commonly reported in the literature. The uneven reaction stems from limited electrolyte diffusion through the porous channels into the central part of thick cathodes during cycling, which is amplified both across the sulfur electrodes and within the same electrode plane. A combination of strategies is suggested to increase sulfur utilization, improve nanoarchitectures for electrolyte diffusion and reduce consumption of the electrolytes and additives.