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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Small capacity, low cost (Ni-H2) design concept for commercial, military, and higher-volume aerospace applications

Nickel-Hydrogen (Ni-H2) batteries have become the technology of choice for both commercial and defense-related satellites in geosynchronous orbits. Their use for low-earth- orbit (LEO) applications is not as advanced, but seems just as inevitable because of their inherent advantages over nickel-cadmium batteries. These include superior energy density, longer cycle life, and better tolerance to over-charge and reversal. Ni-H2 cells have the added advantage in both construction and operation of not presenting the environmental possibility of cadmium pollution. Unfortunately, but necessarily, the design of these cells has been driven to high cost by the sophistication of the satellites and their uses. Now, using most of the same concepts but less costly materials and techniques, a low-cost, small cell design has been developed. Combined with the concept of the common pressure vessel, this new design promises to be ideal for the "small-sat" and commercial markets which, increasingly, are calling for large numbers of less-expensive satellites.

James R Wheeler↗
NASA NTRS2016

An Influenced Future

Phobos is a vital precursor and catalyst before our next giant leap to Mars. The principle period of a Phobos' mission could be a series of robotic precursor missions for experimental perception, soil examination, ecological approval and landing site distinguishing proof. For my summer intern position at Johnson Space Center I chipped away at creating a GUNNS (General Use Nodal Network Solver) based power subsystem model for the miniATHLETE hopper, which is a conceptual (idea-based) robotic lander that will operate on Phobos. Keeping in mind the end goal to begin on my venture, I needed to comprehend my undertaking before whatever else, in which I concentrated on C++ to see how to implement the code that GUNNS generates to a Trick S_define file. Prior to coming to this internship at Johnson Space Center Dr. Edwin Zack Crues provided a class on modeling and simulation, which introduced me to the Trick simulation environment. The goal of my project was to develop a GUNNS based power subsystem model for the miniATHLETE hopper. The model needed to incorporate a solar array, battery, hopping legs, and onboard scientific instruments (sensitive measuring/recording devices). The secondary bonus goal after I completed the electrical aspect of my model was to develop a GUNNS based thermal subsystem model for the miniATHLETE hopper. Stringing the two aspects together, I would need to code up a signal aspect to make the system work as one. Accomplishing my goals would not be an easy thing, however I had successfully completed the electrical aspect model with twenty-four servos, six cameras, and multiple sensors. Venturing to complete my project has eluded me to many failures in my design to tune many things like the battery to the proper voltage and the load to the proper wattage. During this time I had touched up on advanced topics in calculus in which I implemented in the converter in my electrical model. I am currently working with my mentor Zu Qun Li to create a signal aspect to control the temperatures inside my electrical aspect model. During my time at JSC I had effectively figured out how to create subsystem models utilizing Trick and GUNNS. I obtain essential knowledge of power and thermal subsystem design for a robotic vehicle. I also learned how to work and communicate in a team effectively to accomplish a goal. Before coming to Johnson Space Center my future career and educational goals included uncertainty, however now I have a completely new look on my path to a prosperous future. My NASA experience has unquestionably impacted me to accomplish and surpass my own particular desires. After my time at Johnson Space Center I plan to apply for a coop position for NASA. This has been a dream come true that I adored each moment being at JSC realizing that I am far fit for doing things most individuals can just long for.

Owens, Christopher↗
DOE OSTI2025

Unravelling electro-chemo-mechanical interplay in layered oxide cathode degradation in solid-state batteries

Solid-state batteries (SSBs) hold notable promise for advancing energy storage technologies. However, their commercial viability is limited by the poor cycle stability and complex degradation mechanism. This study underscores the pivotal role of electro-chemo-mechanical interactions in driving the failure of SSBs. Leveraging advanced x-ray imaging and spectroscopy techniques, we analyzed LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cathodes from cycled Li x In||Li 6 PS 5 Cl (LPSC)||NMC811 SSBs, uncovering the interplay between microstructure, chemical heterogeneity, mechanical characteristics, and electrochemical performance. Our results show that revealing electro-chemo-mechanical interactions is essential to develop strategies to suppress the degradation of SSBs. Particularly, we revisit a LiNbO 3 (LNO) coating layer to mitigate electrochemical degradation. The LNO@NMC811 cathode retains 116 milliampere-hours per gram after 200 cycles, showing excellent stability, while the uncoated NMC811 cathode keeps degrading over time, with suppressed chemical heterogeneity and mechanical failure. This work highlights the importance of synergizing advanced material design with coating techniques, ensuring uniform lithium flux and improving mechanical properties to achieve stable, high-performance SSBs.

Zheng, Xueli [SLAC National Accelerator Laboratory↗
DOE OSTI2022

Light-Level Geolocation of the LANL Population of Western Bluebirds

Options for tracking and reconstructing animal movement are increasingly accessible due to rapidly decreasing costs, smaller sizes, and a proliferation of analytical inference techniques (Rutz and Hays, 2009; Wikelski et al., 2007). A wide variety of options exists for determining movement patterns of animals—from high-resolution pinpoint ARGOS satellite tags to time-consuming and logistically challenging radio telemetry. One option, light-level geolocation, offers small, affordable devices with long battery lives known as global location sensors (GLS), making them ideal for gathering preliminary migratory data. Geolocation works by inferring patterns of animal movement from light-level transitions between day and night (Hill and Braun, 2001). The recent advances in tracking technologies allow biologists to zoom in on migratory behavior, delineating heretofore-unidentified intraspecific migratory behavior (Delmore et al., 2012). The ubiquity of migratory divides (populations within a species that exhibit different migratory patterns) remains largely unknown, but their existence can lead to favorable demographic metrics (e.g., genetic diversity) in conservation contexts (Møller et al., 2011) and necessitate the development of population-specific conservation plans (Delmore et al., 2012). Delimiting the populations within a species that migrate and the extent of their migrations relative to individuals that remain resident across a species’ range has important evolutionary, ecological, and conservation implications. Within this context, Los Alamos National Laboratory (LANL) biologists have leveraged the local Avian Nestbox Network (ANN; Fair and Myers, 2002) to evaluate the migratory behaviors of a common local bird species, the Western Bluebird (Sialia mexicana).

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Design and Performance of lithium-Ion Batteries for Achieving Electric Vehicle Takeoff, Flight, and Landing

Today, the burgeoning drive towards global urbanization with over half the earth’s population living in cities, has created major challenges with regards to intracity and intercity transit and mobility. This problem is compounded due to the fact that almost always urbanization and increase in standard of living drives individual automobile ownerships. Over 95% of automobiles are presently powered by some form of fossil fuel and as an unintended consequence, urban centers have also been centers for peak greenhouse gas emissions, a major contributor to global climate change. A revolutionary solution to this conundrum is flight capable electric automobiles or electric aerial vehicles that can tackle both urban mobility and climate change challenges. For such advanced electric platforms, energy storage and delivery component is the vital component towards achieving takeoff, flight, cruise, and landing. The requirements and duty cycle demands on the energy storage system is drastically different when compared to the performance metrics required for terrestrial electric vehicles. As the widely deployed lithium ion-based battery systems are often the primary go-to energy storage choice in electric vehicle related applications, it is imperative that performance metrics and specifications for such batteries towards areal electric vehicles need to be established. In this nascent field, there exists ample opportunities for battery material innovations, understanding degradation mechanism, battery design, development and deployment of battery control and management systems. Thus, this chapter comprehensively discusses battery requirements and identifies battery material chemistries suitable for handling aerial electric automobile duty cycles. The chapter also discusses the battery cell-level metrics pertaining to electrochemical, chemical, mechanical, and structural parameters. Furthermore, specific models for battery degradation, state of health (SOH), capacity and models for full cell performance and degradation are also discussed here. Finally, the chapter also discusses battery safety and future directions of batteries that would power these next generation urban electric aircrafts.

Amin, Ruhul↗
DOE OSTI2021

Vehicle Technologies and Hydrogen and Fuel Cell Technologies Research and Development Programs Benefits Assessment Report for 2020

The U.S. Department of Energy’s Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. VTO and HFTO regularly revisit and update relevant research and development goals and areas of emphasis in response to the latest technological advancements and in alignment with current national priorities. As such, analyses of expected benefits resulting from VTO and HFTO investments and anticipated goal achievements are updated periodically and will be again for 2021 in the context of the latest national-level transportation decarbonization goals. The analysis in the present report is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding to achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The evaluation includes detailed analyses into the benefits of technology improvements on the U.S. light-duty (LD) vehicle fleet and separately on the U.S. medium- and heavy-duty (MDHD) vehicle fleet. This report summarizes the outcomes from each of these analyses both independently and in combination.

08 HYDROGEN↗
NASA NTRS2017

Space Technology: Game Changing Development Deep Space Engine (DSE) 100 lbf and 5 lbf Thruster Development and Qualification

Science mission studies require spacecraft propulsion systems that are high-performance, lightweight, and compact. Highly matured technology and low-cost, short development time of the propulsion system are also very desirable. The Deep Space Engine (DSE) 100-lbf thruster is being developed to meet these needs. The overall goal of this game changing technology project is to qualify the DSE thrusters along with 5-lbf attitude control thrusters for space flight and for inclusion in science and exploration missions. The aim is to perform qualification tests representative of mission duty cycles. Most exploration missions are constrained by mass, power and cost. As major propulsion components, thrusters are identified as high-risk, long-lead development items. NASA spacecraft primarily rely on 1960s' heritage in-space thruster designs and opportunities exist for reducing size, weight, power, and cost through the utilization of modern materials and advanced manufacturing techniques. Advancements in MON-25/MMH hypergolic bipropellant thrusters represent a promising avenue for addressing these deficiencies with tremendous mission enhancing benefits. DSE is much lighter and costs less than currently available thrusters in comparable thrust classes. Because MON-25 propellants operate at lower temperatures, less power is needed for propellant conditioning for in-space propulsion applications, especially long duration and/or deep-space missions. Reduced power results in reduced mass for batteries and solar panels. DSE is capable of operating at a wide propellant temperature range (between -22 F and 122 F) while a similar existing thruster operates between 45 F and 70 F. Such a capability offers robust propulsion operation as well as flexibility in design. NASA's Marshall Space Flight Center evaluated available operational Missile Defense Agency heritage thrusters suitable for the science and lunar lander propulsion systems.

Barnett, Gregory↗
NASA NTRS2019

Recent Advances in High Altitude Pseudosatellites (HAPS) and Potential Roles in Future Earth Observing Systems

In August 2001 the NASA Environmental Research Aircraft and Sensor Technology (ERAST) Program flew the Helios aircraft to an altitude of nearly 100,000ft, demonstrating a new type of remote sensing platform. Nearly 20 years later the earth science community has unmet observational requirements to loiter over regions of interest for days or weeks as well as to follow airmasses to study chemistry and dynamics in concert with spaceborne observations. Recent advances in materials science and engineering have enabled improved battery power density, solar panel efficiency, and light yet strong structural materials required to effectively operate high-altitude (50-70k ft altitude) Pseudo-Satellites (HAPS) for 30+ days. The rapid commercialization of small unmanned aircraft has also contributed to the maturation of HAPS by making avionics, GPS, and other sub-systems smaller and less expensive. HAPS payloads provide high-resolution data that complement geostationary and polar orbiting satellites, while also enabling in-situ sampling of atmospheric chemistry and dynamics. Recent commercial interest in HAPS for 4G/5G and WIFI has funded development of a new generation of aircraft available to the science community. Here I report on a project under the NASA Airborne Science Program to test and demonstrate earth observations from a prototype aircraft being developed under a NASA Small Business Innovative Research Phase II. This aircraft will demonstrate the ability for a solar electric aircraft to deliver a 2u cubesat-based passive optical imaging satellite to 70,000ft for 30 or more days. Discussion will include the anticipated maturation timeline for HAPS, development and operational challenges, and examples of mission concepts that might contribute to future earth observing systems.

Helios aircraft↗
NASA NTRS2021

Ultra Long-Lived, Self-Surveying Autonomous Air Quality Sensing - Executive Summary

We set out to evolve ultra-low power air quality sensing technologies developed at JSC to add a highly accurate positioning sensor based on SBIR technology to give a self-surveying air quality monitoring platform with years-long lifetime on a small, disposable coin cell battery. Using Radio Frequency Identification (RFID) technology for data transport, the system can take advantage of RFID-based inventory management systems in place on lunar exploration assets to provide this capability with extremely small SWAP impacts. Years-long operational lifetimes enable flexible, autonomous environmental monitoring during lengthy intervals between and unprecedented situational awareness during crewed missions. Software integration of the localization system into the JSC RFID sensing platform was advanced, but the COVID-19 pandemic complicated and slowed maturation of the localization system SBIR product, and center closure indefinitely deferred a final hardware integration and system demonstration. In the meantime, progress was made to mature the air-quality sensing platform for flight, including hardware, software, antenna, and mechanical improvements. The underlying RFID sensing capability was also adapted to a drawer motion sensing system, which is currently (FY21) being taken toward an ISS flight demonstration as part of the RFID Enhanced Autonomous Logistics Management (REALM)-3 experiment.

Raymond Summers Wagner↗
NASA NTRSDate not supplied

Delay Tolerant, Radio Frequency Identification (RFID )-enabled Sensing

Radio Frequency Identification (RFID) technology offers a completely passive method to transmit fixed data sequences from an RFID tag, which typically doesn’t have its own power supply, to an interrogator. Radio frequency (RF) energy harvested from the interrogator is rectified by the tag and used to charge an integrated circuit (IC). The IC then modulates the received signal with the data stored on the tag and reflects the energy back to the interrogator. RFID has seen great proliferation in terrestrial inventory management applications, and it has recently made the jump to spaceflight applications onboard the International Space Station, augmenting an existing optical bar‐code infrastructure for tracking supplies. A number of advanced automated logistics management (ALM) concepts employing RFID are currently being developed and evaluated, including so‐called “smart” shelves, cubbies, and trash receptacles using low‐power, embeddable RFID interrogators. An infrastructure where both crew members and robotic assistants, such as autonomous free flyers, are similarly equipped with small RFID interrogators seems likely. It therefore behooves us to consider extending this infrastructure beyond ALM to applications such as low power, embedded sensing. Typically, data on an RFID tag can only be written by an RFID interrogator, using interrogator energy. In recent years, however, a few efforts have focused on using that energy to drive data acquisition from the tag IC, allowing the tag to modify its stored data sequence with sensor data before replying to an interrogator. In this way, the tag can act as a completely passive sensing device. One problem exists with this approach, however: the tag cannot gather data when an interrogator is not present. Thus, strictly passive RFID sensing tags cannot gather data at regular intervals, in the manner of a typical wireless sensor network, without careful, and impractical, planning of mobile interrogator movements. To address this shortcoming, we look to a recent advance in RFID technology which allows an external microprocessor to power the tag IC and write directly into its RFID memory using a wired serial interface. In this paradigm, data gathering is driven by a small, on‐board power supply (using batteries or harvested energy), and data transfer is provided passively through the RFID interrogation service. Since communication typically consumes the lion’s share of power in WSNs, such a technique has the potential to enable extremely long‐lived, embedded wireless sensing when used with extremely low‐current microcontrollers. Since the communication channel is only open when an interrogator is present and actively interrogating the RFID sensing tag, transport of periodically‐sampled sensor data presents itself as a delay/disruption‐tolerant networking (DTN) problem. In this paper, we present the design of a DTN‐like overlay on the common EPC Global, Class 1, Generation 2 RFID standard. This overlay allows seamless, guaranteed data transfer using the EPC Global protocol, supporting extremely low‐power, embedded sensing using an infrastructure likely to be already in place for ALM applications. We evaluate a prototype implementation of a complete end‐to‐end system using a robotic RFID interrogation agent, and we present future directions for the development of this sensing technique.

Raymond S. Wagner↗
NASA NTRS2017

Advanced Stirling Convertor Control Unit Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

Future NASA missions could include establishing Lunar or Martian base camps, exploring Jupiters moons and travelling beyond where generating power from sunlight may be limited. Radioisotope Power Systems (RPS) provide a dependable power source for missions where inadequate sunlight or operational requirements make other power systems impractical. Over the past decade, NASA Glenn Research Center (GRC) has been supporting the development of RPSs. The Advanced Stirling Radioisotope Generator (ASRG) utilized a pair of Advanced Stirling Convertors (ASC). While flight development of the ASRG has been cancelled, much of the technology and hardware continued development and testing to guide future activities. Specifically, a controller for the convertor(s) is an integral part of a Stirling-based RPS. For the ASRG design, the controller maintains stable operation of the convertors, regulates the alternating current produced by the linear alternator of the convertor, provides a specified direct current output voltage for the spacecraft, synchronizes the piston motion of the two convertors in order to minimize vibration as well as manage and maintain operation with a stable piston amplitude and hot end temperature. It not only provides power to the spacecraft but also must regulate convertor operation to avoid damage to internal components and maintain safe thermal conditions after fueling. Lockheed Martin Coherent Technologies has designed, developed and tested an Engineering Development Unit (EDU) Advanced Stirling Convertor Control Unit (ACU) to support this effort. GRC used the ACU EDU as part of its non-nuclear representation of a RPS which also consists of a pair of Dual Advanced Stirling Convertor Simulator (DASCS), and associated support equipment to perform a test in the Radioisotope Power Systems System Integration Laboratory (RSIL). The RSIL was designed and built to evaluate hardware utilizing RPS technology. The RSIL provides insight into the electrical interactions between as many as 3 radioisotope power generators, associated control strategies, and typical electric system loads. The first phase of testing included a DASCS which was developed by Johns Hopkins UniversityApplied Physics Laboratory and simulates the operation and electrical behavior of a pair of ASCs in real time via a combination of hardware and software. Testing included the following spacecraft electrical energy storage configurations: capacitive, battery, and supercapacitor. Testing of the DASCS and ACU in each energy storage configuration included simulation of a typical mission profile, and transient voltage and current data during load turn-on/turn-off. Testing for these devices also included the initiation of several system faults such as short circuits, electrical bus over-voltage, under-voltage and a dead bus recovery to restore normal power operations. The goal of this testing was to verify operation of the ACU(s) when connected to a spacecraft electrical bus.

Dugala, Gina M.↗
DOE OSTI2025

Spin‐State and Clustering Effects in Fe‐Complex Negolytes for Near‐Neutral Aqueous Redox Flow Batteries

Cost-effective redox-active materials are essential for advancing redox flow batteries (RFBs). Iron, with its abundance and suitability as a redox couple, is a promising candidate; however, achieving stable and fast redox reactions in aqueous RFBs remains a challenge. Here, this study presents an Fe-based negolyte stabilized by a hexadentate ligand, where Fe–ligand bonds are enhanced through intermolecular interactions. The sulfonate-substituted Fe complex exhibits a formal potential of −0.44 V versus Ag/AgCl and an exceptionally high rate constant of 0.69 cm s −1 . Near-neutral RFBs incorporating 0.5 M Fe complex show excellent cycling stability, with no discernible capacity fading over 300 cycles. This performance is attributed to intermolecular hydrogen bonds that reinforce Fe–ligand coordination and promote the formation of stable trimeric clusters. Operando electrochemical Raman spectroscopy and density functional theory reveal that π-backdonation from Fe(II) to the imino-phenolate moiety further stabilizes the complex after reduction. In contrast, the hydroxyl-substituted complex exhibits inferior stability due to weaker hydrogen bonding and less pronounced π-backdonation. These findings underscore the importance of ligand design and intermolecular interactions in developing cost-effective, high-performance redox-active materials for aqueous RFBs.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Grid Resilient, Self-Powered, Fuel Flexible, High Efficiency Heating System (Final Report)

The Grid Independent High Efficiency System (GIHES) delivers a heating system that operates free from the power grid and provides ultra-low emissions and high efficiency heating for residential and commercial buildings. The project demonstrated two weeks of continuous grid independent operation of a storage water heater equipped with a powered damper. The Thermoelectric Generator (TEG) integrated GIHES technology revolutionizes heating systems to provide grid resilient hot water production, while delivering significant value to the end user by eliminating impacts of power interruption and enhancing comfort, convenience and productivity. The system maximizes the thermal-to-electric conversion efficiency by optimizing location and orientation of the TEGs and durability while lowering system costs. The TEGs generate enough power to charge a battery and run the storage water heater unit with a powered damper uninterrupted by providing the required parasitic electrical power for start-up, shutdown and during idling. Several TEGs were analytically and experimentally evaluated based on the size, surface area and the power being generated before designing and fabricating a complete multi-TEG assembly for integration with the water heater. The GIHES technology can be extended to boilers, furnaces and tankless water heaters and integrated with heat pump to further increase the overall equipment efficiency. The technology has the potential to reduce the amount of dispatch power and peak power plant operation. An advanced burner was designed, developed and 3D printed for fuel flexible operation. The burner was designed to enable tighter integration with TEGs for potentially higher TEG output, should this be necessary. A bench-scale test rig to perform testing of a 200,000 Btu/h burner and capable of handling up to 10% H2 (by volume) was setup at GTI’s laboratory with appropriate safety and controls to ensure smooth and safe operation. Testing of the 3D burner showed < 5 ppm NOx emissions can be achieved for the entire firing range and with different levels of hydrogen blends with natural gas. The burner will enable a more integrated TEG-burner module design for improved system performance, should this be required in the future. Techno-economic analysis (TEA) of the TEG integrated with the water heaters was performed. The testing data and the power output were used to develop the TEA. The analysis for the storage unit with damper showed that the TEG integrated system costs $95. This is much lower than a one-time charge needed to wire and install dedicated power. Discussions with TEG manufacturers and OEM’s will provide more detailed information and methods to further lower these costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

High-Mileage Courier Fleet Vehicle On-road Logger Data

This dataset describes the performance and fuel efficiency of AVTA test vehicles operating in commercial courier fleets the Phoenix, AZ metro area between 2010 and 2016. Aftermarket data loggers were installed in two to four vehicles of each of 30+ distinct year/make/models (see reference ["INL Advanced Vehicle Testing Activity: On-road Logger and Laboratory Battery Pack Testing Vehicle List"](https://avt.inl.gov/sites/default/files/pdf/reports/DatasetVehicleList.pdf) for full list of vehicles). Loggers recorded vehicle operation as they were driven up to 160,000 miles in up to three years of fleet testing. Parameters were logged at 1-second intervals, including - vehicle speed, - engine and/or electric motor speed, - fuel and/or electricity consumption, and - ambient temperature. This dataset includes both raw second-by-second data and trip-level metrics. (This dataset will be shared by API; a small sample of the vehicle and logger data has been extracted and is available for download while the API is being developed.)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2018

Advanced Stirling Convertor Control Unit Testing at NASA Glenn Research Center in the Radioisotope Power Systems System Integration Laboratory

Future NASA missions could include long-duration flyby, orbital, lander, or rover applications where generating power from sunlight may be limited. Radioisotope power systems (RPSs) provide a dependable power source for missions where inadequate sunlight or operational requirements make other power systems impractical. Over the past 16 years, NASA Glenn Research Center has been supporting the development of RPSs. The advanced Stirling radioisotope generator (ASRG) utilized a pair of advanced Stirling convertors (ASCs). Although flight development of the ASRG has been canceled, much of the technology and hardware continued development and testing to guide future activities. Specifically, a controller for the convertor(s) is an integral part of a Stirling-based RPS. For the ASRG design, the controller maintains stable operation of the convertors, regulates the alternating current produced by the linear alternator of the convertor, provides a specified direct-current output voltage for the spacecraft, and synchronizes the piston motion of the two convertors to minimize vibration as well as manage and maintain operation with a stable piston amplitude and hot-end temperature. It not only provides power to the spacecraft but also must regulate convertor operation to avoid damage to internal components and maintain safe thermal conditions after fueling. Lockheed Martin Coherent Technologies, Inc., has designed, developed, and tested an ASC control unit engineering development unit (ACU EDU) to support this effort. GRC used the ACU EDU as part of its nonnuclear representation of a RPS that also consists of a Dual advanced Stirling convertor simulator (DASCS), and associated support equipment to perform a test in the Radioisotope Power Systems System Integration Laboratory (RSIL). The RSIL was designed and built with flexibility to evaluate hardware utilizing RPS technology. The RSIL provides insight into the electrical interactions between as many as three radioisotope power generators, associated control strategies, and typical electric system loads. The first phase of testing included a DASCS that was developed by Johns Hopkins University Applied Physics Laboratory and simulates the operation and electrical behavior of a pair of ASCs in real time via a combination of hardware and software. Testing included the following spacecraft electrical energy storage configurations: capacitor, battery, and supercapacitor. Testing of the DASCS and ACU in each energy storage configuration included simulation of a typical mission profile and transient voltage and current data during load turnon and turnoff. Testing for these devices also included the initiation of several system faults such as short circuits, electrical bus overvoltage, undervoltage, and a "dead bus" recovery to restore normal power operations. The goal of this testing was to verify operation of the ACU(s) when connected to a spacecraft electrical bus. The results of these tests are presented here.

General↗
DOE OSTI2025

Multi-Functional Smart Structures for Smart Vehicles

This report summarizes the development of a new class of recyclable multi-functional composite materials for production of lightweight smart structures and surfaces. Functional high stiffness conductive composites were processed using molding methods that integrated continuous fiber and additively manufactured features. Methods for integration of sensing functionality and controls were also developed to reduce system cost while providing a new capability for structural health monitoring. This new class of composites is applicable to a broad range of vehicle interior, exterior and battery enclosure systems. By way of demonstration, a vehicle instrument panel cross car beam was developed that provided a 38% mass savings compared to steel while maintaining a cost penalty competitive to alternate lightweight material solutions. These technologies were validated for implementation by a uniquely qualified project team comprising a US automotive OEM, Tier 1 and Tier 2 supplier, with key contributions from Oak Ridge National Lab, Purdue University and Michigan State University.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Development of a High-Rate Lithium-Air Battery Using a Gaseous CO 2 Reactant

Li-air batteries are considered a potential alternative to Li-ion batteries for transportation applications due to their high theoretical specific energy. Most works in this area focus on use of O 2 as the reactant. However, newer concepts for using gaseous reactants (such as CO 2 , which has a theoretical specific energy density of 1,876 Wh/kg) provide opportunities for further exploration. The main objective of this project was the development of a novel strategy that enables operation of Li-CO 2 batteries at high-capacity and high-rate, with a long-cycle-life. The team was able to: (1) Synthesize two novel transition metal chalcogenide (TMC) catalysts that work in synergy with ionic liquid-based electrolytes to enhance the efficiency of reactions during discharge and charge processes; (2) Fabricate high-porosity cathode electrodes with 3D printing to increase electrode surface area and gas permeability; (3) Develop a multiscale modeling framework that integrates Density Functional Theory (DFT), Ab-Initio Molecular Dynamics (AIMD), classical Molecular Dynamics (MD), and Finite Element Analysis (FEA) to investigate atomic and cell-level properties of Li-CO 2 batteries; (4) Assemble a stackable Li-CO 2 pouch-cell able to deliver a capacity of >200 mAh. These achievements were realized through an integrated approach based on materials synthesis, testing, characterization, analysis, and computation. This project produced a thorough understanding of key chemical, electronic, and kinetic parameters that govern the operation of Li- CO 2 batteries in realistic conditions. The methodologies employed, and the insight generated, will be valuable beyond advancing the field of Li-CO 2 batteries

25 ENERGY STORAGE↗
DOE OSTI2025

Advanced Brine Processing to Enable U.S. Lithium Independence (CRADA Report)

Current production of LiOH, which is needed to make Li-ion battery cathode active materials, utilizes a multistep process including solar evaporation, precipitation with Na 2 CO 3 and then conversion to LiOH using Ca(OH) 2 . This process requires a large amount of land area for solar evaporation, the right weather conditions, and chemicals for the conversion process that result in NaCl and CaCO 3 waste products. The production of Ca(OH) 2 is very energy intensive and evolves significant quantities of CO 2 . An alternative process flow utilizing direct lithium extraction techniques, followed by a chemical free conversion process can have benefits in reducing the needed land requirements and chemicals for traditional brine processing. There are many potential direct lithium extraction technologies that are currently being developed. The direct lithium extraction process from typical brine sources will produce a LiCl solution with some impurities including typically high concentrations of Na. This brine then needs to be converted to LiOH for use in battery cathode production. Ideally this conversion could occur without the use of additional chemicals. Electrochemistry can do this conversion either via electrolysis or bipolar membrane electrodialysis (BPED) to produce LiOH and HCl in solution. BPED utilized bipolar membranes to split water, which has a reduced potential as compared to splitting water at electrodes into hydrogen and oxygen gas. This reduced potential required results in a significant energy savings for BPED over electrolysis methods. This CRADA project aimed to develop such an integrated process using direct lithium extraction followed by BPED to produce a LiOH solution. That solution can then be crystallized into battery grade LiOH. In particular, Albemarle utilized a direct lithium extraction process to produce a concentrated LiCl solution that could be used for the BPED process. The BPED process was first tested using various LiCl solutions with impurity ions added at bench scale to understand the effects of impurities and determine processing parameters. Then testing was performed using the direct lithium extracted brine at the bench scale before scaling the process up. After the process was scaled up a long duration test was carried out to estimate the lifetime of the membranes, which is key to the economics of the BPED process.

25 ENERGY STORAGE↗