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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Novel structured Sm 0.5 Sr 0.5 CoO 3-δ cathode for intermediate and low temperature solid oxide fuel cells

The performance of solid oxide fuel cell (SOFC) can be significantly enhanced using nanostructured cathode obtained by infiltration/impregnation method. However, this method has been limited due to multi-step preparation process and instability of the obtained nanoscale catalyst under long-term operation. We report here a simple, cost-effective and reproducible approach to fabricate nanostructured Sm 0.5 Sr 0.5 CoO 3-δ (SSC) cathode with enhanced performance and stability. The SSC powders were prepared by a freeze-drying method through a combustion route using Pluronic F-127 as the template. The SSC freeze-drying powders have unique morphology and a significant phase change at 750 °C. The oxygen non-stoichiometry (δ) of the SSC powders is 0.18 at room temperature, while the δ values are 0.66, 0.75 and 0.90 at 600 °C, 700 °C and 800 °C, respectively. The novel structured SSC cathode was prepared by screen-printing and one-step sintering process using the freeze-drying SSC powders. Maximum cell power densities of 0.83 and 1.13 W cm -2 are achieved at 550 °C and 600 °C, respectively for single cells with the novel structured SSC cathode. Moreover, single cells show excellent stability at 600 °C under a current density of 600 mA cm -2 over 250 h. This work expands opportunities to exploit nanotechnology in a wide range of intermediate and low temperature energy conversion devices.

25 ENERGY STORAGE↗
DOE OSTI2026

Achieving high rate performance in hybrid pristine-recycled cathodes using model-informed electrode designs

Direct recycling lithium-ion battery cathodes, a process that retains the engineered oxide structures from end-of-life materials, presents a cost-effective and energy-efficient alternative to other battery recycling methods. However, while direct-recycled cathodes have demonstrated performance comparable to that of pristine materials at low cycling rates, their high-rate performance remains uncertain. Morphology changes in cathode particles, a main mode of degradation, directly impact rate performance by limiting surface kinetics and solid-phase diffusion. If direct recycling processes do not sufficiently restore pristine-like morphologies, the recycled materials may retain structural defects that hinder high-rate performance. The present work uses a physics-based pseudo-2D model to simulate hybrid electrodes with pristine and artificially “aged/recycled” NMC materials to investigate potential impacts of incorporating performance-limited aged cathode materials into cells. The study highlights how differences in transport and kinetic properties can influence rate capabilities in mixed electrodes — particularly in high-loading cells in high-demand applications. However, model results also reveal a possible mitigation strategy via dual-layer electrode architectures with lower-performing materials positioned near the current collector. Simulations of 4.0 mAh cm −2 cells cycled at 4C using a dual-layer architecture provided approximately 5%–30% more capacity in constant-current protocols compared to homogeneously blended electrode architectures with the same loadings and mixed-material compositions. These findings highlight the importance of strategic electrode design in minimizing potential performance losses and facilitating the integration of recycled materials into high-performance batteries, advancing sustainable and cost-effective battery manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2025

Polyanion-type iron-based sulfate cathode materials: From fundamental research to industrialization

Sodium-ion batteries (SIBs) with the merits of abundant sodium resources and low cost are considered significant supplements to lithium-ion batteries in large-scale energy storage systems. Among the discovered cathode materials for SIBs, iron-based sulfate materials have attracted widespread attention due to their high operating voltage, superior structural stability, and high safety. Here, in this review, we summarize the research achievements of iron-based sulfate cathode materials in fundamental research, as well as provide a comprehensive overview of its industrialization progress for the first time. Meanwhile, effective modification strategies (including morphology design, hybridization with carbon materials, and construction of heterostructure) and further research directions to boost the sodium storage performance of iron-based sulfate cathode materials are also proposed. This review can provide valuable guidance for developing high-performance iron-based sulfate cathode materials for practical application.

cathode materials↗
DOE OSTI2018

Infiltrated Sr 0.9 Y 0.1 CoO 2.5+δ nanoparticles as a cathode material for solid oxide fuel cells operated at 450–650 °C

Catalytically active cathode materials are highly desirable for the development of low-temperature solid oxide fuel cells (LT-SOFCs). In the present study, we report the performance of a high-loading Sr 0.9 Y 0.1 CoO 2.5+δ (SYC10) nanoparticles (NPs) as a catalytic cathode infiltrated in Ce 0.8 Gd 0.2 O 2-δ (GDC) backbones for LT-SOFCs and the use of a low-loading SYC10 NPs as a catalyst for promoting the performance of a commercial cathode. The loading and calcination temperature of SYC10 NPs were systematically optimized to achieve the lowest area-specific polarization resistance at ≤650 °C. A significant reduction in polarization resistance of commercial LSCF cathode by SYC NPs has also been demonstrated at 650 °C.

08 HYDROGEN↗
DOE OSTI2017

Cost and energy demand of producing nickel manganese cobalt cathode material for lithium ion batteries

The price of the cathode active materials in lithium ion batteries is a key cost driver and thus significantly impacts consumer adoption of devices that utilize large energy storage contents (e.g. electric vehicles). A process model has been developed and used to study the production process of a common lithium-ion cathode material, lithiated nickel manganese cobalt oxide, using the co-precipitation method. The process was simulated for a plant producing 6500 kg day –1 . The results indicate that the process will consume approximately 4 kWh kg NMC –1 of energy, 15 L kg NMC –1 of process water, and cost $23 to produce a kg of Li-NMC333. The calculations were extended to compare the production cost using two co-precipitation reactions (with Na 2 CO 3 and NaOH), and similar cathode active materials such as lithium manganese oxide and lithium nickel cobalt aluminum oxide. Finally, a combination of cost saving opportunities show the possibility to reduce the cost of the cathode material by 19%.

25 ENERGY STORAGE↗
DOE OSTI2016

A new composite cathode for intermediate temperature solid oxide fuel cells with zirconia-based electrolytes

Improving the electrocatalytic activity of electrode materials is vitally important to achieve practically meaningful performance for intermediate temperature solid oxide fuel cells (IT-SOFCs). Here the present work develops a composite cathode consisting of an electronic conductor Sr-doped LaMnO 3 (LSM) and an ionic conductor Y- and Ce- co-doped Bi 2 O 3 (BYC7). BYC7 is an excellent oxide-ion conductor, exhibiting a high and stable ionic conductivity of 0.008 S cm -1 at 500 °C. The polarization resistance of LSM-BYC7 cathode in a symmetrical cell with doped ZrO 2 as electrolyte varies from 5.76 at 500 °C to 0.25 Ω cm 2 at 650 °C. The surface diffusion and charge transfer at the triple phase boundaries are the rate determining steps based on the dependence of polarization resistance on partial pressure of oxygen. The maximum power density of a ZrO 2 -based anode-supported cell with LSM-BYC7 composite cathode is 56.4, 154.6, 327.9, and 451.0 mW cm-2 at 500, 550, 600, and 650 °C respectively. AC impedance analysis reveals that the performance of IT-SOFC prepared in this study is actually limited by the anode, not by LSM-BYC7 cathode.

25 ENERGY STORAGE↗
DOE OSTI2019

Development of manganese-rich cathodes as alternatives to nickel-rich chemistries

High-energy, inexpensive and safe electrochemistries have been the main goals of lithium-ion battery research for many years. Historically, manganese-based cathodes have long been studied for their attractive cost and safety characteristics [1]. However, due to issues related to both surface and bulk instabilities, manganese-rich electrodes have yet to find substantial success in the high-energy lithium-ion battery market. With current trends in cathode chemistries leaning heavily toward Ni-rich compositions, the factors of cost and safety are again at the forefront of research and development efforts. This paper reports the recent progress made at Argonne National Laboratory (USA) to stabilize manganese-rich cathode structures and surfaces with a specific focus on composite materials with intergrown layered and spinel components; it presents an overview of their electrochemical properties in terms of capacity, energy, and cycle-life in cells with metallic lithium, graphite, and Li 4 Ti 5 O 12 anodes. These layered-spinel cathodes show promise as alternatives to highly nickel-rich electrode compositions, which bodes well for continued advances.

25 ENERGY STORAGE↗
DOE OSTI2019

Structural underpinnings of cathode protection by in situ generated lithium oxyfluorophosphates

The in situ strategy of cathode protection opportunistically uses PF$_6^-$ anions in electrolyte as chemical reagents to convert inactive precursor molecules to active electrolyte additives. With our approach, a bifunctional x(SiMe 3 ) 2 precursor replaces fluoride in the hexafluorophosphate, forming either a bidentate monoanion P(x)F$^-_4$ or a linear x(PF$_5^-$) 2 dianion, depending on the bridge $x$ (e.g., oxalato, malonato, succinato, and catecholato). While the efficiency of these species as cathode protective agents has been demonstrated, the mechanism for their beneficial action remains unknown. In this study, several molecular precursors have been synthesized, and the topology and energetics of secondary anions were correlated with their cycling performance. Regardless of their structural motif, all such additives demonstrated improved electrochemical performance by reducing initial cathode impedance and lowering the rate of capacity fade compared to the baseline electrolyte. However, we note bidentate monoanions with a malonato bridge showed significant advantage over other molecular designs for mitigating the impedance rise, suggesting that structural strain in the anion is important for easing surface modification of the cathode.

25 ENERGY STORAGE↗
DOE OSTI2020

LiNi x Fe y Al z O 2 , a new cobalt-free layered cathode material for advanced Li-ion batteries

Recently, rapid fluctuations in cobalt prices have created a worsening supply chain constraint that has become a serious cause of concern amidst global battery manufacturers. To address this challenge, we report herein a new class of cobalt-free, nickel-rich layered cathode material termed the NFA class with general formula LiNi x Fe y Al z O 2 (x + y + z = 1). Using co-precipitation reaction in a continuous stirred tank reactor, we synthesized NFA(OH) 2 precursors with the constituent Ni, Fe and Al elements successfully incorporated. The obtained LiNFAO 2 cathode was characterized using X-Ray diffraction, Mössbauer spectroscopy and scanning electron microscopy. Electrochemical behavior was assessed using cyclic voltammetry, galvanostatic charge/discharge, electrochemical impedance spectroscopy and galvanostatic intermittent titration technique at various states of lithiation/delithiation. Electrochemical performance evaluations revealed that our cobalt-free material delivers high capacity of 190 mAh/g at 0.1C. Rate and cycling performance evaluations also indicated good rate capability and cycling stability with 88% capacity retention after 100 cycles at C/3. Using NFA cathodes, we also fabricated a 0.5Ah (C/3) cobalt-free Li-ion battery which demonstrated reasonable cycling stability with ~72% capacity retained after 200 cycles. Overall, our work demonstrates the immense potential of the cobalt-free NFA class cathodes as viable candidates towards development of next generation cost effective lithium ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2021

Quantifying the Influence of Charge Rate and Cathode-Particle Architectures on Degradation of Li-Ion Cells Through 3D Continuum-Level Damage Models

In this article, we develop a 3D, continuum-level damage model implemented on statistically generated LiNi 0.5 Mn 0.3 Co 0.2 O (NMC 532) secondary cathode particles. The primary motivation of the particle-level model is to inform cathode-particle design through detailed exploration of the influence of secondary and primary particle sizes on the damage predicted during operation, and determine charging profiles that reduce cathode fracture. The model considers NMC 532 secondary particles containing an agglomeration of anisotropic, randomly oriented grains. These brittle, Ni-based cathodes are prone to mechanical degradation, which reduces overall battery cycle life. The model predicts that secondary-particle fracture is primarily due to non-ideal grain interactions and high-rate charge demands. The model predicts that small secondary-particles with large grains develop significantly less damage than larger secondary particles with small grains. The model predicts most of the chemo-mechanical damage accumulates in the first few cycles. The chemo-mechanical model predicts monotonically increasing capacity fade with cycling and rate. Comparing to experimental results, the model is well suited for capturing initial capacity fade mechanisms, but additional physics is required to capture long-term capacity fade effects.

25 ENERGY STORAGE↗
DOE OSTI2026

Developing cathode infiltration processes for all-solid-state bilayer LLZO cells

To realize the bilayer architecture of lithium lanthanum zirconate (LLZO) for application in solid-state batteries (SSBs), the scaffold structure must be optimized, and effective cathode infiltration strategies must be established. In this study, we fabricate a modified bilayer LLZO using a sacrificial layer to enhance surface porosity, and systematically investigate various cathode infiltration techniques to fill the scaffold with oxide cathode active materials (CAM). Structural characterizations showed that the sacrificial layer significantly increased open surface porosity, enabling the surface of the scaffold to be filled with CAM. To further increase infiltration depth, applying vacuum or vibration was compared, with the full-depth infiltration achieved using a sonicator-based vibration. Full cells prepared using the modified bilayer LLZO and vibration-assisted technique demonstrated successful operation. This work demonstrates a practical and scalable approach for engineering bilayer LLZO structures and integrating oxide cathodes into porous scaffolds, offering a promising pathway toward high-performance solid-state batteries.

Bilayer↗
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 OSTI2016

Solid state cathode materials for secondary magnesium-ion batteries that are compatible with magnesium metal anodes in water-free electrolyte

With high elemental abundance, large volumetric capacity, and dendrite-free metal deposition, magnesium metal anodes offer promise in beyond-lithium-ion batteries. However, the increased charge density associated with the divalent magnesium-ion (Mg{sup 2+}), relative to lithium-ion (Li{sup +}) hinders the ion-insertion and extraction processes within many materials and structures known for lithium-ion cathodes. As a result, many recent investigations incorporate known amounts of water within the electrolyte to provide temporary solvation of the Mg{sup 2+}, improving diffusion kinetics. Unfortunately with the addition of water, compatibility with magnesium metal anodes disappears due to forming an ion-insulating passivating layer. In this short review, recent advances in solid state cathode materials for rechargeable magnesium-ion batteries are highlighted, with a focus on cathode materials that do not require water contaminated electrolyte solutions for ion insertion and extraction processes. - Graphical abstract: In this short review, we present candidate materials for reversible Mg-battery cathodes that are compatible with magnesium metal in water-free electrolytes. The data suggest that soft, polarizable anions are required for reversible cycling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Effect of transition metal composition on electrochemical performance of nickel-manganese-based lithium-rich layer-structured cathode materials in lithium-ion batteries

To evaluate the effect of transition metal composition on the electrochemical properties of Li-rich layer-structured cathode materials, Li{sub 1.2}Ni{sub x}Mn{sub 0.8−x}O{sub 2} (x=0.2, 0.25, 0.3, and 0.4) were synthesized, and their electrochemical properties were investigated. As nickel content x increased in Li{sub 1.2}Ni{sub x}Mn{sub 0.8−x}O{sub 2} (x=0.2, 0.25, 0.3, and 0.4), charge-discharge capacities at a low C-rate (0.05 C) decreased. The results obtained by dQ/dV curves indicate that, as the nickel content increased, the discharge capacity below 3.6 V greatly decreased, but that above 3.6 V increased. As the C-rate of the discharge process increased, the discharge reaction of Li{sub 1.2}Ni{sub x}Mn{sub 0.8−x}O{sub 2} (x=0.2) below 3.6 V greatly decreased. In contrast, that above 3.6 V slightly decreased. This indicates that the discharge reaction above 3.6 V exhibits higher rate performance than that below 3.6 V. For the high-nickel-content cathodes, the ratio of the discharge capacity above 3.6 V to the total discharge capacity was high. Therefore, they exhibited high rate performance. - Graphical abstract: Figure shows the discharge curves of Li{sub 1.2}Ni{sub x}Mn{sub 0.8−x}O{sub 2} (x=0.2 and 0.3) within potential range of 2.5−4.6 V (vs. Li/Li{sup +}) at 0.05 and 3 C. At low C-rate (0.05 C), the discharge capacity of high-nickel-content cathode (Li{sub 1.2}Ni{sub 0.3}Mn{sub 0.5}O{sub 2}) was less than that of low-nickel-content cathode (Li{sub 1.2}Ni{sub 0.2}Mn{sub 0.6}O{sub 2}); however, the discharge potential and capacity of Li{sub 1.2}Ni{sub 0.3}Mn{sub 0.5}O{sub 2} was higher than those of Li{sub 1.2}Ni{sub 0.2}Mn{sub 0.6}O{sub 2} at high C-rate (3 C). This means that the increase in Ni/Mn ratio was effective in improving rate-performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Synthesis of MnO{sub 2}/C composite nanotubes as advanced cathode of supercapacitors

Graphical abstract: Self-supported porous MnO{sub 2}/C nanotube arrays are prepared by combined hydrothermal plus carbonization methods and demonstrated with high capacitance and good cycling life as cathode of supercapacitors. - Highlights: • MnO{sub 2}/C nanotube arrays are synthesized by a hydrothermal method. • MnO{sub 2}/C nanotube arrays show good high-rate performance. • MnO{sub 2}/C nanotube arrays show an excellent cycling performance. - Abstract: Controllable synthesis of high-capacity cathode is the research hotspot in the field of supercapacitors. In this work, with the help of sacrificial ZnO template, MnO{sub 2}/C nanotube arrays are formed by hydrothermal synthesis plus glucose carbonization. MnO{sub 2}/C composite nanotubes of 120–130 nm are formed and grow vertically to the substrate forming the final nanotube arrays. Fast ion/electron transfer is realized in this unique porous nanotube architecture. As cathode of supercapacitors, the MnO{sub 2}/C nanotube arrays exhibit high specific capacitance (790 F g{sup −1} at 5 A g{sup −1}), excellent rate performance (570 F g{sup −1} at 30 A g{sup −1}) and long-term cycling stability (90.7% capacitance retention after 20,000 cycles). The proposed electrode construction strategy is favorable for fabrication of other capacitive cathodes for energy storage.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Slug-flow synthesis of NCMA: Effect of substitution of cobalt with aluminum on the electrochemical performance of Ni-rich cathode for lithium-ion battery

Nickle-rich Li[Ni 1-x-y Co x Mn y ]O 2 (x, y≤0.1) (NCM) layered materials are known as promising cathode materials for next-generation lithium-ion batteries and electric vehicles owing to their high-reversible capacity and operating voltage of up to 3.6 vs Li/Li + . However, issues, such as irreversible phase transition, cation mixing, microcrack formation, thermal and structural stability of the material prevent its widespread adoption. Although, cation doping is a well-known technique to enhance the electrochemical performance of the NCM-based cathode material, the performance of the material is very sensitive to the doping amount. In this study, three Al-doped quaternary Ni-rich cathode materials Li[Ni 0.85 Co (0.1-x) Mn 0.05 Al x ]O 2 (where, x=0–0.04) (NCMA) are synthesized through three-phase slug-flow based continuous manufacturing process followed by high temperature calcination to study the effect of Aldoping on the performance of the cathode material while reducing Co. The slug flow-based production platform has several advantages, like particle size uniformity, high production rate, and homogeneity in elemental distribution. It is found that with an increase in Al content, the specific capacity decreases but the cyclic stability and rate capability increases. Furthermore, optimum Al-doping not only compensates for the adverse effect of low Co by decreasing the extent of cation mixing, but it also minimizes the electrode polarization and cracking of the particles.

25 ENERGY STORAGE↗
DOE OSTI2024

Na 4 Fe 1.5 Mn 1.5 (PO 4 ) 2 (P 2 O 7 ): A low-cost and earth-abundant cathode for robust sodium storage

The mixed compounds of phosphates and pyrophosphates are attractive cathodes for sodium-ion batteries (SIBs) owing to their robust open framework structure and superior diffusion dynamics. However, most reported mixed phosphate cathodes generally suffer from low operating potential. Herein, we develop a bimetallic Na 4 Fe 1.5 Mn 1.5 (PO 4 ) 2 (P 2 O 7 )/C-rGO (NFMPP/C-rGO) cathode, which possesses two working plateaus at 2.92 and 3.95 V. The obtained NFMPP/C-rGO demonstrates a stable high capacity of over 120 mAh g −1 at 0.1 C. In-situ XRD characterization discloses a solid solution reaction for the Fe 2+/3+ redox couple and a two-phase reaction for the Mn 2+/3+ redox couple. In conclusion, first-principles calculations reveal the migration of Na + in NFMPP has low barriers. This work provides a new, low-cost, earth-abundant, and stable cathode choice for practical SIBs.

Cathode materials↗
DOE OSTI2020

Interfacial engineering for stabilizing polymer electrolytes with 4V cathodes in lithium metal batteries at elevated temperature

Poly (ethylene oxide) (PEO) polymer electrolytes are promising candidates for next-generation rechargeable lithium batteries. However, the poor interfacial stability between 4 V cathodes and PEO electrolytes impedes their applications in 4 V lithium batteries with high energy density. Here, we demonstrate a facile and effective strategy to enhance the interfacial stability by the synergy of Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP) coating on the cathode surface, and salt combination in the electrolyte, even with a cut-off voltage of 4.25–4.4 V vs. Li + /Li. Nano-LAGP coated Li|PEO|LiCoO 2 cell delivers stable cycling with a capacity retention of 81.9%/400 cycles and 84.7%/200 cycles at 60 °C when charged to 4.25 and 4.3 V in pure polyether electrolyte, respectively. Steady cycling is also demonstrated at room temperature and with LiNi 0.5 Co 0.2 Mn 0.3 O 2 (NCM523) cathode. This work offers a viable and scalable approach to improve the stability between PEO electrolytes and 4 V cathodes and open up new possibilities for practical application of 4 V lithium metal batteries.

25 ENERGY STORAGE↗