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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Impact of Testing Method on Safety Assessment of Aged Li-Ion Cells: Part II – Aged Cells Without Li Plating

Understanding the safety profile of aged Li-ion batteries is essential for developing effective battery management and hazard mitigation strategies. However, most safety assessments have focused on fresh batteries, with just a few calorimetry studies on aged batteries with metal oxide positive electrodes. This study provides a broad assessment of commercial 18650-type Li-ion batteries with NCA, NMC, and LFP positive electrodes, both uncycled and aged under conditions that promoted solid electrolyte interphase (SEI) growth as the dominant degradation mechanism. The cells underwent mechanical (nail penetration, crush), electrical (overcharge, overdischarge), and thermal (accelerating rate calorimetry) abuse tests. Safety was rated on general characteristics such as mass loss, maximum temperature, and EUCAR (European Council for Automotive R&D) hazard level, as well as characteristics specific to individual abuse tests. Generally, aged cells with SEI growth exhibited similar or improved safety compared to uncycled cells, contrasting with our previous findings on NCA cells with Li plating as the dominant aging mechanism (Part I of this series). Yet, some tests and characteristics indicated reduced aged cell safety, such as earlier triggering of mechanical failure. These results emphasize the need to examine aged battery safety across diverse empirical techniques, degradation modes, and chemistries.

Lithium-ion cells↗
DOE OSTI2025

Mechanically induced thermal runaway severity analysis of Li-ion batteries and continuous energy release monitoring

The large-scale deployment of Li-ion batteries in stationary energy storage and electrical vehicle applications demands a strong focus on safety, particularly on the thermal runaway risk and severity evaluation. A standardized single-side mechanical indentation test protocol was developed to induce an internal short-circuit (ISC) and evaluate cells' thermal runaway severity at different state of charge (SOC). The observed hazard severity (OHS in five categories) and evaluated scores in this work have a comprehensive consideration of each cell's capacity, initial voltage, SOC, temperature and voltage change, allowing a better evaluation of the cells' thermal runaway potential. This method was applied to about 200 Li-ion batteries in order to build an extensive thermal runaway database covering various SOCs, capacities and chemistries. In this study, we monitored the transitions of stored electrochemical energy and applied mechanical energy into both thermal energy and acoustic emissions (AE). The surface temperature and mechanical failures were monitored by infrared imaging and AE to capture critical events within battery cells throughout the mechanical indentation tests. Furthermore, the initial temperature maps can predict two types of follow-up events: thermal runaway or gradual heat release via conduction. Analyzing each cell's severity, AEs, and leveraging the evolving database offer insights into predicting occurrences of thermal runaway. The test method, thermal runaway severity evaluation and prediction, and the corresponding database provide battery designers, manufacturers, and end-users a clear overview of Li-ion batteries' thermal runaway potential under mechanical abuse, advancing the safety design of Li-ion batteries.

Acoustic emission↗
DOE OSTI2025

Control Strategies and Validation in the Hybrid Optimization and Performance Platform (HOPP)

The Hybrid Optimization and Performance Platform (HOPP) is a tool that simulates hybrid power plants in various configurations, and also calculates the financial feasibility of these plants. This report outlines an overview of HOPP and the energy storage dispatch strategies available. It then presents three case studies which demonstrate different applications of HOPP. The first case looks at the profitability of hybrid power plants in different locations in the USA. The second case examines the availability of hybrid power plants to provide energy reliability services. The third case presents a plant that produces both hydrogen and electricity, and demonstrates a dispatch strategy that chooses the most profitable energy vector based on price signals. The next section shows the validation of HOPP on operational data, using data from both unit-scale and utility-scale power plants. This validation process demonstrated that HOPP can simulate the power output of both wind and solar PV plants at both scales with comparable fidelity to an existing commercial software tool. Finally, HOPP is applied in a field test which applies an optimal dispatch strategy to a physical battery in a unit-scale hybrid plant at NREL. HOPP's optimal dispatch strategy, applied in a real-world setting, improved this hybrid plant's ability to meet a load signal while minimizing operational costs.

14 SOLAR ENERGY↗
DOE OSTI2024

Investigation of Fe-Ni Battery/Module for Grid Service Duty Cycles

Iron–nickel (Fe-Ni) batteries are renowned for their durability and resilience against overcharging and operating temperatures. However, they encounter challenges in achieving widespread adoption for energy storage applications due to their low efficiency and the need for regular maintenance and electrolyte replacement, which adds to maintenance costs. This study evaluates and demonstrates the capabilities of Fe-Ni batteries for participating in grid energy storage applications. Stable performance was observed frequency regulation (FR) testing at 100% and 50% state of charge (SOC)s, while at 50% SOC, there was a 14% increase in efficiency compared to 100% SOC. Although 25% SOC achieved higher efficiency, limited cyclability was observed due to reaching the discharge cutoff voltage. Optimal SOC selection, battery monitoring, maintenance, and appropriate charging strategies of Fe-Ni batteries seem to be crucial for their FR applications. Fe-Ni batteries exhibit stable peak shaving (PS) results, indicating their suitability and reliability under various load conditions for PS testing. Extended cycling tests confirm their potential for long-term grid-scale energy storage, enhancing their appeal for PS and FR applications.

25 ENERGY STORAGE↗
DOE OSTI2026

MAT 332: Recyclable-By-Design Carbon Fiber Composites for Battery Enclosures

This work aims to fabricate a small-scale battery module with the baseline RBD-CFRC and conduct mechanical crush test to develop an initial thermal runaway model. Test the adhesive properties of the RBD-CFRCs using their resin constituent, ultrasonic welding, and other resins employed today. Recommend a future direction for resin development to enable the welding of RBDCFRCs to dissimilar materials. Time and Cost Permitting. Iterate on resin development for flame resistance and adhesive properties, demonstrating how thermal runaway can be reduced or joining properties can be improved.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Effects of ambient temperature on electric vehicle range considering battery Performance, powertrain Efficiency, and HVAC load

Here, this study investigates the impact of ambient temperature on the range of electric vehicles (EVs) by analyzing its effects on usable battery energy (UBE), heating, ventilation, and air conditioning (HVAC) energy consumption, and powertrain energy losses. Chassis dynamometer tests within a thermal chamber were conducted under various temperature conditions to investigate these impacts. The results indicate that lower temperatures lead to a decrease in UBE for lithium-ion batteries in EVs. At −18 °C, the UBE exhibited reductions of 4---8 % compared to the UBE at 22 °C. Battery thermal management strategies significantly affected the UBE loss, with different strategies resulting in distinct UBE reductions. HVAC energy consumption, especially for interior heating, proved to be the most dominant variable affecting EV driving range. Larger discrepancies between the HVAC target temperature (22 °C) and the ambient temperature increased HVAC energy usage. The type of HVAC system also influenced energy consumption, where EVs equipped with heat pumps demonstrated lower energy consumption for heating compared to those relying solely on resistance heaters. Ambient temperature also influenced motor energy consumption due to increased frictions, powertrain losses and tire rolling resistance at lower temperatures; consequently, regenerative braking energy decreased in cold conditions. Combining these effects influenced the overall energy consumption and driving range of EVs. At −18 °C, the driving range saw a substantial decrease of up to 60 % compared to 22 °C, while a slight decrease was observed at 35 °C.

Ambient Temperature↗
DOE OSTI2025

Metallicity, Atomic Disorder, and Li-Ion Storage in Fast-Charging Anodes

Oxides of Nb with Wadsley-Roth shear structures comprise a family of stable, high-rate anode materials for Li-ion batteries. A particular pair of them offers the unusual opportunity to test how important metallic conduction of the starting electrode is for electrode performance. The selected pair of compounds with similar 4 × 3 Wadsley-Roth block structures are insulating Ti 2 Nb 10 O 29 and metallic Nb 12 O 29 . A combination of diffraction, electrochemistry, magnetic measurements, and entropic potential measurements is employed to establish key findings for these two anode materials. We find that starting with a metallic oxide is not especially advantageous over a comparable material that readily transitions into a metallic state upon lithiation. Second, the rate performance appears to be dictated by ion mobility, and atomic Ti/Nb disorder in Ti 2 Nb 10 O 29 contributes to improved capacity retention at high rates by suppressing Li-ion ordering. However, subtle details in the nature of redox processes make Nb 12 O 29 a slightly better electrode material for long-term cycling at slower rates.

crystal structure↗
DOE OSTI2026

Design and simulation of a muon detector to characterize geological overburden

This study presents the design, construction, and simulation of a mobile muon detector tailored for geological overburden characterization. The detector employs plastic scintillator paddles with silicon photomultipliers (SiPMs) and a QuarkNet data acquisition system, offering a portable solution suitable for remote field deployment. The simulator’s modular aluminum frame allows for adjustable geometry and directional sensitivity, while its battery system supports over a week of autonomous operation. Preliminary experimental tests confirmed that its muon flux measurements were consistent with theoretical expectations. A comprehensive simulation framework using Geant4 and CORSIKA was developed to model detector response and overburden effects. Analytical and Monte Carlo methods were used to assess quadrant resolution and infer muon directionality. This work lays the foundation for future overburden mapping and supports the development of reconstruction algorithms for geological applications.

72 - PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Wholesale Electricity Analysis via Simulation & Learning Experiments (WEASLE): Platform Development and Pilot Competition

This document reports the development of the Wholesale Electricity Analysis via Simulation and Learning Experiments (WEASLE) platform and the pilot competition that was conducted to test the platform. Due to the increasing reliance on variable renewable energy resources for bulk power, the pilot competition, called the Energy Storage Participation Algorithm Competition (ESPA-Comp), was used to test the effect of various market designs on storage utilization and market efficiency. Basic details of the platform are provided, including an overview of the market clearing engine, the battery dispatch and degradation models, electric grid topology and resource mix, and software architecture. Two market designs were tested: a two-settlement market analogous to typical ISO design today, and a multi-settlement market that allows additional forward-trading periods during the real-time market. Results from the pilot competition show that the storage bidding problem is nontrivial and is well suited for future challenges. We find that: 1) all four teams utilized different approaches to the bidding problem, 2) different methodological approaches led to substantially different offer behaviors, 3) resource profits are clustered by team and methodological approach, 4) simulated offers reduced market surplus by about 0.5%, 5) substantially different prices between two-settlement and multi-settlement markets albeit minimal difference in overall market surplus.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Lithium-Ion Battery Design for Grid-Scale Energy Storage App

A software that delivers parameters from energy storage system (ESS) to container, rack, module and single cell design, as well as data analysis on arbitrage energy and frequency regulation of ESS in different regions, has been developed. The Lithium-ion Battery Design for Grid-scale Energy Storage App V1.0 has the capability to output the system, module and cell design with the energy, power, capacity, group method, cost of single cell, and single cell test protocol which break down from input energy storage system data in different regions. The default chemistry of the battery is LiFePO4 and graphite. The energy density of the graphite/LiFePO 4 pouch cell ranges from 100 Wh/kg to 200 Wh/Kg in the software. Graphite/LiFePO 4 pouch cell (up to 1Ah in lab) manufacturing line is also built and can be used to evaluate the test protocol, moreover, for electrolyte evaluation in other ESMI seedling projects. The software enables rapid prototyping to accelerate energy storage research, development, and manufacturing.

Liu, Dianying [Pacific Northwest National Laborato↗
DOE OSTI2025

Navigating thermal stability intricacies of high-nickel cathodes for high-energy lithium batteries

High-nickel oxide cathodes, LiNi x M 1−x O 2 (x ≥ 0.8), are preferred in automotive lithium batteries, but they face thermal instability challenges. Inconsistent literature reports and unstandardized testing protocols further complicate quantitative assessments of the thermal stability of these cathodes. Here, we present here a statistical thermal analysis based on the differential scanning calorimetry measurements of 15 representative cathode materials with different compositions, morphologies and states of charge. The findings reveal that each cathode has a critical state of charge that defines its safe operating limit, which is affected by the metal–oxygen bond strength and surface reactivity. The thermal runaway temperature is dictated by the layered Li 1−x NiO 2 to LiNi 2 O 4 spinel-like phase transition, which is thermodynamically determined by the metal–oxygen bond covalency and kinetically influenced by the cation mixing and particle size. Raman spectroscopy is used to predict the thermal runaway temperature on the basis of the linear relationship between them. Finally, we propose a thermal stability index to quantify cathode thermal stability as a guide for developing safer high-nickel cathodes.

batteries↗
DOE OSTI2024

EchemAMR (electro-chemical microsctructure scale models with adaptive meshing) [SWR-23-111]

A 3D microstructure resolving electrochemical transport and interfacial chemistry solver. Electrode microstructure plays an important role in determining the performance of an electrochemical system, e.g. lithium ion battery. EchemAMR is a microstructure scale model that solves the governing equations for ion transport, electrical current continuity, interfacial chemistry and structural mechanics. Complex microstructure geometries from imaging can be directly imported into EchemAMR. A volume fraction based description of the geometry on Cartesian grid with an immersed interface formulation enables simplified meshing and large-scale simulations with millions of degrees of freedom. EchemAMR has been tested against systems with analytic solutions for numerical convergence and highly resolved lithium ion battery microstructures. EchemAMR demonstrates excellent mass conversation and efficient scaling on heterogenous High-Performance Computing (HPC) with central and graphics processing units.

Sitaraman, Hariswaran↗
DOE OSTI2025

200 h of discharge cycling with an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) offer an approach to energy storage and electricity generation by harnessing low-grade heat (T < 150 °C). A TRAB discharge resembles that of a flow battery, where electrochemical reactions produce electrical power from energy stored within aqueous electrolytes. While there are many types of TRABs, the all-aqueous copper TRAB (Cu aq -TRAB) has produced the largest power and energy storage densities. Despite many improvements to TRAB performance, most tests have only lasted a few hours, which are not representative of operation times expected of these devices. Herein, we operated a Cu aq -TRAB for 200 h of constant current discharging to assess battery performance and component stability. After 200 h of testing, the average power density increased slightly to 7.2 mW cm -2 , which was within 0.01 % of starting conditions. Likewise, the average energy density for the final cycle was only 0.03 % lower than the initial cycle. The overall insensitivity of the power cell to cycling represents a major milestone in the advancement of TRAB systems. In conclusion, energy dispersive X-ray spectroscopy provides evidence to suggest that these small changes in power and energy density are likely to the membrane acclimating to TRAB electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2025

Theory of Cation Solvation in the Helmholtz Layer of Li-Ion Battery Electrolytes

The solvation environments of Li + in conventional nonaqueous battery electrolytes, such as LiPF 6 in mixtures of ethylene carbaronate (EC) and ethyl methyl carbonate (EMC), are often used to rationalize transport properties and solid electrolyte interphase (SEI) formation. Solvation environments in the compact electrical double layer (EDL) next to the electrode, also known as the Helmholtz layer, determine (partially) what species can react to form the SEI, with bulk solvation environments often being used as a proxy. Here, we develop and test a theory of cation solvation in the Helmholtz layer of nonaqueous Li-ion battery electrolytes. First, we validate the theory against bulk and diffuse EDL atomistic molecular dynamics (MD) simulations of LiPF 6 EC/EMC mixtures as a function of surface charge, where we find the theory can qualitatively capture the solvation environments. Next, we turn to the Helmholtz layer, where we find the main effect of the solvation structures next to the electrode is an apparent reduction in the number of binding sites between Li + and the solvents, again where we find reasonable agreement with our developed theory. Finally, by solving a simplified version of the theory, we find that the probability of Li + binding to each solvent remains equal to the bulk probability, suggesting that the bulk solvation environments are a reasonable place to start when understanding battery electrolytes. Our developed formalism can be parametrized from bulk MD simulations and used to predict the solvation environments in the Helmholtz layer through reducing the number of available coordination sites, which can be used to determine what could react and form the SEI.

Helmholtz↗
DOE OSTI2024

Microscale mechanical property variations of Al-substituted LLZO: insights from compression testing and molecular dynamics simulations

Ceramic solid electrolytes based on LLZO (Li 7 La 3 Zr 2 O 12 ) are promising candidates for all-solid-state batteries due to their high ionic conductivity and good apparent stability vs. lithium metal, however they are prone to mechanical failure. Lithium metal intrusions, alongside cell stack pressure, transition polycrystalline solid electrolyte grains into a compressed state that promotes crack propagation and fracture. Here this work examines the mechanical response of Al-substituted LLZO to compressive forces by measuring ultimate strength under pillar compression with a flat punch tip. Failure modes characterized by in situ scanning electron microscopy show diverse splitting patterns arising from internal porosity, grain boundaries, and slip planes. Large correlated variations in compressive strength (0.93–2.63 GPa) and Young's modulus (72.1–150.97 GPa) are observed across microscale regions of the solid electrolyte. Molecular dynamics simulations of LLZO with different porosities describe the variation of compressive strength and Young's modulus, and enable a microscale porosity model to be fit accounting for Young's modulus reduction across the solid electrolyte. Overall, the results indicate the importance of microscale mechanical testing of ceramic solid electrolytes to identify preferential sites for mechanical degradation and Li intrusion, and ensure the robust design of all-solid-state lithium metal batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Observation and Modeling of Dynamic Fracture Behaviors of Battery Cell Under Impact Loading Using Enhanced Representative Volume Element Concept

The burgeoning electric automobile industry has increased interest in battery safety. Battery cells experience significant mechanical stress during operation, including the impact of accidents and vibrations from driving. The potential for thermal runaway reactions in battery cells raises safety concerns. Although numerous researchers have defined the dynamic behavior of battery cells and proposed numerical models to describe it, few studies have focused on the high-strain rate mechanical impact phase correlated with the onset of fracture. In this study, we describe the dynamic behavior of pouch battery cells and propose a modeling method to study their mechanical failure under impact situations. Impact tests are conducted at various velocities and heights. To overcome numerical issues commonly encountered under rapid deformation scenarios, a new finite element model is developed based on the representative volume element model. The proposed approach efficiently simulates continuous crack propagation and brittleness behavior during impact by permitting the individual behavior of the cell components. Therefore, engineers can reliably design safer electric vehicle battery cells by measuring the properties of the cell components.

ENERGY STORAGE↗
DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗
DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗