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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Quantification of Inactive Lithium and Solid–Electrolyte Interphase Species on Graphite Electrodes after Fast Charging

Rapid charging of Li-ion batteries is limited by lithium plating on graphite anodes, whereby Li+ ions are reduced to Li metal on the graphite particle surface instead of inserting between graphitic layers, which directly contributes to cell capacity loss because of the low reversibility of the Li plating/stripping process. Furthermore, precisely identifying the onset and amount of Li plating is therefore vital in order to remedy these issues. We demonstrate a titration technique with a detection limit of 20 nmol (5 × 10 –4 mAh) of Li that can be used to quantify inactive Li that remains on the graphite electrode after fast charging. The titration is extended to quantify the total amount of solid carbonate species and lithium acetylide (Li 2 C 2 ) within the solid–electrolyte interphase (SEI), and electrochemical modeling is used to determine the Li plating exchange current density (10 A/m 2 ) and stripping efficiency (65%) of plated Li metal on graphite. These techniques provide a highly accurate measure of the onset of Li plating and quantitative insight into graphite SEI evolution during fast charging.

25 ENERGY STORAGE↗
DOE OSTI2021

Detecting onset of lithium plating during fast charging of Li-ion batteries using operando electrochemical impedance spectroscopy

Electrochemical plating of Li metal on the graphite electrode is the key limitation behind slow charging times of Li-ion batteries (LIBs) in electric vehicles (EVs). Currently, electrochemical methods to detect the onset of Li plating while a battery is fast charging are sparse. In this study, we use operando electrochemical impedance spectroscopy to reliably detect the onset of Li plating on graphite electrodes in three-electrode LIBs. An increase in the graphite solid-electrolyte interface (SEI) resistance indicates that Li plating has occurred. By cross-validating with a highly sensitive ex situ chemical titration, we determine that this technique can detect very small amounts of plated Li (<0.6% of the graphite electrode's capacity). We also offer physical explanations for the observed impedance behavior. Finally, we show that this technique can be applied to standard two-electrode LIB systems, making the method an important step toward safely implementing fast charging protocols for LIBs in EVs.

25 ENERGY STORAGE↗
DOE OSTI2022

Hierarchical Control of Megawatt-Scale Charging Stations for Electric Trucks with Distributed Energy Resources

Electrifying medium- and heavy-duty trucks is critical to decarbonizing the transportation sector. Energy needs of electric trucks will likely require megawatt-scale charging stations, which could significantly stress the electric distribution grid. Distributed energy resources (DER) can alleviate this stress and reduce charging costs with proper management. To that end, this work develops a hierarchical predictive control algorithm for future multi-port megawatt-scale charging stations that can provide real-time energy management for stations, decide charging rates, dispatch energy storage system (ESS), and provide grid voltage support. We integrate three algorithmic components: (i) an energy management optimization (EMO) that provides supervisory control to DER assets and charging loads at minute scale, (ii) a real-time energy management system (RT-EMS) that heuristically compensates for fast disturbances at sub-second scale, and (iii) a model predictive control (MPC)-based battery management system (BMS) that communicates future charging demands to the EMO, to manage the overall megawatt-scale site. Additionally, validation in a controller hardware-in-the-loop (CHIL) environment shows that the hierarchical controller can reduce the total energy consumption from the grid by approximately 28% compared to an uncontrolled case for the station configuration in this paper, without impacting charging time.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Impact of electric vehicle charging on the power demand of retail buildings

As electric vehicle penetration increases, charging is expected to have a significant impact on the grid. Electric vehicle charging stations will greatly affect a building site's power demand, especially with the onset of fast charging with power levels as high as 350 kW per charger. Here, we assess how electric vehicle charging stations would impact a retail big box grocery store, exploring numerous station sizes, charging power levels, and utilization factors in various climate zones and seasons. We measure the effect of charging by assessing changes in monthly peak power demand, electricity usage, and annual electricity bill, computed using three distinct rate structures. We find that an electric vehicle station has the potential to dwarf a big box building's power demand if behind the same meter, increasing monthly peak power demand at the site by over 250%. Cold-climate areas paired with rate structures incorporating high demand charges are most susceptible for significant changes to the annual electricity bill, with increases as high as 88%.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Underpotential lithium plating on graphite anodes caused by temperature heterogeneity

Rechargeability and operational safety of commercial lithium (Li)-ion batteries demand further improvement. Plating of metallic Li on graphite anodes is a critical reason for Li-ion battery capacity decay and short circuit. It is generally believed that Li plating is caused by the slow kinetics of graphite intercalation, but in this paper, we demonstrate that thermodynamics also serves a crucial role. We show that a nonuniform temperature distribution within the battery can make local plating of Li above 0 V vs. Li 0 /Li + (room temperature) thermodynamically favorable. This phenomenon is caused by temperature-dependent shifts of the equilibrium potential of Li 0 /Li + . Supported by simulation results, we confirm the likelihood of this failure mechanism during commercial Li-ion battery operation, including both slow and fast charging conditions. This work furthers the understanding of nonuniform Li plating and will inspire future studies to prolong the cycling lifetime of Li-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

High-heat transfer lithium-ion batteries: A new era in battery thermal management

Despite advances in lithium-ion battery technology, critical challenges remain that must be addressed to accelerate electric vehicle (EV) adoption and global energy transformation. Significantly improved battery thermal management (BTM) is key to overcoming these challenges. BTM approaches focus on increasing heat transfer coefficients via air, liquid, or refrigerant cooling, but less attention is given to reducing the battery's thermal resistance, a major bottleneck for heat transfer. This work introduces a novel approach to reduce battery thermal resistance by integrating in-plane heat transfer with optimized cell geometry, minimized thermal resistances, and reduced interfacial resistances, representing a departure from previous methods. The standard prismatic can cell incorporating this technology is referred to as the high heat transfer (HHT) battery. An equivalent resistance battery thermal model is developed for speed and accuracy, validated against experimental data in the literature, demonstrating strong correlation and ensuring reliable predictions for real-world performance. Thermal performance metrics of the conventional and HHT batteries are compared using a parametric study with air, liquid, and refrigerant boundary conditions across a range of aspect ratios. The HHT battery shows a heat removal rate up to 20 times higher than a conventional battery. These findings suggest that HHT technology could be transformative for EV battery performance, enabling fast charging, mitigating thermal runaway, extending battery life, reducing cold-weather power loss, increasing reliability, lowering costs, and enabling higher energy density, all critical for EV adoption and energy transformation. Future work will focus on prototyping and real-world testing to refine these findings for commercial-scale applications.

25 ENERGY STORAGE↗
DOE OSTI2022

The Evolution of LiNi 0.5 Mn 0.3 Co 0.2 O 2 Particle Damage from Fast Charging in Optimized, Full Li-Ion Cells

Fast charging batteries are critical to the widespread adoption of electric vehicles to compete with refueling times of combustion-based vehicles. In the near term, adapting current commercial battery technologies to perform better under fast charging conditions through engineering optimizations will greatly expedite the process while exploratory fast-charging electrode materials are being pursued. To do so, the degradation modes in optimized Li-ion batteries need to be completely explored to understand fast charging limits while maintaining a high energy density and a long cycle life. While lithium plating on graphite still remains a challenge, cathode degradation also plays a key role in battery performance. In this work, we used nano- and micro-X-ray computed tomography to characterize the mechanical degradation of LiNi 0.5 Mn 0.3 Co 0.2 O 2 (NMC532) in optimized Li-ion batteries cycled at three rates, 1C, 6C, and 9C, and at different stages of cycle life, 225 and 600 cycles. We report despite using a conservative upper voltage cutoff limit aimed to minimize extensive cathode degradation, higher charging rates and increased cycling caused the polycrystalline NMC532 particles to fracture and pulverize, which likely drives cathode capacity fade and contributes to the decrease in overall cell performance.

25 ENERGY STORAGE↗
DOE OSTI2022

Carbon-Binder Weight Loading Optimization for Improved Lithium-Ion Battery Rate Capability

Battery performance is strongly correlated with electrode microstructure and weight loading of the electrode components. Among them are the carbon-black and binder additives that enhance effective conductivity and provide mechanical integrity. However, these both reduce effective ionic transport in the electrolyte phase and reduce energy density. Therefore, an optimal additive loading is required to maximize performance, especially for fast charging where ionic transport is essential. Such optimization analysis is however challenging due to the nanoscale imaging limitations that prevent characterizing this additive phase and thus quantifying its impact on performance. Herein, an additive-phase generation algorithm has been developed to remedy this limitation and identify percolation threshold used to define a minimal additive loading. Improved ionic transport coefficients from reducing additive loading has been then quantified through homogenization calculation, macroscale model fitting, and experimental symmetric cell measurement, with good agreement between the methods. Rate capability test demonstrates capacity improvement at fast charge at the beginning of life, from 37% to 55%, respectively for high and low additive loading during 6C CC charging, in agreement with macroscale model, and attributed to a combination of lower cathode impedance, reduced electrode tortuosity and cathode thickness.

25 ENERGY STORAGE↗
DOE OSTI2020

Mechanistic Analysis of Microstructural Attributes to Lithium Plating in Fast Charging

Metallic lithium deposition on graphite anodes is a critical degradation mode in lithium-ion batteries, which limits safety and fast charge capability. A conclusive strategy to mitigate lithium deposition under fast charging yet remains elusive. Herein, we examine the role of electrode microstructure in mitigating lithium plating behavior under various operating conditions, including fast charging. The multilength scale characteristics of the electrode microstructure lead to a complex interaction of transport and kinetic limitations that significantly governs the cell performance and the occurrence of Li plating. We demonstrate, based on a comprehensive mesoscale analysis, that the performance and degradation can be significantly modulated via systematic design improvements at the hierarchy of length scales. It is found that the improvement in kinetic and transport characteristics achievable at disparate scales can dramatically affect Li plating propensity.

25 ENERGY STORAGE↗
DOE OSTI2022

Grid impact analysis using controller-hardware-in-the-loop for high-power vehicle charging stations

A controller-hardware-in-the-loop (CHIL) architecture for the evaluation of grid impacts arising from high-power vehicle charging stations is presented in this paper. Unlike simulation-based studies, the proposed method can be used to capture the interactions of the grid and the charging load along with charger controllers in real time. The proposed method can be used to evaluate the impact of charging load on the grid in terms of voltage variations and line congestion. The proposed CHIL platform allows for de-risking the vehicle charging station deployment by simulating the complex interactions among all the components of a vehicle charging station - i.e., the grid, vehicle, and charger controller - in a realistic manner before using the charging station in a grid. Further, the proposed CHIL approach can be used to evaluate the voltage regulation causalities of the vehicle charging station. Experimental results are presented in the paper to illustrate the applicability of the proposed method in a laboratory environment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Big Box Retail Grocery Store and Electric Vehicle Station Load Profiles

This dataset includes yearlong, one-minute resolution time series profiles for the big box retail grocery stores stores simulated in Phoenix, Houston, Denver, and Minneapolis, as well as electric vehicle charging time series profiles for the various ports, charging levels, and station utilizations produced for the study "Impact of electric vehicle charging on the power demand of retail buildings", published in 2021 (https://doi.org/10.1016/j.adapen.2021.100062). Please cite as: Gilleran, M., Bonnema, E., Woods, J. et al. Impact of electric vehicle charging on the power demand of retail buildings. Advances in Applied Energy 4, (2021). https://doi.org/10.1016/j.adapen.2021.100062

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Electrolyte Design for NMC811||SiO x -Gr Lithium-Ion Batteries with Excellent Low-Temperature and High-Rate Performance

The use of high-nickel NMC811 cathode and SiO x -Gr anode can greatly improve the overall energy densities of lithium-ion batteries. However, the unfavorable solid electrolyte interphase (SEI) layer generated from the decomposition of EC-based electrolytes lead to the poor cycling stability of NMC811||SiO x -Gr cells. Here we report an electrolyte design of 1.5 M LiPF 6 dissolved in FEC/MA/BN 2:2:6 by volume, which can form thin, robust, and homogeneous SEI layer to greatly improve the charge transfer at the electrode-electrolyte interface. Importantly, the designed electrolyte shows an outstanding low temperature performance that it can deliver a capacity of 123.3 mAh g –1 after 50 cycles at −20 °C with a current density of 0.5 C, overwhelming the standard EC-based electrolyte (1.2 M LiPF 6 EC/EMC 3:7 by volume) with a capacity of 35.7 mAh g –1 . The electrolyte also has a superior rate performance that it achieves a capacity of 122.5 mAh g −1 at a high current density of 10 C. Moreover, the LTE electrolyte holds the great potential of extreme fast-charging ability because of the large part of CC contribution in the CCCV charging model at high charging current densities.

Electrochemistry↗
DOE OSTI2025

Minimization of Cathode|Solid-Electrolyte Interfacial Delamination through the Application of Interphase Layers

Next-generation lithium-ion batteries are expected to use solid electrolytes (SEs) to enable higher energy density and extreme fast-charge capabilities. One major mode of degradation at the cathode|SE interface is delamination between the cathode active materials and SEs, which leads to performance decay. Experimental observations indicate that implementation of interphase layers can minimize the cathode|SE delamination induced capacity fade. A multiscale computational methodology is developed here to investigate the applicability of boron substituted lithium carbonate (Li 2+x B x C 1–x O 3 , x = 0.5, or LBCO) to minimize the delamination at the cathode|SE interface. Atomistic simulations indicate that the fracture energies at both the cathode|LBCO and LBCO|SE interfaces are higher than those at the cathode|SE interface, which reduces the extent of delamination. Mesoscale simulations indicate that, apart from increasing the fracture energy, decreasing the evolution of strain energy by lowering the elastic modulus of the interphase layer can also minimize the extent of delamination at the cathode|SE interface. However, the adoption of an interphase layer with high ionic conductivity is necessary to minimize the ohmic losses during operation at higher current densities. This study provides guidance on selecting interphase layers with specific properties and thicknesses to minimize both interfacial delamination and impedance growth.

LBCO↗
DOE OSTI2024

2023 Annual Merit Review Vehicle Technologies Office Results Report

The 2023 U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy's (EERE) Vehicle Technologies Office (VTO) Annual Merit Review (AMR) was held June 12-15, 2023, as a hybrid event with in-person and virtual attendance. The review encompassed work done by VTO: 257 individual activities were reviewed by 266 reviewers. Exactly 991 individual review responses were received for the VTO technical reviews. The objective of the meeting was to review the accomplishments and plans for VTO over the previous 12 months, and provide an opportunity for industry, government, and academia to give inputs to DOE with a structured and formal methodology. The meeting also provided attendees with a virtual forum for interaction and technology information transfer.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Synergistic Anion and Solvent-Derived Interphases Enable Lithium-Ion Batteries under Extreme Conditions

Lithium-ion batteries (LIBs) face increasingly stringent demands as their application expands into new areas, including extreme temperatures and fast charging. To meet these demands, the electrolyte should enable fast lithium-ion transport and form stable interphases on electrodes simultaneously. In practice, however, improving one aspect often compromises another. For instance, the trend toward electrolytes forming anion-derived interphases typically reduces transport efficiency due to weak-solvating solvents. Here, we propose that instead of relying on anions to form the interphase, leveraging both solvents and anions to form interphases can potentially lead to a balancing point between robust interphase formation and effective ion transport. Guided by this design principle, 2,2-difluoroethyl ethyl carbonate (DFDEC) was identified as the promising solvent. With the new electrolyte using DFDEC as the major solvent and lithium bis(fluorosulfonyl) imide (LiFSI) as the salt, graphite||LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) full cells are capable of fast charging and demonstrate long-term cycling stability with a cutoff voltage of 4.5 V. Notably, the battery shows a capacity retention of 84.3% after 500 cycles with an average Coulombic efficiency (CE) as high as 99.93%. This new electrolyte also enables stable battery cycling across a wide temperature range (-20 to 60 °C), with excellent capacity retention.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Behind-the-Meter Storage [Slides]

This is an overview of the work happening with Behind-the-Meter Storage. NREL is the Project Lead for Behind-the-Meter storage. The goal of this research is to produce behind-the-meter battery solutions deployed at scale to meet the functional requirement of high-power electric-vehicle charging.

25 ENERGY STORAGE↗
DOE OSTI2025

Extending the operating range and safety of Li-ion batteries with new fluorinated electrolytes

Orbia Fluor and Energy Materials (formerly Koura) has successfully developed a new class of fluorinated electrolyte solvents for lithium-ion batteries. In collaboration with Silatronix and Argonne National Laboratory, the team synthesized and screened over 20 novel fluorinated compounds, optimizing formulations that significantly enhance battery performance across critical metrics such as thermal stability, fast-charging capability, and cycling life at extreme temperatures. Electrolytes with fluorinated molecules developed in this program demonstrated superior performance in 2 Ah pouch cells, achieving over 1000 fast-charge cycles with minimal capacity fade, outperforming conventional carbonate-based electrolytes. Mechanistic studies revealed that the fluorinated electrolytes promote a stable solid electrolyte interphase at the anode and reduce cathode metal dissolution, contributing to improved long-term stability. These advancements mark a significant step toward safer, more efficient batteries for applications ranging from grid storage to defense systems to electric vehicles. We gratefully acknowledge DOE’s financial support through contract DE-EE0009642.

25 ENERGY STORAGE↗