Effects of cryogenic freezing upon lithium-ion battery safety and component integrity
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Sunderlin, Nathaniel↗
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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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Thermodynamics of order and randomness in dopant distributions inferred from atomically resolved imaging
Abstract Exploration of structure-property relationships as a function of dopant concentration is commonly based on mean field theories for solid solutions. However, such theories that work well for semiconductors tend to fail in materials with strong correlations, either in electronic behavior or chemical segregation. In these cases, the details of atomic arrangements are generally not explored and analyzed. The knowledge of the generative physics and chemistry of the material can obviate this problem, since defect configuration libraries as stochastic representation of atomic level structures can be generated, or parameters of mesoscopic thermodynamic models can be derived. To obtain such information for improved predictions, we use data from atomically resolved microscopic images that visualize complex structural correlations within the system and translate them into statistical mechanical models of structure formation. Given the significant uncertainties about the microscopic aspects of the material’s processing history along with the limited number of available images, we combine model optimization techniques with the principles of statistical hypothesis testing. We demonstrate the approach on data from a series of atomically-resolved scanning transmission electron microscopy images of Mo x Re 1- x S 2 at varying ratios of Mo/Re stoichiometries, for which we propose an effective interaction model that is then used to generate atomic configurations and make testable predictions at a range of concentrations and formation temperatures.
25 ENERGY STORAGE↗
Lithium-Ion Battery Life Model with Electrode Cracking and Early-Life Break-in Processes
This paper develops a physically justified reduced-order capacity fade model from accelerated calendar- and cycle-aging data for 32 lithium-ion (Li-ion) graphite/nickel-manganese-cobalt (NMC) cells. The large data set reveals temperature-, charge C-rate-, depth-of-discharge-, and state of charge (SOC)-dependent degradation patterns that would be unobserved in a smaller test matrix. Model structure is informed by incremental capacity analysis that shows loss of lithium inventory and cathode-material loss as the dominant capacity fade mechanisms. The model includes terms attributable to solid-electrolyte interface (SEI) growth, electrode cracking, cycling-driven acceleration of SEI growth, and "break-in" mechanisms that slightly decrease or increase available Li inventory early in life. The study explores what mathematical couplings of these mechanisms best describe calendar aging, cycle aging, and mixed calendar/cycle aging. Various approaches are discussed for extracting relevant stress factors from complex cycling profiles to predict lifetime during real-world battery loads using models trained on constant-current laboratory test results. The complexity of the present human-driven model identification process motivates future work in machine learning to more widely search and statistically discern the optimal model that correctly extrapolates capacity fade based on physical knowledge.
25 ENERGY STORAGE↗
LA100 Equity Strategies: Executive Summary
LA100 Equity Strategies is a collaborative effort between LADWP, NREL, UCLA, and Kearns & West that employs an interdisciplinary approach utilizing distinct - but connected - research efforts informed and guided by the project Steering Committee, which met monthly through the duration of the project. Chapters 1 through 4 address recognition and procedural justice through recognition, process, and community strategies, while Chapters 5 through 12 address distributional justice through program and infrastructure strategies. Chapters 13 through 17 provide policy and program strategies. Each chapter provides data, methods, tools, insights, and strategies to help LADWP make data-driven, community- informed decisions for equitable investments and program development.
14 SOLAR ENERGY↗
Threat Landscape for BESS and IBR
The cyber risk landscape for BESS and IBR can be broken up by threats, vulnerabilities, and consequences for these systems. This presentation walks through the cyber risk landscape for BESS through the lens of consequence-informed awareness and mitigation for each risk factor. Threats with varying capabilities have been demonstrated in real-world events. Though threat actors can rarely be directly influenced by organizations, exposure of systems to adversaries can be limited (a known issue with IBR systems) to reduce likelihood of adversaries accessing systems with disruptive consequences. Common trends in disclosed IBR vulnerabilities include weak password generation or managements for various devices or services and web portal vulnerabilities that provide unauthorized access to data or capabilities or elevated user privileges. Understanding these common vulnerabilities and considering the consequences if these types of vulnerabilities were to occur can help mitigate risk. Consequences range from loss-of-view events that have no reliability impact to asset damage or grid stability impacts. Five case studies are briefly shared to highlight trends in real-world events affecting IBR.
14 - SOLAR ENERGY↗
Prototype for Unclassified Algorithm
Continuing previous efforts to investigate and develop the Unclassified Radioisotope Algorithm, the goal of the FY19-FY20 effort was to develop a prototype detector system which uses the algorithm to confirm warhead attributes related to the presence of either weapons grade plutonium (WGPu) or highly enriched uranium (HEU). The final deliverable is a prototype attribute measurement system built with common, commercially available gamma radiation detector components, capable of confirming the presence of specific, complex radioactive sources of interest, without the collection and storage of gamma energy spectra. This is accomplished by processing each gamma pulse as it is received, applying weight values based on the energy and incrementing or decrementing scalar counters which can be compared with expected values to determine if the measured source is consistent with WGPu or HEU. This report documents the design of the prototype system as well as the development of the algorithm and performance testing results. While the previously conceptualized, simple algorithm resulted in a prohibitive amount of false positives, the goal for a simple attribute measurement system capable of verifying Ba-133 and Ra-226 (weapons grade plutonium and highly enriched uranium surrogate testing sources) at over 95% accuracy with sub 5% false positive rate was demonstrated.
45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
Intelligent Monitoring Systems and Advanced Well Integrity and Mitigation
Long-term seismic monitoring of carbon capture and storage projects is needed to verify that the injected gas is safely stored in the subsurface until permanence can be assured. Conventional surface seismic monitoring techniques are usually expensive, require highly invasive surface operations, and need significant time investments on the part of personnel for both the field effort and processing the acquired data. For these reasons, permanent reservoir monitoring technologies are preferred, as they can offer a cost-effective solution for long-term monitoring. As part of the monitoring program of the Archer Daniels Midland’s large-scale injection of CO 2 in Decatur, Illinois, USA, a continuous seismic monitoring array was installed using a combination of surface orbital vibrator (SOV) sources and fiber-optic cables for distributed acoustic sensing (DAS) acquisition with the objective to build a continuous monitoring array. The aim of the presented project was to build a monitoring array and platform that integrates real-time seismic data with conventional data streams and provides continuous data analysis using dynamic computational models to deliver a comprehensive real-time assessment of subsurface conditions. It is in this context that the Intelligent Monitoring Systems and Advanced Well Integrity and Mitigation project was proposed with the objective to develop an integrated architecture that utilizes a permanent seismic monitoring network, combines the real-time geophysical and process data with reservoir flow and geomechanical models to create a comprehensive monitoring, visualization, and control system that delivers critical information for process surveillance and optimization.
54 ENVIRONMENTAL SCIENCES↗
Sandia Academic Alliance Program Collaboration Report: 2020-2021 Accomplishments
University partnerships play an essential role in sustaining Sandia’s vitality as a national laboratory. The SAA is an element of Sandia’s broader University Partnerships program, which facilitates recruiting and research collaborations with dozens of universities annually. The SAA program has two three-year goals. SAA aims to realize a step increase in hiring results, by growing the total annual inexperienced hires from each out-of-state SAA university. SAA also strives to establish and sustain strategic research partnerships by establishing several federally sponsored collaborations and multi-institutional consortiums in science & technology (S&T) priorities such as autonomy, advanced computing, hypersonics, quantum information science, and data science. The SAA program facilitates access to talent, ideas, and Research & Development facilities through strong university partnerships. Earlier this year, the SAA program and campus executives hosted John Myers, Sandia’s former Senior Director of Human Resources (HR) and Communications, and senior-level staff at Georgia Tech, U of Illinois, Purdue, UNM, and UT Austin. These campus visits provided an opportunity to share the history of the partnerships from the university leadership, tours of research facilities, and discussions of ongoing technical work and potential recruiting opportunities. These visits also provided valuable feedback to HR management that will help Sandia realize a step increase in hiring from SAA schools. The 2020-2021 Collaboration Report is a compilation of accomplishments in 2020 and 2021 from SAA and Sandia’s valued SAA university partners.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Design and requirements of a hydrogen component reliability database (HyCReD)
Hydrogen technologies are expected to play a key role in the decarbonization of several sectors including energy storage and transportation. Rigorous investigation and quantification of the risk and reliability issues associated with hydrogen technologies will be critical to ensuring both their wider adoption and safe, economical operations. Quantitative risk assessment (QRA) is an important tool that has been used to enable the safe deployment of many engineering systems, including hydrogen fueling stations and hydrogen storage systems. However, QRA studies require reliability data which is currently lacking for expanding applications of hydrogen systems. Here, to address this gap, we present a new structure for a hydrogen component reliability database (HyCReD) that can be used to generate reliability data to be used in QRA, reliability, safety studies, maintenance planning, and more. Building on our previous work examining four major hydrogen safety data collection tools (West et al., 2022) [1], our approach in this work was to consult scientific literature on reliability data collection as well as a number of existing reliability engineering databases in the oil & gas, chemical processing, and nuclear power plant sectors. The evaluation of these databases led to identifying best practices to be implemented in a data collection framework for a hydrogen component reliability database. Based on these best practices, a set of 24 requirements for the proposed database are presented, covering its characteristics and the types of data to be collected. We define the structure of the HyCReD database and 25 data elements to be collected, spanning system description, failure, shutdown, or near-miss events, and maintenance events. The data elements are then defined according to international standards used in the safety and reliability practice and potential choice lists are provided for each field. Since this database is being piloted for hydrogen fueling stations, a generic station component hierarchy developed by West (2021) [2] is used to standardize system data. Finally, we demonstrate populating the database with information extracted from five narrative reports on hydrogen fueling station incidents.
08 HYDROGEN↗
Li-Ion Diffusion Correlations in LiAlGeO 4 : Quasielastic Neutron Scattering and Ab Initio Simulation
Here, we investigated the impact of Li stoichiometry and host flexibility on Li + diffusion processes in LiAlGeO 4 at the microscopic level using quasielastic neutron scattering (QENS) and ab initio molecular dynamics (AIMD) simulations. Using sufficiently long AIMD trajectories, we could simulate the observed QENS signal and identify the localized dynamics of Li in crystalline LiAlGeO 4 . Such information is vital to identify the bottleneck of diffusion processes and design materials for battery application. Our AIMD simulations in LiAlGeO 4 reveal that the Li + conductivity can be significantly improved by manipulating the Li stoichiometry and/or host flexibility via amorphization. We determined that excess Li stoichiometry enhances the Coulomb repulsion of neighboring Li sites and softens the host structure to enable faster Li + diffusion along the hexagonal c-axis. In the amorphous structure, random orientations of AlO 4 and GeO 4 polyhedral units create a wide distribution of intersite distances and significantly soften the host structure, greatly enhancing the Li + diffusion. The simulations are used to understand the nature of diffusion, especially the role of the host structure, the possible hopping pathways, and the diffusion behavior in various structures of LiAlGeO 4 .
localized dynamics↗
Crystal structure of calcium-ferrite type NaAlSiO4 up to 45 GPa
Abstract Alkali-rich aluminous high-pressure phases including calcium-ferrite (CF) type NaAlSiO4 are thought to constitute ~20% by volume of subducted mid-ocean ridge basalt (MORB) under lower mantle conditions. As a potentially significant host for incompatible elements in the deep mantle, knowledge of the crystal structure and physical properties of CF-type phases is therefore important to understanding the crystal chemistry of alkali storage and recycling in the Earth’s mantle. We determined the evolution of the crystal structure of pure CF-NaAlSiO4 and Fe-bearing CF-NaAlSiO4 at pressures up to ~45 GPa using synchrotron-based, single-crystal X-ray diffraction. Using the high-pressure lattice parameters, we also determined a third-order Birch-Murnaghan equation of state, with V0 = 241.6(1) Å3, KT0 = 220(4) GPa, and KT0′ = 2.6(3) for Fe-free CF, and V0 = 244.2(2) Å3, KT0 = 211(6) GPa, and KT0′ = 2.6(3) for Fe-bearing CF. The addition of Fe into CF-NaAlSiO4 resulted in a 10 ± 5% decrease in the stiffest direction of linear compressibility along the c-axis, leading to stronger elastic anisotropy compared with the Fe-free CF phase. The NaO8 polyhedra volume is 2.6 times larger and about 60% more compressible than the octahedral (Al,Si)O6 sites, with K0NaO8 = 127 GPa and K0(Al,Si)O6 ~304 GPa. Raman spectra of the pure CF-type NaAlSiO4 sample shows that the pressure coefficient of the mean vibrational mode, 1.60(7) cm–1/GPa, is slightly higher than 1.36(6) cm−1/GPa obtained for the Fe-bearing CF-NaAlSiO4 sample. The ability of CF-type phases to contain incompatible elements such as Na beyond the stability field of jadeite requires larger and less-compressible NaO8 polyhedra. Detailed high-pressure crystallographic information for the CF phases provides knowledge on how large alkali metals are hosted in alumina framework structures with stability well into the lowermost mantle.
Geochemistry & Geophysics↗
Development and Validation of a Simulation Tool to Predict the Combined Structural, Electrical, Electrochemical and Thermal Responses of Automotive Batteries
Battery safety is one of the most important design factors of electrified vehicles (EVs) since battery failure may lead to a catastrophic consequence. To improve the safety of battery systems in EVs, battery behaviors under various abuse conditions should be well understood. One way to examine battery response under extreme conditions is to conduct abuse tests in different scenarios. They can provide first-hand pass/fail information on battery safety, but they are usually expensive and time-consuming, which is inconvenient during design iterations and optimization. On the other hand, computational modeling can predict the battery behaviors in a more efficient and cost-effective way, which becomes an important tool to evaluate battery safety. Modeling battery responses and failure is challenging since it involves multiple coupled physical processes, needs to consider complex material properties and is computationally intensive. This project aims to develop a practical simulation tool to predict the combined structural, electrical, electrochemical, and thermal responses of automotive batteries to crash-induced crush and short circuit and validate it for conditions relevant to automotive crash. Advanced material constitutive models will be utilized to capture the mechanical response of cell components. Moreover, methods will be developed to reduce computational complexity of the model and allow battery safety simulations to extend from cell-level to module/pack level with affordable computational resources.
25 ENERGY STORAGE↗
Integrated Process Optimization for Biochemical Conversion
This research is motivated by the challenges faced during biomass processing in bioenergy plants. It has been observed that variations in biomass characteristics, such as moisture, ash, and carbohydrate contents cause variations in feeding of the system which led to underutilization of equipment and the reactor. The objective of this research is to ensure a continuous flow of biomass to the reactor in plants that use the biochemical conversion process to generate liquid fuels. The overall goal is to lower the cost of producing biofuels, which could lead to improving US’s energy independency and growing US’s rural economy. The research team developed analytical models, such as discrete element method (DEM) models and mathematical models. The DEM models are unit-level models that explicitly capture biomass characteristics and quantify the impacts of biomass characteristics on bulk material properties and the performance of specific equipment. The mathematical models are system-level models that capture the impacts of system infeed rate, equipment processing rate, storage location and capacity, and biomass characteristics on system throughput. The functional relations predicting the bulk material properties from DEM models are incorporated to the mathematical models. The models developed were validated and evaluated using data collected at Idaho National Laboratory’s biomass processing facility. Via these models, we identified process control strategies that ensure a continuous flow of biomass to the reactor, while meeting the requirements of biochemical conversion process. Our analysis indicates that sequencing of biomass bales based on moisture level, and carbohydrate contents could have a positive impact on reducing processing time and inventory level and increasing throughput rate. Short bale sequences that repeat frequently, seem to have the greatest impact on improving system’s performance. Based on our experiments, the total annual system operating costs reduced by 20-30%, and the maximum inventory level reduced by 3 to 4 times. The operating costs include the annual equipment amortization cost and processing cost. The implementation of the models developed requires the use of standardized bale format, Radio Frequency Identification technology, sensing and real time monitoring of material attributes, automated material handling equipment, and automated process control. The scope of the model proposed can be extended to include the whole supply chain. The supply chain models help identify how many bales of different biomass feedstock to purchase given biomass availability in the region, biomass price and quality, and the biomass processing capabilities of the biorefinery. Thus, the outcomes of supply chain models can be used to inform the design of long-term contracts among farmers and the biorefinery.
09 BIOMASS FUELS↗
An Accelerated Testing and Analysis Framework for Qualification of Battery Materials Part I: A Case Study with LFP Cathodes
The growing demand for batteries used within automotive, aviation, and grid applications has exacerbated the need to supplement critical battery material feedstocks, such as those for anode and cathode active materials. New or supplementary material sources, however, universally comprise unique properties that can affect the lifetime and performance of resultant batteries. Even minor differences between new sources and established supplies can delay qualification, making it difficult for new suppliers to commercialize and resulting in a less resilient supply chain. Accordingly, the influence of composition, microstructure, and morphology on electrochemical performance should be characterized quickly and accurately to accelerate commercialization of new sources. This work introduces a tiered framework to assess new material viability and understand the influence of physicochemical properties on battery performance. The Tier 1 testing described here is rapid and low-effort to recognize materials with fundamental flaws and potentially disqualify them. Later testing would require more effort but provide higher-fidelity information with a goal of application-based validation. A case study examining commercial sources of LiFePO4 (LFP) is presented, using Tier 1 of the protocol to identify rapid electrochemical and physicochemical signals that correlate with performance and provide early go/no-go decisions for LFP materials without requiring long-term cycling.
25 ENERGY STORAGE↗
Characterizing the Evolution of Trapped scCO 2 Curvature in Bentheimer and Nugget Sandstone Pore Geometry
During a Geologic Carbon Storage process, supercritical CO 2 (scCO 2 ) is subjected to a series of dynamic and static conditions where the relationship between pore geometry and the trapped scCO 2 curvature remains to be established. To mimic the dynamic process, two sandstones, Bentheimer and Nugget, were subjected to two successive drainage and imbibition (D-I) cycles and X-ray computed tomography scanned at each residual state to capture the wettability evolution at static conditions in the same pore geometry. Both sandstones contain similar grain size distributions, pore size distributions, and pore interconnectivity but differ in that the Nugget formation contains approximately half the porosity of the Bentheimer sandstone, and the pore network contains dead-end pores. scCO 2 size distributions, strain calculations, and geometric contact angle measurements were used to characterize the curvature of scCO 2 in different pore types between cycles. An increase in geometric contact angle was the greatest when advancement along the pore network of the same ganglion occurred between cycles while strain increased the most with pore-filling trapping. Moreover, Nugget sandstone results in a greater aggregated residual saturation and shows a clear increase in scCO 2 sizes with an additional D-I cycle while scCO 2 in the Bentheimer core shows a more complex response with some ganglion increasing and some decreasing in size with an additional D-I cycle. From this work, we suspect the pore geometry is playing a role in scCO 2 size distributions and use this information to suggest using water pulses to enhance trapping capacity in lower porosity sandstones.
58 GEOSCIENCES↗
Cabin Thermal Management Analysis for SuperTruck II Next-Generation Hybrid Electric Truck Design
In this article, we present a multistage, coupled thermal management simulation approach, informed by physical testing where available, to aid design decisions for PACCAR's SuperTruck II hybrid truck cabin concept. Focus areas include cabin insulation, battery sizing, and sleeper curtain position, as well as heating, ventilating, and air-conditioning (HVAC) component and accessory configurations, to maintain or improve thermal comfort while saving energy. The authors analyzed weather data and determined the national vehicle miles traveled weighted temperature and solar conditions for long-haul trucks. Example weather day profiles were selected to approximate the 5th and 95th percentile weighted conditions. A daylong drive cycle was developed to impose appropriate external wind conditions during rest and driving periods. Using the National Renewable Energy Laboratory's vehicle HVAC modeling and simulation tool VTCab, HVAC load design trade-off studies for the new truck geometry concept were completed. Parameters analyzed included effects of paint color, insulation, glass transmissivity, and curtain location. Simulation results helped with early design material selections for efficient cabin climate control. A detailed three-dimensional computer-aided engineering (CAE), computational fluid dynamics (CFD), radiation, and human physiology co-simulation, referred to in this article as CAE Thermal-CFD, was used to evaluate thermal comfort and energy impacts of diffuser configurations and air supply settings in driving and hoteling modes. Analysis revealed that it is more difficult to heat the cabin in hoteling mode during the winter than to cool the space in the summer. This seasonal load profile drives the requirement of additional energy storage for heating comfort. To determine the battery capacity requirement, multiday HVAC operation drive cycle simulations were then completed, showing that a 15-kWh battery would be required for HVAC operation during hoteling. Results helped reduce cabin thermal loads, determine component sizing requirements, and improve occupant comfort to save fuel and contribute to the economic viability of the hybrid system.
33 ADVANCED PROPULSION SYSTEMS↗
Immersive Scientific Visualization of Molten-Salt Reactor Waste Characteristics Using Virtual Reality
Immersive visualization is changing how we explore, communicate, and understand complex scientific systems. In nuclear energy, an area in which data are often multidimensional, time-dependent, and difficult to interpret, virtual reality (VR) represents a powerful and intuitive informational medium. This work introduces a VR-based platform that visualizes the post-shutdown behavior and waste management lifecycle of molten-salt reactors (MSRs), a next-generation reactor type with unique operational and safety characteristics. The platform, built in Unity, is streamed on the Meta Quest 3 headset. It transforms high-fidelity simulation data into an interactive, immersive experience. Users can explore time-dependent reactor characteristics such as nuclide decay, which is a key factor for evaluating reactor waste strategies. The datasets were generated using the MOOSE (Multiphysics Object-Oriented Simulation Environment) framework and then processed through ParaView scripting for smooth integration into Unity. From a visualization standpoint, the platform emphasizes spatial storytelling, temporal exploration, and user-centered interaction. Users can navigate 3D reactor geometries, slice through volumetric data, and manipulate time to observe how physical phenomena evolve. Real-scale rendering and embodied interaction make the experience feel tangible. The interface is designed to be accessible, even to those without nuclear or simulation expertise. This lowers the barrier for stakeholders, policymakers, and the general public, while still supporting expert analysis and collaborative decision-making. This work shows how immersive visualization can function as both a scientific tool and a communication interface. By integrating simulation, processing, and visualization into a cohesive workflow, we offer a scalable framework for immersive scientific storytelling. The modular design supports future extensions to other reactor types and lifecycle stages, from shutdown to long-term storage, making the platform adaptable for both research and outreach.
99 - GENERAL AND MISCELLANEOUS↗
Challenging Practices of Algebraic Battery Life Models through Statistical Validation and Model Identification via Machine-Learning
Various modeling techniques are used to predict the capacity fade of Li-ion batteries. Algebraic reduced-order models, which are inherently interpretable and computationally fast, are ideal for use in battery controllers, technoeconomic models, and multi-objective optimizations. For Li-ion batteries with graphite anodes, solid-electrolyte-interphase (SEI) growth on the graphite surface dominates fade. This fade is often modeled using physically informed equations, such as square-root of time for predicting solvent-diffusion limited SEI growth, and Arrhenius and Tafel-like equations predicting the temperature and state-of-charge rate dependencies. In some cases, completely empirical relationships are proposed. However, statistical validation is rarely conducted to evaluate model optimality, and only a handful of possible models are usually investigated. This article demonstrates a novel procedure for automatically identifying reduced-order degradation models from millions of algorithmically generated equations via bi-level optimization and symbolic regression. Identified models are statistically validated using cross-validation, sensitivity analysis, and uncertainty quantification via bootstrapping. On a LiFePO 4 /Graphite cell calendar aging data set, automatically identified models utilizing square-root, power law, stretched exponential, and sigmoidal functions result in greater accuracy and lower uncertainty than models identified by human experts, and demonstrate that previously known physical relationships can be empirically "rediscovered" using machine learning.
25 ENERGY STORAGE↗