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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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Challenges and Prospects of Sodium‐Ion and Potassium‐Ion Batteries for Mass Production

The exponential growth of the lithium‐ion (LIB) market is causing a significant disparity between the supply chain and demand for its resources. In this regard, sodium‐ion and potassium‐ion batteries are promising alternatives to LIBs due to their low cost. However, the larger sizes of Na + and K + ions create challenges that prevent them from achieving energy densities comparable to LIBs while maintaining an acceptable cycle life. Here, in this perspective, the aim is to evaluate the status of Na‐ion and K‐ion batteries and the challenges associated with them on both fundamental and commercial levels. The focus is on the structural instability arising from phase transitions during cycling, intricate chemical degradation processes, and potential avenues for enhancing their performance with a specific goal of improving their viability for grid‐scale energy storage. Materials production and abundance limitations for the chemistries of the state‐of‐the‐art materials and account for critical parameters from both the perspective of researchers and investors are analyzed. This analysis aims to provide insights into the strategic trade‐offs required to effectively implement the technology in real‐world applications, such as grid‐scale storage and other areas. Furthermore, the utilization of metals with low or no supply‐chain problems as an important aspect of these trade‐offs is considered.

25 ENERGY STORAGE

Design and Synthesis of Cubic K 3−2 x Ba x SbSe 4 Solid Electrolytes for K–O 2 Batteries

Developing K-ion conducting solid-state electrolytes (SSEs) plays a critical role in the safe implementation of potassium batteries. In this work, a chalcogenide-based potassium ion SSE is reported, K 3 SbSe 4 , which adopts a trigonal structure at room temperature. Single-crystal structural analysis reveals a trigonal-to-cubic phase transition at the low temperature of 50 °C, which is the lowest among similar compounds and thus provides easy access to the cubic phase. The substitution of barium for potassium in K 3 SbSe 4 leads to the creation of potassium vacancies, expansion of lattice parameters, and a transformation from a trigonal phase to a cubic phase. As a result, the maximum conductivity of K 3−2x Ba x SbSe 4 reaches around 0.1 mS cm −1 at 40 °C for K 2.2 Ba 0.4 SbSe 4 , which is over two orders of magnitude higher than that of undoped K 3 SbSe 4 . This novel SSE is successfully employed in a K–O 2 battery operating at room temperature where a polymer-laminated K 2.2 Ba 0.4 SbSe 4 pellet serves as a separator between the oxygen cathode and the potassium metal anode. Effective protection of the K metal anode against corrosion caused by O 2 is demonstrated.

25 ENERGY STORAGE

Probing the role of local tunnel variations in early-stage lithiation of α-MnO₂ nanowires via in situ TEM

Understanding lithium-ion transport in tunnel-structured manganese oxides is essential for designing high-performance lithium-ion battery electrode materials. Here, we elucidate the early-stage lithiation mechanism of potassium-stabilized α-MnO 2 nanowires using in situ transmission electron microscopy (TEM) coupled with electron energy-loss spectroscopy (EELS), high-resolution TEM (HRTEM), and geometric phase analysis (GPA). Real-time TEM imaging reveals clear volume expansion at the reaction front, while EELS analysis uncovers lithium-ion diffusion far beyond this region, where no visible expansion is observed, indicating fast, defect-assisted transport. GPA and HRTEM analyses show that localized tensile and compressive strain fields, originating from pre-existing local tunnel structural variations, persist after lithiation. The tensile-strained regions enable lithium-ion insertion with minimal lattice distortion, offering additional free volume that facilitates rapid lithium-ion accommodation ahead of the structural transformation. Our results demonstrate a local tunnel variation-mediated fast diffusion pathway that precedes bulk reaction, underscoring the critical role of local strain in enabling early-stage lithium transport. Given the structural versatility of MnO 2 and its ability to accommodate diverse atomic arrangements beyond the well-known tunnel phases (β-, γ-, δ-, λ-, R-phases), our findings highlight the importance of understanding and engineering local structural environments. This work provides fundamental insights into the interplay between defects, strain, and ion dynamics, and presents defect engineering as a promising approach to enhance both rate performance and structural stability in manganese-based cathodes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND

Fabrication of freeform potassium dihydrogen phosphate crystals by belt-on-wheel polishing for spatially tailored polarization control in high-power lasers

Large-aperture (>30 cm) optical components that provide spatially tailored control of the properties of a laser beam, such as phase, polarization, and amplitude, have been the focus of much research and development in recent years. Such optics can improve energy throughput and target implosion efficiency in high-power laser systems conducting inertial confinement fusion research. Here, a method is demonstrated for fabricating freeform surface topographies into the birefringent crystalline material, potassium dihydrogen phosphate (KDP). Belt-on-wheel polishing with an oil-based fluid, developed to mitigate the deliquescent properties of KDP, is used to deterministically polish a freeform topography into KDP, enabling the fabrication of a wave plate with spatially arbitrary retardance. Testing of the laser-induced damage threshold of belt-on-wheel polished KDP was conducted at a wavelength of 351 nm and a pulse duration of 1 ns. The results revealed that the polished surfaces are highly resistant to laser-induced damage, making them suitable for large-aperture, high-power laser applications.

Urban, Nathaniel D. [Univ. of Rochester, NY (Unite

Nonleaking battery terminals

Three different terminals were designed for usage in a 40 ampere/hour silver zinc battery which has a 45 percent KOH by weight electrolyte in a plastic battery case. Life tests, including thermal cycling, electrical charge and discharge for up to three years duration, were conducted on these three different terminal designs. Tests for creep rate and tensile strength were conducted on the polyphenylene oxide (PPO) plastic battery cases. Some cases were unused and others containing KOH electrolyte were placed on life tests. The design and testing of nonleaking battery terminals for use with a potassium hydroxide (KOH) electrolyte in a plastic case are discussed.

Snider, W. E.

Data Base and Guidelines Document Developed for Lithium-Ion Battery

Lithium-Ion (Li-Ion) batteries are fast becoming the battery chemistry of choice for aerospace applications requiring (rechargeable) power supplies. These batteries offer high-energy density and high-specific energy combined with excellent rate capability and cycle potential. The increased energy content and operational characteristics of this system require defined safety and handling procedures to ensure the safe implementation. Standardized approaches to defining, determining, and addressing safety, handling, and qualification for Li-Ion batteries have been developed and published as an NESC-sponsored Li-Ion Battery Guidelines Document. A data base was established cataloging cells and batteries that have been considered for aerospace applications.

Data Base and Guidelines

International Space Station Lithium-Ion Battery

The International Space Station (ISS) Electric Power System (EPS) currently uses Nickel-Hydrogen (Ni-H2) batteries to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The Ni-H2 batteries are designed to operate at a 35 depth of discharge (DOD) maximum during normal operation in a Low Earth Orbit. Since the oldest of the 48 Ni-H2 battery Orbital Replacement Units (ORUs) has been cycling since September 2006, these batteries are now approaching their end of useful life. In 2010, the ISS Program began the development of Lithium-Ion (Li-ion) batteries to replace the Ni-H2 batteries and concurrently funded a Li-ion cell life testing project. This paper will include an overview of the ISS Li-Ion battery system architecture and the progress of the Li-ion battery design and development.

Battery

International Space Station Lithium-Ion Main Battery Thermal Runaway Propagation Test

In 2010, the ISS Program began the development of Lithium-Ion (Li-Ion) batteries to replace the aging Ni-H2 batteries on the primary Electric Power System (EPS). After the Boeing 787 Li-Ion battery fires, the NASA Engineering and Safety Center (NESC) Power Technical Discipline Team was tasked by ISS to investigate the possibility of Thermal Runaway Propagation (TRP) in all Li-Ion batteries used on the ISS. As part of that investigation, NESC funded a TRP test of an ISS EPS non-flight Li-Ion battery. The test was performed at NASA White Sands Test Facility in October 2016. This paper will discuss the work leading up to the test, the design of the test article, and the test results.

International Space Statio

Lithium Ion Battery Design and Safety

This viewgraph presentation makes several recommendations to ensure the safe and effective design of Lithium ion cell batteries. Large lithium ion cells require pressure switches and small cells require pressure disconnects and other safety devices with the ability to instantly interrupt flow. Other suggestions include specifications for batteries and battery chargers.

Au, George

Bipolar and Monopolar Lithium-Ion Battery Technology at Yardney

Lithium-ion battery systems offer several advantages: intrinsically safe; long cycle life; environmentally friendly; high energy density; wide operating temperature range; good discharge rate capability; low self-discharge; and no memory effect.

Russell, P.