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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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DOE OSTI2026

Use of Hardware-in-the-Loop to De-Risk Field Deployment of Hydrogen Assets

Grid-forming assets are required in microgrids to act as voltage-frequency masters. These grid-forming assets can operate in two modes of operation: grid-following mode and grid-forming mode. In grid-following mode of operation, these assets will follow real power and reactive power setpoints and in grid-forming mode of operation these assets will follow voltage and frequency setpoints. Traditionally, diesel generators or natural gas-based generators are widely used to act as a voltage-frequency master. However, many utilities are aiming to replace generators with grid forming-inverters supplied by solar photovoltaics (PV), batteries or fuel cells. Since grid-forming assets need a long-term reliable energy source, fuel cells are a reasonable and viable choice to supply the grid-forming inverters, but some of the challenges facing the wide deployment of grid-forming fuel cell inverters need to be addressed. Specifically, in our proposed work, we aim to focus on the interconnection and interoperability requirements of grid-forming fuel cell inverters. Currently, state-of-the-art fuel cell inverters follow the general interconnection requirements of distributed energy resources (DERs) and general interoperability requirements of DERs, but these requirements were built with PV and battery systems in mind. Fuel cells have different operational requirements, and therefore these requirements need to be appropriately modified for the grid operators to use. These additional steps add to the investment and operational cost to the grid operators. Through the ARIES platform, this proposed project aims to bridge this gap and use power hardware-in-the-loop (PHIL) and controller hardware-in-the-loop (CHIL) experiments to inform the creation of open-source interconnection and interoperability information that can aid in faster and cheaper installation and operation of grid-forming fuel cell inverters.

08 HYDROGEN↗

DOE OSTI2024

Validation of Interconnection and Interoperability of Grid-Forming Inverters Sourced by Hydrogen Technologies in View of 100% Renewable Microgrids

controller hardware-in-the-loop↗

NASA NTRSDate not supplied

SIBatt-3D In-Space/On-Surface 3D Printing of Sodium Ion Batteries using ISRU Materials

Sustainable on-demand power solutions are an absolute necessity as humanity works to establish a permanent presence on the moon and make the journey to Mars. NASA’s SIBatt-3D Early Career Initiative project at MSFC is developing shape-conformable Sodium-Ion batteries that can be 3D printed in-space as needed during extended space missions. SIBatt-3D makes use of the unique advantages of 3D printing to create shape-conformable batteries with improved performance that reduce dead volume in devices and seeks to utilize materials found in Lunar/Martian regolith as feedstocks to provide sustainable power for surface operations on the Moon and Mars. SIBatt-3D’s batteries also have terrestrial implications such as improved battery safety and sustainability.

3D Printing↗

DOE OSTI2024

What’s stopping electric vehicle batteries from having a second life?

We face the grand challenge of a growing number of end-of-life lithium-ion batteries over the upcoming years. A recent Cell Reports Sustainability article presents a model for effective end-of-life battery management in China for rural electrification. Here, we emphasize the need for incorporating various stakeholders early in the design phase to remove the barriers to the reuse of retired batteries.

25 ENERGY STORAGE↗

NASA NTRS1979

Solar power conditioner

Efficient power-conditioning circuit designed to utilize maximum power available from solar cell array, controls output of array so that excess energy not needed by load is diverted to charge batteries for reserve power when sufficient sunlight is not available.

Jan, L.↗

NASA NTRS1983

Large Electrochemical Storage Systems

Study released in 1979 assesses status of electrochemical energy storage for power plants that utilize Suns heat to drive electric generators. Major conclusion was that familiar lead/acid battery is only existing cell to meet needs for near-term demonstration programs.

Krauthamer, S.↗

NASA NTRS1992

Pressurized Lunar Rover

The pressurized lunar rover (PLR) consists of a 7 m long, 3 m diameter cylindrical main vehicle and a trailer which houses the power and heat rejection systems. The main vehicle carries the astronauts, life support systems, navigation and communication systems, directional lighting, cameras, and equipment for exploratory experiments. The PLR shell is constructed of a layered carbon-fiber/foam composite. The rover has six 1.5 m diameter wheels on the main body and two 1.5 m diameter wheels on the trailer. The wheels are constructed of composites and flex to increase traction and shock absorption. The wheels are each attached to a double A-arm aluminum suspension, which allows each wheel 1 m of vertical motion. In conjunction with a 0.75 m ground clearance, the suspension aids the rover in negotiating the uneven lunar terrain. The 15 N-m torque brushless electric motors are mounted with harmonic drive units inside each of the wheels. The rover is steered by electrically varying the speeds of the wheels on either side of the rover. The PLR trailer contains a radiosotope thermoelectric generator providing 6.7 kW. A secondary back-up energy storage system for short-term high-power needs is provided by a bank of batteries. The trailer can be detached to facilitate docking of the main body with the lunar base via an airlock located in the rear of the PLR. The airlock is also used for EVA operation during missions. Life support is a partly regenerative system with air and hygiene water being recycled. A layer of water inside the composite shell surrounds the command center. The water absorbs any damaging radiation, allowing the command center to be used as a safe haven during solar flares. Guidance, navigation, and control are supplied by a strapdown inertial measurement unit that works with the on-board computer. Star mappers provide periodic error correction. The PLR is capable of voice, video, and data transmission. It is equipped with two 5 W X-band transponder, allowing simultaneous transmission and reception. An S-band transponder is used to communicate with the crew during EVA. The PLR has a total mass of 6197 kg. It has a nominal speed of 10 km/hr and a top speed of 18 km/hr. The rover is capable of towing 3 metric tons (in addition to the RTG trailer).

Creel, Kenneth↗

NASA NTRS1992

Hubble Space Telescope nickel-hydrogen battery and cell testing - An update

NASA's HST uses Ni-H2 batteries. NASA-Marshall has been conducting developmental tests of such batteries in both six-battery and 22-cell single battery arrays. Tests have recently been conducted on such batteries with a view to the possible need to free additional memory in the HST onboard computer; the electrical power system could contribute to this end by eliminating its software control charge mode capability, which requires significant computer memory capacity.

Brewer, Jeffrey C.↗

NASA NTRS2000

Demonstration of Plasma Arc Environmental Technology Applications for the Demilitarization of DOD Stockpiles

Since 1989 the U.S. Army Construction Engineering Research Laboratories (USACERL) have been active participants in the research and development toward establishing Plasma Arc Technology (PAT) as an efficient, economical, and safe hazardous waste immobilization tool. A plasma torch capable of generating high temperatures makes this technology a viable and powerful tool for the thermal destruction of various military industrial waste streams into an innocuous ceramic material no longer requiring hazardous waste landfill (Class 1) disposal. The emerging pl asma environmental thermal treatment process, has been used to safely and efficiently meet the waste disposal needs for various demilitarized components disposal needs, such as: pyrotechnic smoke assemblies, thermal batteries, proximity fuses, cartridge actuated devices (CAD's), and propellant actuated devices (PAD's). MSE Technology Applications, Inc., (MSE) has proposed and fabricated a Mobile Plasma Treatment System to be a technology demonstrator for pilot-scale mobile plasma waste processing. The system is capable of providing small-scale waste remediation services, and conducting waste stream applicability demonstrations. The Mobile Plasma Treatment System's innovative concept provides the flexibility to treat waste streams at numerous sites and sites with only a limited quantity of waste, yet too hazardous to transport to a regional fixed facility. The system was designed to be operated as skid mounted modules; consisting of a furnace module, controls module, offgas module, and ancillary systems module. All system components have been integrated to be operated from a single control station with both semi-continuous feeding and batch slag-pouring capability.

Smith, Ed↗

NASA NTRS2012

Development of a PEMFC Power System with Integrated Balance of Plant

Autonomous Underwater Vehicles (AUV s) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Batteries are usually employed in these applications, but the energy density and therefore the mission duration are limited with current battery technology. At a certain energy or mission duration requirement, other means to get long duration power become feasible. For example, above 10 kW-hrs liquid oxygen and hydrogen have better specific energy than batteries and are preferable for energy storage as long as a compact system of about 100 W/liter is achievable to convert the chemical energy in these reactants into power. Other reactant forms are possible, such as high pressure gas, chemical hydrides or oxygen carriers, but it is essential that the power system be small and light weight. Recent fuel cell work, primarily focused on NASA applications, has developed power systems that can meet this target power density. Passive flow-through systems, using ejector driven reactant (EDR) flow, integrated into a compact balance of plant have been developed. These systems are thermally and functionally integrated in much the same way as are automotive, air breathing fuel cell systems. These systems fit into the small volumes required for AUV and future NASA applications. Designs have been developed for both a 21" diameter and a larger diameter (LD) AUV. These fuel cell systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for the reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.

Wynne, B.↗

NASA NTRSDate not supplied

Development of Hierarchical Control for a Lunar Habitat DC Microgrid Model Using Power Hardware-in-the-Loop

As interest in space exploration grows, developing a lunar habitat has become a key component of extending missions into deep space. To guarantee reliable power management of a habitat’s DC microgrid, control schemes are needed that can manage the different assets (batteries, photovoltaics, loads) effectively. Proposed hierarchical control schemes are further developed into hardware solutions using Opal-RT’s real-time simulation software and Power Hardware-in-the-Loop platform. Experimental results of a simulated DC microgrid and physical DC/DC components can allow better realization and performance of applications such as battery discharge control.

PHIL↗

NASA NTRSDate not supplied

Enabling Mission Flexibility to Battery Driven Deep Space Endeavors With Generalized Battery-Health-Monitoring Using Physics-Based and Data-Driven Reduced-Order Models

The needs and requirements for an electrochemical energy storage for deep space exploration is well explored. It is often understood that different mission sites and environmental conditions require different battery chemistries or technologies. Additionally, various engineering solutions are deployed to overcome specific chemical challenges. One often overlooked need is the “health” monitoring of an electrochemical storage system. The term generalized health monitoring, as envisioned in this work, refers to the monitoring of various aspects such as electrode health, electrolyte health, reaction pathway health, cooling system health, sensor health, and BMS health [1]. Generalized health monitoring allows mission leads, engineers, and scientists to incorporate flexibility in mission designs, make on-the-fly mission changes, and extend the duration of science missions. Moreover, it enables automation and data-driven decision-making without compromising safety and performance. Recently, our group developed a hierarchy of thermal reduced-order models (TROM) by combining a physics-based modeling approach and data-driven model reduction techniques applied to flight data [2]. The resulting TROMs were found to be not only accurate but also identifiable from the flight data. Consequently, the coefficient of variance of the model parameters is small over the course of hundreds of flights, allowing for monitoring the parameter evolution trajectories as the battery ages and degrades. These parameters constitute the metrics of the generalized health of a battery. Monitoring their evolution allows such models to be used for anomaly detection and prognostics, improving early detection of abnormal behavior and thus enabling timely maintenance, longer battery life, and enhanced battery safety. For this presentation, the practicality of the thermal model will be validated on a pack of 14cells under various topology configurations such as 1S14P, 2P7S, 7S2P, and 1P14S. It is well known that manufacturing and non-uniform aging lead to variability in the performance of a cell, which is exacerbated by cell balancing during active load. Additionally, in extreme scenarios, the paramount objective is to complete the mission, regardless of the stresses on the battery. Topology-induced balancing issues further stress the battery. The goal of this study is to determine if the noise (identifiability) in the reduced-order thermal model parameters is sensitive to topology, cell spacing, cooling strategy, and manufacturing or age variability. The variability in cells is considered by assuming a multimodal distribution for microscopic parameters of a cell (such as porosity, tortuosity, reaction kinetics, volumetric thermal conductivity, and volumetric heat capacity). The compounded effect of manufacturing variability, topological selection, cooling strategies, and cell balancing ages each cell in a battery differently. The study aims to clarify whether the challenge in extracting maximum information depends on the minimum number of sensors or models used for data extraction.

Automation↗

DOE OSTI2025

Gas-solid reaction-based selective lithium leaching strategy for efficient LiFePO 4 recycling

As the electric-vehicle market continues to expand, LiFePO 4 (LFP) batteries, valued for their intrinsic safety and cost-effectiveness, are being increasingly utilized. However, this widespread adoption highlights the urgent need for innovative and environmentally friendly recycling methods for spent LFP batteries due to their relatively low material value and the environmental challenges associated with traditional recycling processes. Here, in this study, we present a novel selective lithium leaching technique that involves a gas–solid reaction with chlorine gas. This method achieves a remarkable leaching efficiency of 99.8 % and a selectivity of 98.8 % at 200 °C within just 10 min, without generating acidic wastewater. The resulting LiCl solution was successfully converted into Li 2 CO 3 with an excellent purity of 99.5 %, while producing NaCl solution as the only byproduct. Notably, the olivine structure of the LFP was preserved as FePO 4 after lithium leaching. The regenerated LFP demonstrated excellent performance, retaining 94.1 % of its capacity after 150 cycles, while the lithium-leached FePO 4 delivered a reversible capacity exceeding 150 mAh/g. This approach not only enhances the efficiency of LFP recycling but also paves the way for more sustainable battery technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2025

An unwanted guest in the electrochemical oxidation of high-voltage Li-ion battery electrolytes: the life of highly reactive protons

Lithium-ion batteries (LIBs) are central to the urgent societal need to decarbonize both transportation and energy storage on the grid. Unfortunately, despite their attractive energy/power density, as well as high coulombic and energy efficiencies, further improvement of this technology – especially their durability – is desperately needed. To support these efforts, our study focuses on fundamental understanding of the decomposition pathways for LIB electrolytes at the cathode–electrolyte interface (CEI), as the nature of these reactions directly controls the extent to which cell capacity and voltage decays in these systems. In this study, we employ electrochemical methods, coupled with product analysis using NMR spectroscopy and mass spectrometry, to determine the decomposition mechanisms in both model and technologically relevant electrolytes. Remarkably, we discovered the electrochemical formation of protons with high chemical activity, comparable to known superacids, at potentials relevant to practical Li-ion batteries. Their reactivity toward every individual component of the CEI provides a unified thermochemical origin for a myriad of side reactions that are commonly associated with the electrochemical reaction. In particular, electrochemically generated protons react with intact EC molecules to form CO 2 and other short and long chain ethers. They also undergo an acid–base reaction with LiPF 6 , to form the weaker acid HF, and with the cathode active material, leaching transition metals into the electrolyte. Collectively, the results of this study all point to the urgent need to either mitigate this proton formation or introduce benign harvesting additives via new electrolyte design strategies.

Ilic, Stefan [Argonne National Laboratory (ANL), A↗

NASA NTRS2022

COMPASS Final Report: 2008 International Lunar Network (ILN)

The Compass team developed three designs for a soft lander for the International Lunar Network (ILN) using different power systems. These systems included solar arrays and batteries and two radioisotope power system (RPS) options scaled down from previous designs. These are a half Stirling radioisotope generator and a one-eighth Radioisotope Thermoelectric Generator (RTG). The COMPASS design consists of a soft-lander capable of network science (seismic, magnetospheric, laser reflector, and thermal transfer) that can land anywhere on the near side of the Moon and operate for at least six years. The baseline version, using only batteries and solar arrays, requires a very large battery (~80 kg) for the roughly 20 W night-time power requirements. The lander launch mass (with solid rocket breaking motor) is almost 900 kg. With such a large battery, the lander will require a launcher larger than the desired Minotaur V; a Taurus II (being developed for NASA Commercial Orbital Transportation Services (COTS)) or larger (Delta II or Atlas V) would be needed. The two RPS cases, half an Advanced Stirling Radioisotope Generators (ASRG) and one-eighth RTG have much smaller launch masses of 500 and 600 kg respectively. (The one-eighth RTG case lacks the power for the full science package, so a solar array battery is still needed.) Unfortunately, the Minotaur V’s launch capability is still not large enough (~430 kg to trans-lunar injection (TLI)) for the RPS systems. Consequently, a fourth case was developed to fly a limited science floor suite of instruments (seismometer only) which reduced the RPS Lander launch mass to fit on a Minotaur V.

Radioisotope Power Systems↗

NASA NTRSDate not supplied

NASA SIBatt-3D: In-Space and On-Surface 3D Printing Sodium-Ion Batteries from ISRU Materials

Sustainable on-demand power solutions are an absolute necessity as humanity works to establish a permanent presence on the moon and make the journey to Mars. NASA’s SIBatt-3D project is developing shape-conformable Sodium-Ion batteries that can be 3D printed in-space as needed during extended space missions. SIBatt-3D seeks to utilize materials found in Lunar/Martian regolith as feedstocks to provide sustainable power for surface operations. SIBatt-3D’s batteries also have terrestrial implications such as improved battery safety and sustainability.

Cameroun Sherrard↗

DOE OSTI2026

Battery Life Prediction Using Reduced-Order Physics Models and Machine Learning (CRADA Final Report)

Phase 1 (Original CRADA, plus no-cost extension modifications #1-3, 6/1/2017 to 3/13/2021): The Australian Department of Defence (AUDoD) is performing accelerated aging tests of Li-ion batteries to benchmark their reliability and degradation characteristics. Using its previously developed battery lifetime predictive model framework, the National Laboratory of the Rockies (NLR) will develop analytical models based the AUDoD data to predict lifetime of the multiple Li-ion battery chemistries under real-world use scenarios of interest to AUDoD. The NLR model is based on physical degradation mechanisms encountered by Li-ion batteries and has been previously validated. Phase 2 (CRADA modification #4, plus no-cost extension modification #5, 2/22/2021 to 3/30/2025): Train and support Australian Department of Defence personnel to use NLR software for model-based estimation of Li-ion battery lifetime using accelerated battery aging data collected by the Australian Department of Defence. Under separate DOE funding from 2019 to 2021, NLR enhanced its battery life-prediction software using machine learning algorithms to automate portions of the model-fitting process, requiring significantly less labor and expert judgment and also adding uncertainty quantification, increasing statistical rigor. Under Phase 2, NLR will customize NLR Software and provide it to AuDoD. NLR will enhance its NLR Model to capture aging modes of AuDoD's multi-cell modules, including cell-balancing effects. NLR will develop example single-cell and multi-cell models based on one AuDoD battery aging dataset. NLR will train AuDoD personnel on NLR Software. By the conclusion of the project, NLR will have provided AuDoD the training materials, a user manual and software needed to perform their own analysis of additional and/or future battery aging datasets.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Long duration battery sizing, siting, and operation under wildfire risk using progressive hedging

Battery sizing and siting problems are computationally challenging due to the need to make long-term planning decisions that are cognizant of short-term operational decisions. This paper considers sizing, siting, and operating batteries in a power grid to maximize their benefits, including price arbitrage and load shed mitigation, during both normal operations and periods with high wildfire ignition risk. Here we formulate a multi-scenario optimization problem for long duration battery storage while considering the possibility of load shedding during Public Safety Power Shutoff (PSPS) events that de-energize lines to mitigate severe wildfire ignition risk. To enable a computationally scalable solution of this problem with many scenarios of wildfire risk and power injection variability, we develop a customized temporal decomposition method based on a progressive hedging framework. Extending traditional progressive hedging techniques, we consider coupling in both placement variables across all scenarios and state-of-charge variables at temporal boundaries. This enforces consistency across scenarios while enabling parallel computations despite both spatial and temporal coupling. The proposed decomposition facilitates efficient and scalable modeling of a full year of hourly operational decisions to inform the sizing and siting of batteries. With this decomposition, we model a year of hourly operational decisions to inform optimal battery placement for a 240-bus WECC model in under 70 min of wall-clock time.

25 ENERGY STORAGE↗