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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 OSTI2024

Exploring thermal runaway propagation in Li-ion batteries through high-speed X-ray imaging and thermal analysis: Impact of cell chemistry and electrical connections

Battery safety design is important to consider from the individual Li-ion cell to the level of the macro-system. On the macro-level, failure in one single cell can lead to propagation of the thermal runaway and rapidly set a whole battery pack on fire. Factors that can impact the propagation outcome, such as cell model/chemistry and electrical connection are here investigated using a combination of measurements. Several abusive tests were conducted, combining two different cell models (Molicel P42A and LG M50, both 21700s) in series and parallel connections (16 tests per configuration). Overall, a propagation outcome of 56% was measured from the 32 conducted tests, a minimum temperature of 150 °C was required to initiate propagation, and the fastest propagation occurred in 123 s. Temperature measurements were higher in series connected cells, initiating the discussion of cell chemistry and internal resistance on this effect. The difference in current-flow during thermal runaway in series and parallel connections, and how this can affect the temperature evolution is further discussed. Spatio-temporal mapping of X-ray radiography allowed us to derive the speed of thermal runaway evolution inside the battery and has shown that series connected cells, in particular P42A, occur faster. It was further observed that deviant sidewall behaviors such as temperature-induced breaches and pressure-induced ruptures occurred in P42As only respective nail-penetrated cells only.

25 ENERGY STORAGE↗

NASA NTRS1991

Mass properties survey of solar array technologies

An overview of the technologies, electrical performance, and mass characteristics of many of the presently available and the more advanced developmental space solar array technologies is presented. Qualitative trends and quantitative mass estimates as total array output power is increased from 1 kW to 5 kW at End of Life (EOL) from a single wing are shown. The array technologies are part of a database supporting an ongoing solar power subsystem model development for top level subsystem and technology analyses. The model is used to estimate the overall electrical and thermal performance of the complete subsystem, and then calculate the mass and volume of the array, batteries, power management, and thermal control elements as an initial sizing. The array types considered here include planar rigid panel designs, flexible and rigid fold-out planar arrays, and two concentrator designs, one with one critical axis and the other with two critical axes. Solar cell technologies of Si, GaAs, and InP were included in the analyses. Comparisons were made at the array level; hinges, booms, harnesses, support structures, power transfer, and launch retention mountings were included. It is important to note that the results presented are approximations, and in some cases revised or modified performance and mass estimates of specific designs.

Kraus, Robert↗

DOE OSTI2022

Quantitative spatiotemporal mapping of thermal runaway propagation rates in lithium-ion cells using cross-correlated Gabor filtering

Abuse testing of lithium-ion batteries is widely performed in order to develop new safety standards and strategies. However, testing methodologies are not standardised across the research community, especially with failure mechanisms being inherently difficult to reproduce. High-speed X-ray radiography is proven to be a valuable tool to capture events occurring during cell failure, but the observations made remain largely qualitative. We have therefore developed a robust image processing toolbox that can quantify, for the first time, the rate of propagation of battery failure mechanisms revealed by high-speed X-ray radiography. Using Gabor filter, the toolbox selectively tracks the electrode structure at the onset of failure. This facilitated the estimation of the displacement of electrodes undergoing abuse via nail penetration, and also the tracking of objects, such as the nail, as it propagates through a cell. Further, by cross-correlating the Gabor signals, we have produced practical, illustrative spatiotemporal maps of the failure events. From these, we can quantify the propagation rates of electrode displacement prior to the onset of thermal runaway. The highest recorded acceleration (≈514 mm s -2 ) was when a nail penetrated a cell radially (perpendicular to the electrodes) as opposed to axially (parallel to the electrodes). The initiation of thermal runaway was also resolved in combination with electrode displacement, which occurred at a lower acceleration (≈108 mm s -2 ). Our assistive toolbox can also be used to study other types of failure mechanisms, extracting otherwise unattainable kinetic data. Ultimately, this tool can be used to not only validate existing theoretical mechanical models, but also standardise battery failure testing procedures.

25 ENERGY STORAGE↗

DOE OSTI2026

Revolutionizing Energy Storage: AI, Automation, and Advanced Modeling as Catalysts for Next-Generation Breakthroughs

The Presidential Symposium (PRES) at the 2025 Fall Meeting, hosted by the President’s Office and Energy and Fuels Division, American Chemical Society (ACS) in Washington, DC, brought together a diverse group of chemists, engineers, and materials scientists working in battery materials & systems, automation and artificial intelligence from academia, industry, and national laboratories. The accelerating demand for high-performance, scalable, and sustainable energy storage has catalyzed a paradigm shift in how materials are dis-covered, devices are engineered, and systems are optimized. This Presidential Symposium, entitled “Revolutionizing Energy Storage: AI, Automation, and Advanced Modeling Driving Next-Gen Breakthroughs”, brings together global leaders to unveil transformative strategies anchored in the AAA framework: Artificial Intelligence, Automation, and Advanced Modeling. Artificial Intelligence is redefining the frontiers of energy storage by enabling predictive design, real-time optimization, and intelligent control across diverse chemistries and architectures. Automation is streamlining the synthesis, characterization, and testing of battery materials, dramatically accelerating innovation cycles and unlocking scalable solutions for grid and mobility applications. Advanced Modeling, spanning atomic to system-level scales, provides unprecedented insight into electrochemical dynamics, degradation pathways, and thermal behavior, particularly when coupled with physics-informed machine learning and digital twin technologies. Digital twins, in turn, leverage the AAA framework by integrating real-time data, physics-based models, and AI predictions into dynamic virtual replicas, enabling proactive diagnostics, optimization, and system resilience. Together, these synergistic pillars are not only re-shaping the scientific landscape but also forging a new era of reproducible, data-driven, and resilient energy storage innovation. In conclusion, this symposium marks a pivotal moment in the convergence of computational intelligence and experimental rigor, charting the course for next-generation breakthroughs in lithium-ion, solid-state, and flow battery technologies.

Artificial Intelligence (AI)↗

DOE OSTI2023

Geological Thermal Energy Storage Using Solar Thermal and Carnot Batteries: Techno-Economic Analysis

Energy storage is increasingly necessary as variable renewable energy technologies are deployed. Seasonal energy storage can shift energy generation from the summer to the winter, but these technologies must have extremely large energy capacities and low costs. Geological thermal energy storage (GeoTES) is proposed as a solution for long-term energy storage. Excess thermal energy can be stored in permeable reservoirs such as aquifers and depleted hydrocarbon reservoirs for several months. In this article, we describe a techno-economic model that has been developed to evaluate GeoTES systems. The models are developed by combining the output of specialist models, which enables the performance and cost of both the subsurface and surface systems to be captured. Off-design models are developed so that the performance can be evaluated at each hour of the year. GeoTES can be charged with two different energy sources: (1) concentrating solar thermal and (2) renewable electricity using heat pumps (henceforth known as a "Carnot Battery"). The stored thermal energy can be used to generate electricity and, uniquely, also directly produce heat that can be used by industrial processes. Furthermore, Carnot Battery GeoTES can also be used to form a cold storage reservoir. Preliminary results that quantify the technical and economic performance of these two GeoTES systems are presented.

carnot battery↗

DOE OSTI2023

Geological Thermal Energy Storage Using Solar Thermal and Carnot Batteries: Techno-Economic Analysis: Preprint

Energy storage is increasingly necessary as Variable Renewable Energy (VRE) technologies are deployed. Seasonal energy storage can shift energy generation from the summer to the winter, but these technologies must have extremely large energy capacities and low costs. Geological Thermal energy storage (GeoTES) is proposed as a solution for long-term energy storage. Excess thermal energy can be stored in permeable reservoirs such as aquifers and depleted hydrocarbon reservoirs for several months. In this article, we describe a techno-economic model that has been developed to evaluate GeoTES systems. The models are developed by combining the output of specialist models which enables the performance and cost of both the subsurface and surface systems to be captured. Off-design models are developed so that the performance can be evaluated at each hour of the year. GeoTES can be charged with two different energy sources: (1) concentrating solar thermal and (2) renewable electricity using heat pumps (henceforth known as a "Carnot Battery"). The stored thermal energy can be used to generate electricity and - uniquely - also directly produce heat that can be used by industrial processes. Furthermore, Carnot-Battery-GeoTES can also be used to form a cold storage reservoir. Preliminary results that quantify the technical and economic performance of these two GeoTES systems are presented.

carnot battery↗

NASA NTRSDate not supplied

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) thermal management system (TMS) relies on four loop heat pipes (LHPs) to transport electronic waste heat to the vehicle cooling radiative surface and avoid overheating. The TMS has also ten constant conductance heat pipes (CCHPs) dedicated to balance the thermal load within the internal environment where the avionics boxes are mounted, also called warm electronic box (WEB), and to transport the heat from two of the science payload instruments. The TMS also uses two thermal straps to thermally link the batteries to the WEB. These thermal components, in addition to heaters, thermostat, multi-layer insulation (MLIs), and isolators forms the core of the VIPER TMS. The complex heat transport balance managed by the TMS is challenging to characterize and model. The more fidelity and granularity of a model, the more costly the computational resources needed and the longer the simulation and modeling time. When the priority is to provide quick but reliable assessments of the thermal performance or real time thermal feedback for training of console operators, simplified modeling tools are needed. To satisfy that need, this paper describes the effort to develop and correlate a model of VIPER TMS based on control volume approach. The correlation effort in particular focuses on hibernation, cold thermal balance, and hot thermal balance data from the integrated vehicle thermal vacuum (TVAC) test. Thus, the correlated model captures the heat leaks during hibernations and the performance at two extremes, bounding, operating scenarios.

Loop Heat Pipe↗

NASA NTRSDate not supplied

A Simplified Model of VIPER Thermal Management System. Part II: Integrated Vehicle

Thermal Modeling↗

DOE OSTI2021

Pathways towards managing cost and degradation risk of fast charging cells with electrical and thermal controls

The charging rate of Li-ion batteries is limited by the risks of lithium plating and thermal damage, both of which negatively affect lifetime of the batteries. This work analyzes how to minimize charge time and manage the risk of degradation using both electrical and thermal controls. To accomplish this, an electrochemical-thermal model is developed to introduce a constant-risk fast charging protocol which maximizes the charging current while maintaining the cell within pre-defined design limits selected to minimize the risk of degradation. Results indicate 80%-charging of a typical NMC/graphite cell can be achieved within 10 minutes with a cell cost under $100 kW –1 h –1 (corresponding to an 80 μm thick anode) when charged at moderate allowable risks of degradation. Here, we also demonstrate how stretching the allowable risk (i.e., higher temperatures, larger C-rates, and lower anode potential limits) allows affordable design of fast charging cells.

25 ENERGY STORAGE↗

DOE OSTI2024

Ageing Studies of Mega Battery Packs for Grid Storage Applications Using Physics Based Modeling

The lower Levelized Cost of Electricity (LCOE) from wind and solar photovoltaics has enabled for greater integration of variable energy resources with energy storage tech-nologies such as larger centralized lithium-ion battery megapacks (with 1MWh total energy and 500V rating) to provide utility-scale services to grid operators. The daily cycling of standalone lithium-ion grid storage will reduce the battery cells' capacity due to several degradation mechanisms. A comprehensive physics-based Python tm framework called Liionpack was developed to estimate these megapacks' remaining life and ageing. The study includes various degradation mechanisms coupled to the electrochemical-thermal model at the pack level. The effect of the inhomogeneities from cell-to-cell thermodynamic and kinetic properties for different working conditions including temperature and charge/discharge protocols on the ageing of a megapack are presented here.

Karra, Vikrant↗

DOE OSTI2026

Revealing multiscale competing processes in the solid-state synthesis of single-crystalline layered oxide positive electrodes

Solid-state synthesis involves a web of coupled chemical reactions and physical changes that unfold across multiple scales. Efforts to fine-tune its parameters have historically followed heuristic, trial-driven workflows that demand significant time and resources. In this study, we aimed to open this black box by employing multiscale in situ synchrotron imaging and diffraction. Using LiNi 0.5 Mn 0.3 Co 0.2 O 2 battery positive electrode material as a model system and Ba-based sintering aids, we reveal dopant segregation, intergranular mass transport, and porosity evolution as key drivers of single-crystalline particle formation. Notably, we uncovered a dynamic competition between particle-level grain coalescence and atomic-scale cation disordering, both of which are thermally activated yet have opposing impacts on battery performance. These findings highlight the coupled, multiscale nature of structure development and offer a mechanistic basis for optimizing the solid-state synthesis process. This framework provides a path toward more controlled, efficient, and scalable production of high-performance battery positive electrode materials.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Study of Storage Requirements and Costs for Shaping Renewables and Nuclear Energy (FY23 Summary Report)

To decarbonize electricity generation primarily by using wind and solar resources, it is likely that additional low (or zero) carbon dioxide (CO 2 ) alternatives will be required for ensuring a reliable electricity supply. This study extends the work and modeling framework that we consolidated in FY 2022, by assessing the zero-CO 2 pathways of a Texas power system in which the availability of variable renewable energy (VRE), nuclear energy, and energy storage types (i.e., battery and thermal energy storage [TES]) are considered the sole resources available for expansion. Using the Risk Analysis Virtual Environment (RAVEN) and Holistic Energy Resource Optimization Network (HERON) frameworks, this study investigates the market of two nuclear energy technologies (i.e., large light-water reactors [LWRs] and LWR-type small modular reactors [SMRs]) under two plausible storage coupling scenarios (i.e., electric coupling and direct thermal coupling). We also explore optimal environments for nuclear energy deployment, and identify key performance characteristics that make nuclear energy economically viable in areas with significant intermittent energy sources. Our analysis encompasses 24 cases. We model the least-cost grid systems, highlight the potential for a coupled LWR-TES approach, and utilize SMRs to achieve deep decarbonization in an affordable, technically feasible manner. We also examine seasonal variations in balancing electricity supply and demand, and account for varying performance, costs, and grid constraints. Overall, the findings of our modeling afford valuable insights for supporting future technology investment decisions in the energy sector.

25 ENERGY STORAGE↗

NASA NTRS2014

Modeling Materials: Design for Planetary Entry, Electric Aircraft, and Beyond

NASA missions push the limits of what is possible. The development of high-performance materials must keep pace with the agency's demanding, cutting-edge applications. Researchers at NASA's Ames Research Center are performing multiscale computational modeling to accelerate development times and further the design of next-generation aerospace materials. Multiscale modeling combines several computationally intensive techniques ranging from the atomic level to the macroscale, passing output from one level as input to the next level. These methods are applicable to a wide variety of materials systems. For example: (a) Ultra-high-temperature ceramics for hypersonic aircraft-we utilized the full range of multiscale modeling to characterize thermal protection materials for faster, safer air- and spacecraft, (b) Planetary entry heat shields for space vehicles-we computed thermal and mechanical properties of ablative composites by combining several methods, from atomistic simulations to macroscale computations, (c) Advanced batteries for electric aircraft-we performed large-scale molecular dynamics simulations of advanced electrolytes for ultra-high-energy capacity batteries to enable long-distance electric aircraft service; and (d) Shape-memory alloys for high-efficiency aircraft-we used high-fidelity electronic structure calculations to determine phase diagrams in shape-memory transformations. Advances in high-performance computing have been critical to the development of multiscale materials modeling. We used nearly one million processor hours on NASA's Pleiades supercomputer to characterize electrolytes with a fidelity that would be otherwise impossible. For this and other projects, Pleiades enables us to push the physics and accuracy of our calculations to new levels.

Supercomputing↗

NASA NTRS1980

Status of nickel-hydrogen cell technology

Nickel hydrogen cell technology has been developed which solves the problems of thermal management, oxygen management, electrolyte management, and electrical and mechanical design peculiar to this new type of battery. This technology was weight optimized for low orbit operation using computer modeling programs but is near optimum for other orbits. Cells ranging in capacity up to about 70 ampere-hours can be made from components of a single standard size and are available from two manufacturers. The knowledge gained is now being applied to the development of two extensions to the basic design: a second set of larger standard components that will cover the capacity range up to 150 ampere-hours; and the development of multicell common pressure vessel modules to reduce volume, cost and weight. A manufacturing technology program is planned to optimize the producibility of the cell design and reduce cost. The most important areas for further improvement are life and reliability which are governed by electrode and separator technology.

Warnock, D. R.↗

NASA NTRS2014

Non-Cooled Power System for Venus Lander

The Planetary Science Decadal Survey of 2013-2022 stated that the exploration of Venus is of significant interest. Studying the seismic activity of the planet is of particular importance because the findings can be compared to the seismic activity of Earth. Further, the geological and atmospheric properties of Venus will shed light into the past and future of Earth. This paper presents a radioisotope power system (RPS) design for a small low-power Venus lander. The feasibility of the new power system is then compared to that of primary batteries. A requirement for the power source system is to avoid moving parts in order to not interfere with the primary objective of the mission - to collect data about the seismic activity of Venus using a seismometer. The target mission duration of the lander is 117 days, a significant leap from Venera 13, the longest-lived lander on the surface of Venus, which survived for 2 hours. One major assumption for this mission design is that the power source system will not provide cooling to the other components of the lander. This assumption is based on high-temperature electronics technology that will enable the electronics and components of the lander to operate at Venus surface temperature. For the proposed RPS, a customized General Purpose Heat Source Radioisotope Thermoelectric Generator (GPHSRTG) is designed and analyzed. The GPHS-RTG is chosen primarily because it has no moving parts and it is capable of operating for long duration missions on the order of years. This power system is modeled as a spherical structure for a fundamental thermal analysis. The total mass and electrical output of the system are calculated to be 24 kilograms and 26 Watts, respectively. An alternative design for a battery-based power system uses Sodium Sulfur batteries. To deliver a similar electrical output for 117 days, the battery mass is calculated to be 234 kilograms. Reducing mission duration or power required will reduce the required battery mass. Finally, the advantages and disadvantages of both power systems with regard to science return, risk, and cost are briefly compared. The design of the radioisotope power system is considerably riskier because it is novel and would require additional years of further refinement, manufacturing, safety analysis, and testing that the primary batteries do not need. However, the lifetime of the radioisotope power system makes its science return more promising.

planetary↗

DOE OSTI2021

Occupant Preference-Aware Load Scheduling for Resilient Communities

The load scheduling of resilient communities in the islanded mode is subject to many uncertainties such as weather forecast errors and occupant behavior stochasticity. To date, it remains unclear how occupant preferences affect the effectiveness of the load scheduling of resilient communities. This paper proposes an occupant thermal preference-aware load scheduler for resilient communities operating in the islanded mode. First, key resilience indicators are selected to quantify its impacts on the load scheduling of a resilient community. A deterministic model predictive control-based load scheduling framework is adopted as the baseline. Then, a chance-constrained controller is proposed to address the occupant-induced uncertainty in room temperature setpoints. Finally, the chance-constrained controller is compared with the deterministic controller on a virtual community testbed based on a real-world net-zero energy community in Florida, U.S. Results have shown that the proposed chance-constrained controller performs better in terms of serving occupants’ thermal preference and the required battery sizes compared to the deterministic controller with the presence of the assumed stochastic occupant behavior. This work indicates that it is necessary to consider the stochasticity of the occupant behavior when designing optimal load schedulers for resilient communities.

Wang, Jing↗

NASA NTRS2011

Enabling Long-Duration Lunar Equatorial Operations With Thermal Wadi Infrastructure

Long duration missions on the Moon s equator must survive lunar nights. With 350 hr of cryogenic temperatures, lunar nights present a challenge to robotic survival. Insulation is imperfect, so it is not possible to passively contain enough heat to stay warm through the night. Components that enable mobility, environmental sensing and solar power generation must be exposed, and they leak heat. Small, lightweight rovers cannot store enough energy to warm components throughout the night without some external source of heat or power. Thermal wadis, however, can act as external heat sources to keep robots warm through the lunar night. Electrical power can also be provided to rovers during the night from batteries stored in the ground beside wadis. Buried batteries can be warmed by the wadi s heat. Results from analysis of the interaction between a rover and a wadi are presented. A detailed three-dimensional (3D) thermal model and an easily configurable two-dimensional (2D) thermal model are used for analysis.

Jones, Heather L.↗

DOE OSTI2024

Gaining insight into lithium-ion battery degradation by a calorimetric approach

With the growing demand for lithium-ion batteries (LIBs) in transportation and renewable energy sectors, ensuring reliability and mitigating degradation are crucial challenges for their widespread deployment. Here this study investigates the relationship between thermal characteristics and degradation/reliability by developing an in-situ heat measurement methodology for LIBs operating under grid services. Using adiabatic mode-based calorimetry, we examine the thermal behavior of two commercial cells with different cathode chemistries (Ni-rich layered oxide and olivine) before and after two years of grid service (peak shaving) and demonstrate a strong correlation between thermal characteristics and electrochemical performance and its degradation. By further analyzing the heat sources separation (differentiating between irreversible and reversible heat), we disclose the underlying degradation mechanisms of LIBs. These findings emphasize the critical role of thermal characteristics in determining LIB reliability and deterioration, while the obtained heat data can aid in the development and calibration of LIB state-of-health models for grid applications.

25 ENERGY STORAGE↗