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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 OSTI2023

North American Lithium-Ion Battery Supply Chain Database Development - Phase II

Lithium-ion batteries (LIBs) are used in a wide range of applications, including cell phones, laptops, power tools, electric vehicles, and grid storage, and are essential for economic growth and addressing climate change. However, the significant demand for LIBs has led to supply chain issues for the United States, as China dominates the processing of battery materials and battery production. To address this concern, NAATBatt International, a trade association of North American battery companies, supported the National Renewable Energy Laboratory in developing a database of companies that mine, process, manufacture, reuse, and recycle batteries in North America. The purpose of this database was to identify strengths and gaps in the supply chain, so that private-government partnerships could develop strategies to create a competitive LIB supply chain in the US. NREL published the first version of this database in 2021 and the second version in 2022. The database includes companies that have a manufacturing facility in North America and are engaged in materials, cells, packs, end-of-life management, as well as those involved in LIB battery modeling, distribution, service and repair, and R&D. In this presentation, we will discuss our approach to collecting data and categorizing various segments and products. We will also provide a summary of the data and present various maps to illustrate the distribution of companies in the database.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗
DOE OSTI2021

Electric-Drive Vehicle Power Electronics Thermal Management: Current Status, Challenges, and Future Directions

Effective thermal management of traction-drive power electronics is critical to the advancement of electric-drive vehicles and is necessary for increasing power density and improving reliability. Replacing traditional silicon devices with more efficient, higher temperature, higher voltage, and higher frequency wide-bandgap (WBG) devices will enable increased power density but will result in higher device heat fluxes. Compact packaging of high-temperature WBG devices near low-temperature-rated components creates thermal management challenges that need to be addressed for future power-dense systems. This paper summarizes the thermal performance of on-road automotive power electronics thermal management systems and provides thermal performance and pumping-power metrics for select vehicles. Thermal analyses reveal that the package/conduction resistance dominates the total thermal resistance (for existing automotive systems). We model advanced packaging concepts and compare the results with existing packaging designs to quantify their thermal performance enhancements. Double-side-cooled configurations that do not use thermal interface materials are package concepts predicted to provide a low junction-to-fluid thermal resistance (compared to current packages). Dielectric-fluid-cooled concepts enable a redesign of the package to reduce the package resistance, can be implemented in single- and two-phase cooling approaches, and allow for cooling of passive components (e.g., capacitors) and bus bars.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Community Public Mobility Using On-Demand, Low-Speed Electric Vehicles: A Case Study in Downtown St. Louis, Missouri

Legacy fixed route transit systems designed to serve commuters struggle to provide efficient and effective service for short neighborhood trips and for population groups unable to access and egress transit stops using active modes (e.g., elderly, disabled). Neighborhood on-demand transit (ODT) services using low-speed electric vehicles (LSEV) are an innovative technological solution that can help fill this gap in service (e.g., short, high-frequency trips) for diverse populations and trip types. This study evaluated user characteristics and travel behavior for a neighborhood ODT service (using LSEVs) in downtown St. Louis, Missouri using responses from a community survey (n=244), ridership data, and vehicle trajectory information. A comparative analysis between neighborhood ODT, fixed route transit, and transportation network companies (TNC) was also conducted from the perspectives of total travel time, cost, and greenhouse gas emissions. Ultimately, the goal of the analysis was to motivate and inform holistic public mobility systems where different services are optimized to meet specific community needs. Findings indicate that the neighborhood ODT was effective at reaching diverse populations (elderly (20%), lower income (27%), and households with limited access to private vehicles (34%)). ODT reduced total travel time by 32% compared to fixed route transit, produced 2.4 - 4.3 times less greenhouse gas emissions per passenger mile (compared to transit and TNCs), and was more affordable (free to users) than alternative options ($1 for transit, $10-12 for TNCs). Overall satisfaction rates were high, with 80% of respondents rating the service a 4 or 5 out of 5.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Optimal hybrid power plants for electric vehicle charging demand

Transmission constraints, increasing motivations to decarbonize, and concerns over peak electric vehicle (EV) load impacts on local grids have driven electric customers to consider behind-the-meter, hybrid power plant generation and storage at the distributed-grid level for EV charging. In this study, we develop capabilities to optimize hybrid power plant component capacities for EV charging. We then demonstrate these capabilities in a case study for Boulder, Colorado, using public EV charging data as well as wind and solar resource data. Our results show system designs that balance the cost of energy with load-meeting and peak shaving performance. Within the case study, systems designed for wind, solar photovoltaic (PV), and storage resulted in lower cost of energy than those optimized for PV and storage only. This indicates that in areas where wind resource exists, hybrid power plants that include wind, PV, and battery assets can better meet EV charging loads (including peak loads that are prone to overloading local grids) than PV and battery assets alone. Future work to address limitations in this paper include extending cost modeling to include performance losses (e.g., based on operations or weather) and charging station costs to estimate levelized cost of charging, and quantifying uncertainty and error in our aggregation methods for estimating EV charging loads at the hourly timescale.

14 SOLAR ENERGY↗
DOE OSTI2020

Electrification Annual Progress Report (FY2019)

During fiscal year 2019 (FY 2019), the U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO) funded early stage research & development (R&D) projects that address Batteries and Electrification of the U.S. transportation sector. The VTO Electrification Sub-Program is composed of Electric Drive Technologies, and Grid Integration activities. The Electric Drive Technologies group conducts R&D projects that advance electric motors and power electronics technologies. The Grid and Charging Infrastructure group conducts R&D projects that advance grid modernization and electric vehicle charging technologies. This document presents a brief overview of the Electrification Sub-Program and progress reports for its R&D projects. Each of the progress reports provide a project overview and highlights of the technical results that were accomplished in FY 2019.

25 ENERGY STORAGE↗
DOE OSTI2019

Planning Optimization for Inductively Charged On-demand Automated Electric Shuttles Project at Greenville, South Carolina

Wireless charging technology presents an ideal fit for autonomous electric vehicles for realizing a fully automated system (vehicle and charger). This paper presents a planning optimization analysis for a pilot project of in-route wireless charging infrastructure serving fixed-route on-demand shared automated electric shuttles (SAESs) at Greenville, South Carolina, USA. A single-objective non-linear mixed integer system planning optimization problem is formulated. A comprehensive cost model representing the overall inductively charged SAESs system is developed, considering road construction, power electronics and materials, traction battery, and installation costs. The optimization problem is solved to determine the best combination of the system key design parameters (number and allocations of wireless chargers, charging power level, track length and on-board battery capacity) that show the most cost-effective solution and allow the SAESs to achieve charge-sustaining operation. The planning platform incorporates representative simulated traffic data (driving speed and routes) for four SAESs in the Greenville using the Simulation of Urban Mobility tool. These data are fed to a vehicle powertrain model and a wireless charger power model to predict the battery power, energy and state-of-charge profiles, which are provided to the search algorithm to assess the design objectives under specific constraints. Finally, the results indicate that implementing high-power (100 kW) wireless charger at a few designated stops for fixed-route SAESs with the proper track length allows the vehicles to realize charge-sustaining operation, infinite range, and zero recharge downtime, with a significant reduction in the on-board battery (36%) and road coverage (69%), at minimum cost.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Recommendations for Minimum Required Diagnostics Information

The rapid growth of electrified transportation, including light- and medium-duty electric vehicles (EVs) as a mobility solution requires a reliable EV-charging infrastructure. To advance charging reliability, the ChargeX Consortium reports “Recommendations for Minimum Required Error Codes for Electric Vehicle Charging Infrastructure” and “Implementation Guide for Minimum Required Error Codes in Electric Vehicle Charging Infrastructure” provided recommendations for a set of minimum required error codes (MRECs), their functional and responsibility classifications, and a guide for their implementation, using Open Charge Point Protocol (OCPP) versions 1.6J4 and 2.0.1.5 These reports outline a recommended practice for consistent error reporting and interpretation, which is essential for communicating issues uniformly across the complex and diverse EV-charging ecosystem. However, MRECs are just one part of diagnosing issues; another critical part is obtaining enough information about the current state and performance of the various charging components to identify root causes for each of the error codes. This additional diagnostics data can be used by technicians or automated systems to understand the context around an issue, allowing for timely resolution, decreased maintenance costs, and increased charging reliability. During everyday operations, data are regularly collected and analyzed across the ecosystem. Although sharing of all that available data would be great for diagnostics, concerns on data ownership, privacy, and original equipment manufacturer (OEM) intellectual property pose a challenge. To overcome this obstacle, this report proposes a set of minimum required diagnostic information (MRDI) and recommends that the industry implement these uniformly across the North American EV charging ecosystem. MRDI provides a means to exchange only data deemed necessary for root cause determination.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Learning electric vehicle driver range anxiety with an initial state of charge-oriented gradient boosting approach

This manuscript focuses on the modeling of electric vehicle (EV) driver’s range anxiety, a fear that a vehicle does not have sufficient range, or state of charge (SOC) of the battery pack, to reach its destination and would strand its occupants. Despite numerous research studies on the modeling of charging behaviors, modeling efforts to understand at what battery percentages do EV drivers charge their vehicles, and what are the associated contributing factors, are rather limited. To this end, an ensemble learning model based on gradient boosting is developed. The model sequentially fits new predictors to new residuals of the previous prediction and, then, minimizes the loss when adding the latest prediction. A total of 18 features are defined and extracted from the multisource data, which cover information on driver, vehicles, stations, traffic conditions, as well as spatial-temporal context information of the charging events. The analyzed dataset includes 4.5-year’s charging event log data from 3,096 users and 468 public charging stations in Kansas City Missouri, and the macroscopic travel demand model maintained by the metropolitan planning organization. Here, the result shows the proposed model achieved a satisfactory result with a R square value of 0.54 and root mean square error of 0.14, both better than multiple linear regression model and random forest model. To reduce range anxiety, it is suggested that the priorities of deploying new charging facilities should be given to the areas with higher daily traffic prediction, with more conservative EV users or that are further from residential areas.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Validation and Parametric Investigations Using a Lumped Thermal Parameter Model of an Internal Permanent Magnet Motor: Preprint

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multi-physics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a Lumped Parameter Thermal Network (LPTN) model of an Internal Permanent Magnet (IPM) synchronous motor within the commercially available Motor-CAD® modeling environment. The IPM motor’s stator is studied at steady state, and winding losses are generated by a constant DC current. The validation is based on temperature comparison with experimental data and with more detailed Finite Element Analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot windings and the end windings - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot windings and end windings. As for the LTPN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance. The latter is often ignored in the literature, whereas its impact on temperature rise was found to be more significant than any other contact resistance within the stator.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Barriers and Opportunities for Energy Technology Adoption in Juneau, Alaska

This report presents findings from a qualitative study examining barriers and opportunities for air source heat pump (ASHP) and electric vehicle (EV) adoption in Juneau, Alaska, with a particular focus on manufactured and multifamily housing. The analysis draws on community insights from end users and middle actors to better understand how technology adoption unfolds in contexts with distinct logistical, infrastructural, and housing constraints. The report is organized according to key barriers and opportunities identified through stakeholder input, providing a structured understanding of adoption dynamics across technologies and housing types. These insights are intended to inform program design and support more effective electrification strategies tailored to local conditions. The study team employed qualitative methods to capture both in-depth and high-level perspectives on technology adoption. Data collection included: 1) two 2-hour focus groups with a total of five end users and seven middle actors, enabling detailed and structured discussion and 2) ten semistructured interviews with manufactured home owners, multifamily landlords, and one tenant, providing complementary insights across housing contexts. Focus groups captured accounts of shared challenges and opportunities while interviews offered more concise reflections on individual experiences. Together, these methods enabled a more comprehensive understanding of both systemic barriers and lived experiences with ASHPs and EVs. The findings reveal that adoption of electrification technologies is shaped by a combination of economic, logistical, and informational factors that vary across housing types, technology characteristics, user groups, and other demographic factors. Addressing these factors requires tailored strategies that reflect local conditions and user experiences. The insights in this report can provide a foundation for organizations such as AEL&P to refine program design, support more effective outreach, and anticipate shifts in energy demand associated with increased electrification. More broadly, the study highlights the importance of incorporating community perspectives when developing electrification initiatives to ensure they are both practical and responsive to real-world constraints.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Electric Vehicle Charging for Residential and Commercial Energy Codes: Technical Brief

Numerous studies show that sales of electric vehicles (EVs) have grown consistently over recent years in the U.S. The U.S. Energy Information Administration (EIA) estimated 3 million EVs were on the road in 2022, and the Edison Electric Institute (EEI) forecasts a total of 26.4 million EVs on the road by 2030. Based on this forecast, EEI projects the need for an additional 12.9 million EV charge ports by 2030. If EV charging infrastructure fails to keep pace with sales of EVs it could result in consumers stranded without options to power their vehicles. EVs are capable of providing substantial benefits to the consumers. EVs are less expensive to operate than conventional internal combustion engine vehicles, have lower maintenance costs, and have the convenience of fueling (charging) at home or work. Studies conducted in California show that costs associated with installing EV charging infrastructure can be substantially more expensive for retrofit scenarios compared to new construction, making inclusion of EV infrastructure in new construction codes a cost-effective policy option to increase infrastructure to meet growing demands. PNNL tracks adoption of mandatory EV provisions across the U.S. As of December 20, 2024, 12 states (California, Oregon, Washington, Colorado, New Mexico, Illinois, Maryland, Delaware, New Jersey, Rhode Island, Massachusetts and Vermont) and 53 local governments have added EV provisions to their building codes, local ordinances and zoning requirements. Originally published in 2022, this tech brief has been revised to align with recent model energy code committee discussions and published EV infrastructure code language. This technical brief summarizes market trends, costs and benefits, and provides sample code language for EV charging infrastructure for consideration to be included in model codes, such as the International Energy Conservation Code (IECC) and ANSI/ASHRAE/IES Standard 90.1, as well as directly by states and local governments in their building codes. The technical brief summarizes related efforts undertaken by states and local governments, and builds upon language considered during the 2021 and 2024 IECC development cycles.

2021 IECC↗
DOE OSTI2022

Breakdown of Electric Vehicle Supply Equipment Installation Costs

The plug-in electric vehicles (PEVs) market is receiving help from the current political climate, incentives at the federal and state levels, excessive cost of petroleum fuel, growing focus on climate solutions, increasing investment and direction by automobile manufacturers and increased awareness through media reports and advertising. Increasingly, the transportation industry, in both the United States and many other countries, is aimed at electric motive energy where practical. Increased investment in research and development have led to increasing vehicle range and lower battery costs; both of which have been deterrents in the past. The increasing demand for PEVs (consisting of the battery electric vehicle [BEV] and plug-in hybrid electric vehicle [PHEV], is challenged by the need for charging infrastructure to support these vehicles. The BEV relies totally on the on-board battery to supply the motive energy while the PHEV utilizes its battery and an installed internal combustion engine (ICE). The maximum benefit is achieved by using the battery power as much as possible. This arrangement requires the use of battery charging equipment, known as electric vehicle supply equipment (EVSE).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Guanajuato Policy Options for Land Transportation Greenhouse Gas Reduction [Slides]

NREL consulted the Mexican state of Guanajuato to help them identify and prioritize policies that are specifically applicable to their land transportation system and help them meet their greenhouse gas (GHG) reduction goals. Three focus groups were held across Guanajuato to get the input from a wide variety of users of the transportation system. These focus groups performed a SWOT (strengths, weaknesses, opportunities and threats) analysis of Guanajuato's transportation system and logged the policy goals of participants. NREL then developed a menu of policy options that have been used successfully in relevant countries and prioritized these policies based on the weighted input from stakeholder groups. The most applicable policies were a paid parking strategy, regional transit master plan, and expanded bike and pedestrian infrastructure. Case studies of these three policies, plus a few more, were then presented to inform Guanajuato of how these policies could successfully be implemented. Finally, the GHG reductions for five of the most applicable policies were estimated to reduce emissions from Guanajuato's land transportation system nearly 40% below business-as-usual emissions by 2050.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Batteries (2021 Annual Progress Report)

This document summarizes the progress of VTO battery R&D projects supported during the fiscal year 2021 (FY 2021). In FY 2021, the DOE VTO battery R&D funding was approximately $\$$115 million. Its R&D focus was on the development of high-energy batteries for EVs as well as very high-power devices for hybrid vehicles. The electrochemical energy storage roadmap (which can be found at the EERE Roadmap web page2) describes ongoing and planned efforts to develop electrochemical storage technologies for EVs. To advance battery technology, which can in turn improve market penetration of PEVs, the program investigates various battery chemistries to overcome specific technical barriers, e.g., battery cost, performance, life (both the calendar life and the cycle life), its tolerance to abusive conditions, and its recyclability/sustainability. VTO R&D has had considerable success, lowering the cost of EV battery packs to $\$$185/kWh in 2019 (representing more than 80% reduction since 2008) yet even further cost reduction is necessary for EVs to achieve head-to-head cost competitiveness with ICEs (without Federal subsidies). In addition, today’s batteries also need improvements in such areas as their ability to accept charging at a high rate, referred to as extreme fast charging (XFC) (15 minute charge) – to provide a “refueling” convenience similar to ICEs, and the ability to operate adequately at low temperatures. Research into “next-gen lithium-ion” batteries which would provide such functionalities is one of the R&D focus areas. VTO is funding research on both “next gen” chemistries (which employ an alloy anode and/or a high voltage cathode) and beyond lithium-ion (BLI) chemistries (which can, for example, employ a lithium metal anode).

25 ENERGY STORAGE↗
DOE OSTI2026

Enhancing the EVI-X National Framework to Address Emerging Questions on Charging Infrastructure Deployment

As national investments in EV charging infrastructure accelerate, this project advances the state-of-the-art in infrastructure analysis to better inform deployment strategies. It enhances NLR's EVI-X Suite, a set of tools supporting national network planning, local site design, and financial evaluation. These capabilities will position VTO to provide timely analysis to the DOT/DOE Joint Office, and to guide the strategic buildout of the national charging network. EVI-X development is closely coordinated with other VTO-funded efforts to ensure consistent, integrated use of key inputs and outputs, including EV adoption scenarios from TEMPO and infrastructure designs developed through EVs@Scale.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗