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DOE OSTI2025

Probing the Effect of Electrode Thermodynamics on Reaction Heterogeneity in Thick Battery Electrodes

Thick electrodes present a viable strategy for enhancing energy density and reducing manufacturing costs of lithium-ion batteries. However, reaction heterogeneity during cycling compromises their rate capability and cycle life. While this nonuniformity is commonly attributed to sluggish charge transport, it is demonstrated here that the thermodynamic properties of the electrode material play an equally critical role. Through combined X-ray fluorescence microscopy and absorption near-edge structure spectroscopy, reaction distributions in LiFePO 4 (LFP) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC) thick electrodes with matched porosity and tortuosity are compared. LFP electrodes develop pronounced depth-oriented state-of-charge (SOC) gradients that worsen with increasing discharge rates, whereas NMC maintains much more uniform SOC distributions under such conditions. This difference originates from their distinct SOC dependence of equilibrium potentials and is quantifiable through a dimensionless “reaction uniformity” number. Intriguingly, LFP thick electrodes also exhibit lateral SOC variations that strengthen during slow discharge. In conclusion, the enhanced reaction uniformity in NMC correlates with better active material utilization and slower capacity fade than LFP, highlighting electrode thermodynamics as a key design consideration for thick electrodes.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Probing the thermodynamics and kinetics of ethylene carbonate reduction at the electrode–electrolyte interface with molecular simulations

Understanding the formation of the solid-electrolyte interphase (SEI) in lithium-ion batteries (LIBs) is an ongoing area of research due to its high degree of complexity and the difficulties encountered by experimental studies. Herein, we investigate the initial stage of SEI growth, the reduction reaction of ethylene carbonate (EC), from both a thermodynamic and kinetic approach with theory and molecular simulation. We employed both the potential distribution theorem (PDT) and the SMD implicit solvent model to EC solvation for the estimation of reduction potentials of Li$^+$, EC, and Li$^+$-solvating EC (s-EC), as well as reduction rate constants of EC and s-EC. We find that solvation effects greatly influence these quantities of interest, particularly the Li$^+$/Li reference electrode potential in EC solvent. Further, we also compute the inner- and outer-sphere reorganization energies for both EC and s-EC at the interface of liquid EC and a hydroxyl-terminated graphite surface, where total reorganization energies are predicted to be 76.6 and 88.9 kcal/mol, respectively. With the computed reorganization energies, we estimate reduction rate constants across a range of overpotentials and show that EC has a larger electron transfer rate constant than s-EC at equilibrium, despite s-EC being more thermodynamically favorable. Furthermore, this manuscript demonstrates how ion solvation effects largely govern the prediction of reduction potentials and electron transfer rate constants at the electrode-electrolyte interface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Numerical investigation of liquid wall ablation in inertial fusion energy chambers

This paper presents a novel approach for modeling liquid wall ablation in liquid wall-protected inertial fusion energy (IFE) chambers. These systems are promising candidates for the implementation of fusion technology, yet significant gaps remain in understanding the underlying physical processes and their implications for design. Following target ignition, a portion of the fusion energy is released as x-rays, which deposit their energy into an array of liquid jets, leading to partial vaporization. Accurately modeling this heat deposition and vaporization process remains challenging due to the complex geometries typical of (pre-conceptual) IFE chamber designs. Furthermore, the subsequent expansion of vaporized material into the chamber’s vacuum environment poses difficulties for conventional CFD methods based on continuum assumptions, which can lead to significant inaccuracies. To address some aspects of these challenges, this work introduces a ray-tracing-based methodology to map the spatial distribution of ablated material in liquid wall-protected systems. In addition, a vacuum-tracking scheme is developed to extend the applicability of an OpenFOAM-based solver to gas dynamics in rarefied environments. The proposed approach has been verified through numerical benchmarks and applied to a practical case involving the HYLIFE-II (High Yield Lithium Injection Fusion Energy) chamber. The methodology advances the modeling capabilities for liquid wall-protected IFE systems and provides valuable tools to support their design and optimization.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Lithium-Ion Batteries with Safer Current Collectors

The US Department of Energy’s Oak Ridge National Laboratory and Soteria Battery Innovation Group collaborated to develop a metallized polymer film as a current collector for lithium-ion batteries and design slit patterns for electrodes to improve battery safety. The metallized polymer film serves as a fuse that will break under high temperature resulting from a short circuit. Consequently, the short circuit will be broken and the heat generated from the short circuit will be alleviated to avoid thermal runaway. The electrodes with slit patterns are expected to be broken into small segments upon mechanical impact, which can isolate the damaged electrodes from the rest. Thus, the heat generation associated with the mechanical impact will be reduced, along with the likelihood of thermal runaway. This effort aimed to improve lithium-ion battery safety by replacing traditional metal foils with metallized polymer films as current collector and introducing slit patterns to battery electrodes. The metallized polymer films were polyethylene terephthalate with a thin metal (aluminum for cathodes and copper for anodes) coating on both sides. Slit patterns with various geometries and dimensions were designed via simulation. Temperature distribution on cells with electrodes with and without slit patterns was also simulated via nemerical modeling. Electrodes on traditional metal foils and metallized polymer films were coated via a pilot-scale slot-die coater at the US Department of Energy Battery Manufacturing Facility at Oak Ridge National Laboratory. The electrodes were calendered to 35% porosity and punched out with and without slit patterns. Pouch cells were assembed with the electrodes inside a dry room for electrochemical and safety testing. Electrodes coated on metallized polymer films exhibited comparable electrochemical performance to their counterparts coated on traditional metal foils. They also showed improved safety in nail penetration and indentation tests.

25 ENERGY STORAGE↗

NASA NTRS2015

NASA Capabilities that Could Impact Terrestrial Smart Grids of the Future

Incremental steps to steadily build, test, refine, and qualify capabilities that lead to affordable flight elements and a deep space capability. Potential Deep Space Vehicle Power system characteristics: power 10 kilowatts average; two independent power channels with multi-level cross-strapping; solar array power 24 plus kilowatts; multi-junction arrays; lithium Ion battery storage 200 plus ampere-hours; sized for deep space or low lunar orbit operation; distribution120 volts secondary (SAE AS 5698); 2 kilowatt power transfer between vehicles.

Power systems↗

DOE OSTI2022

High-efficiency, anode-free lithium–metal batteries with a close-packed homogeneous lithium morphology

Anode-free lithium–metal batteries (LMBs) are ideal candidates for high-capacity energy storage as they eliminate the need for a conventional graphite electrode or excess lithium–metal anode. Current anode-free LMBs suffer from low Coulombic efficiency (CE) due to poor lithium stripping efficiency. Advanced electrolyte development is a promising route to maximize lithium plating and stripping CE and minimize capacity fade. However, a poor understanding of the mechanisms by which advanced electrolytes improve performance hampers progress in the practical development of anode-free LMBs. Here, we use synchrotron techniques and other tools to analyze the influence of three commercially available electrolytes on the composition, heterogeneity, kinetics, morphology, and electrochemistry of anode-free LMBs. Advanced electrolytes improve the electrochemical performance of anode-free LMBs by forming much denser and better-packed Li morphologies on a Cu current collector than on the conventional electrolyte. Li plates uniformly over the electrode area with the advanced electrolytes rather than in a few active sites. Inactive crystalline Li with heterogeneous distribution dominates the capacity degradation of anode-free cells, especially with the conventional electrolyte, indicating that reducing the amount of “dead” crystalline Li will significantly improve the cycling stability of anode-free cells. Finally, the understanding of the Li plating and stripping process obtained from this work will accelerate the development of anode-free LMBs with high efficiency.

25 ENERGY STORAGE↗

NASA NTRSDate not supplied

Comparative Analysis of Thermal Runaway Heat Output as a Function of Trigger Mechanism and Cell Format

High demand for energy storage systems across many fields drives the need for safe and reliable Li-ion batteries. In order to assess the risk of using such batteries in various applications, many types of abuse tests have been developed to push battery cells to their limits and learn how they fail. In this work, internal short circuit (ISC) tests, nail penetration tests, and thermal tests were used to trigger thermal runaway in D-cell, 18650, and 21700 Li-ion cells. High-speed radiography was used to gain insight to the propagation of thermal runaway throughout the cell, while calorimetric and thermal data were recorded in real time. Post-test disassembly of the calorimeter allowed for any mass ejected from the cell to be analyzed and the distribution of mass through the calorimeter to be determined. The impact of cell geometry and trigger mechanism on post-test mass distribution, thermal runaway propagation and internal cell temperature are discussed.

Lithium-ion battery; thermal runaway; calorimetry;↗

DOE OSTI2020

Insights into the Cathode–Electrolyte Interphases of High-Energy-Density Cathodes in Lithium-Ion Batteries

Here we present a comprehensive study of cycled high-Ni (LiNi 1–x M x O 2 , M = metals), Li-rich (Li 1+x Mn y M 1–x–y O 2 ), and high-voltage spinel (LiMn 1.5 Ni 0.5 O 4 ) electrodes with time-of-flight secondary ion mass spectrometry (TOF-SIMS) and X-ray photoelectron spectroscopy in conjunction with electrochemical techniques to better understand their evolving cathode–electrolyte interphase structure during cycling. TOF-SIMS provides fragment-specific information regarding the surface film content for each of the electrodes. High-Ni cathodes show thick surface films initially containing Li 2 CO 3 , later developing oxidized organic carbonates throughout cycling. Li-rich electrode surface films develop strong characteristics during their first activation cycles, where released O 2 oxidizes organic carbonates to form polymeric carbons and decomposes LiPF 6 . High-voltage spinel electrodes operate outside the standard electrolyte stability window, generating reactive oxidized electrolyte species that further decompose LiPF 6 . The distribution and concentration of these different chemical fragments measured by TOF-SIMS are finally summarized by color-coded high-resolution images of cycled high-Ni, Li-rich, and high-voltage spinel electrodes.

25 ENERGY STORAGE↗

DOE OSTI2021

High Interfacial-Energy and Lithiophilic Janus Interphase Enables Stable Lithium Metal Anodes

The stability of solid electrolyte interphase (SEI) layers is critical for developing lithium (Li) metal batteries. However, the fabrication of stable SEI layers is plagued by un-controlled structures, properties, and functions. In this work a controllable design of an ordered LiF-rich and lithiophilic hybrid Janus interphase (LiF-HJI) is reported using organic fluorination reagent as a functional SEI precursor. The LiF-HJI with a lower crystalline LiF layer and an upper Li organosulfide layer provides high interfacial energy with the Li metal and strong Li-ion affinity, allows homogenous Li-ion distribution, fast and uniform Li-ion transport, and excellent mechanical and passivation properties, enabling stable Li metal anodes under harsh conditions, such as high deposition capacities (6 mA h cm -2 ), current densities (10 mA cm -2 ), and rates (5 C). Stable LiF-HJI@Li greatly improves cycling stability and capacity retention (80.1% after 300 cycles) of Li||LiNi 0.8 Co 0.1 Mn 0.1 O 2 cells at a commercial-level areal capacity (≈4.2 mA h cm -2 ). Even under a lean-electrolyte condition of 3 g Ah -1 , 80% capacity retention can be maintained after 100 cycles, demonstrating excellent cycling performance under such harsh conditions.

25 ENERGY STORAGE↗

NASA NTRS1978

Future thrusts of the NASA space power program

General objectives and plan directions are given for current program support in the following areas: (1) solar cells and arrays; (2) batteries and fuel cells; (3) thermoelectric, thermionic, and Brayton cycle conversion systems; (4) circuits and subsystems for the management and distribution of power; and (5) the interactions of the environment with the power system and the spacecraft. Particular emphasis is given to the electrochemical energy conversion storage portion of the program where efforts are directed to improving the energy density and life of nickel cadmium batteries, to validating flight-weight silver hydrogen cells, to promoting the safe use of lithium primary batteries, to completing the silver zinc batteries and the orbital transfer fuel cell technology, to increasing the capacity of space batteries, to and to evaluating new electrochemical concepts for very high energy density. The use of the fuel cell electrolyzer concept for energy storage in both the dedicated and the truly regenerative mode is also being investigated.

Holcomb, L.↗

DOE OSTI2025

Tetrahedral Tilting and Lithium‐Ion Transport in Halide Argyrodites Prepared by Rapid, Microwave‐Assisted Synthesis

Abstract This study demonstrates a rapid, dry, microwave‐assisted (MW) synthesis method that enables preparation of halide argyrodites ( , , ) in less than 20 min. The structures and ion transport properties of the resulting materials are compared with those synthesized by conventional solid‐state synthesis methods. The microwave‐assisted method leads to increased site disorder and elevated Arrhenius prefactors (), which lead to an order of magnitude improvement in the 30 ionic conductivity of MW‐. X‐ray pair distribution function analysis (XPDF) reveals significant rotational disorder of the units, which is impacted by the synthesis method, choice of halide, and presence of / site disorder. These rotational displacements are strongly correlated with ion transport, specifically and entropy of migration (). Overall, this study demonstrates a rapid synthesis route for preparing high‐quality halide argyrodite solid‐state electrolytes in less than 20 min, and further unravels atomistic insights into the interplay of structural disorder, rotational dynamics, and ion transport mechanisms.

36 MATERIALS SCIENCE↗

NASA NTRS2019

Physics-Based Modeling and Simulation of Emerging Battery Technologies for Aerospace

Recently there is a growing interest in the aviation sector to reduce air and noise pollution. Electrochemical energy storage devices such as batteries coupled with a distributed electric propulsion system can reduce noise concerns as well as emissions and allow the concept of Urban Air Mobility to come to fruition. The battery performance needs to improve considerably compared from current state-of-art Li-ion battery (about 200Wh/Kg) to realize all-electric passenger jet for short flights (up to 690 miles). NASA is exploring lithium-oxygen battery chemistry to power hybrid (battery powered electrical system) and all-electric aircraft for short distance and long-distance flights. Li-O2 is one of the advanced Li-ion technologies that promise to provide specific energy of more than 750Wh/Kg. For this presentation, we present our work on improving power density of Li-O2 batteries through the use of multiphysics simulations. Next, a path is outlined to port these model to simulate performance for a new battery chemistry for space application, Li-CO2. Li-CO2 uses carbon dioxide as the active material instead of oxygen. Although this technology is in its early development, the offers two benefits: it can be used as a CO2 scrubber, as oxygen is one of the by-products on charging, and as a backup or a standalone battery for various Mars or Venus missions, where the carbon dioxide content in the atmosphere is high and need battery to operate at higher temperatures.

Mehta, Mohit↗

DOE OSTI2022

Coal-derived graphene foam and micron-sized silicon composite anodes for lithium-ion batteries

Silicon-based materials demonstrate significant potential as lithium-ion batteries (LIBs) anode, but their expansion and degradation present engineering design challenges for commercial application. In this study, a porous three-dimensional (3D) graphene and micron-sized silicon composite anode (Si@G foam) was synthesized using humic acid (HA) derived from coal as a graphene precursor. In-situ formation of graphene structure through reducing HA was confirmed by Raman spectra. The reduced HA (rHA) shows similar electrical conductivity compared to the commercial conductive carbon. SEM images depict a 3D skeleton of coal-derived graphene, with silicon particles distributed on the 3D graphene foam's internal surface. The Si@G composite-anode displays a good reversible capacity of ~656 mAh/g at a current density of 50 mA/g, as well as a high-rate capability of ~433 mAh/g at a current density of 800 mA/g, and outstanding cycling stability –89.8% capacity retention after 300 cycles, which is significantly higher than that of other foam structures. During lithiation and de-lithiation, the graphene foam serves as a matrix of electrical conductors and a volume expansion support for silicon. This 3D graphene network will be beneficial for developing advanced silicon-based anodes for high-performance LIBs.

25 ENERGY STORAGE↗

DOE OSTI2020

Underpotential lithium plating on graphite anodes caused by temperature heterogeneity

Rechargeability and operational safety of commercial lithium (Li)-ion batteries demand further improvement. Plating of metallic Li on graphite anodes is a critical reason for Li-ion battery capacity decay and short circuit. It is generally believed that Li plating is caused by the slow kinetics of graphite intercalation, but in this paper, we demonstrate that thermodynamics also serves a crucial role. We show that a nonuniform temperature distribution within the battery can make local plating of Li above 0 V vs. Li 0 /Li + (room temperature) thermodynamically favorable. This phenomenon is caused by temperature-dependent shifts of the equilibrium potential of Li 0 /Li + . Supported by simulation results, we confirm the likelihood of this failure mechanism during commercial Li-ion battery operation, including both slow and fast charging conditions. This work furthers the understanding of nonuniform Li plating and will inspire future studies to prolong the cycling lifetime of Li-ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Critical Minerals and Materials Matchmaker-CM3

This is the Critical Minerals and Materials Matchmaker (CM3) survey form. CM3 is an online information resource created to help connect users across the critical minerals and materials supply chain. The survey is designed to allow organizations to self-identify their critical minerals and materials-aligned activities and interests, and an interactive map that displays those on-going activities in a dynamic way. To include your critical minerals management activity or activities in CM3, please open and fill out the Critical Minerals and Materials Survey. If your organization has many ongoing or planned activities that would be onerous to enter in the form, or if your activities are difficult to geolocate (such as a transport network), please email the team at edxspatial@netl.doe.gov. This initiative is aligned with the approach of DOE’s H2 Matchmaker and Carbon Matchmaker. Read more information on H2 Matchmaker and Carbon Matchmaker. Below are some questions to help understand if you should fill out the CM3 survey: Does your company work with elements such as lithium, cobalt, copper, graphite, nickel, rare earth minerals, or platinum group metals? Does your organization have research and development activities related to critical materials or their supply chains? Does your company currently work in the critical minerals or materials supply chain? Do you have prospective work in critical minerals or materials in the next 5 years? Does your company mine, process, refine or distribute critical minerals or materials? Do you want to network with other facilities or organizations working in the same areas? Are you curious about the critical mineral and material activity in your surrounding area? Are you interested in aligning your potential needs across the supply chain to different geographic areas within the U.S? For more information, please see the CM3 website (https://www.energy.gov/fecm/articles/critical-minerals-materials-matchmaker-cm3) or email our team at edxspatial@netl.doe.gov.

CM3↗

NASA NTRS1990

A heat receiver design for solar dynamic space power systems

An advanced heat pipe receiver designed for a solar dynamic space power system is described. The power system consists of a solar concentrator, solar heat receiver, Stirling heat engine, linear alternator and waste heat radiator. The solar concentrator focuses the sun's energy into a heat receiver. The engine and alternator convert a portion of this energy to electric power and the remaining heat is rejected by a waste heat radiator. Primary liquid metal heat pipes transport heat energy to the Stirling engine. Thermal energy storage allows this power system to operate during the shade portion of an orbit. Lithium fluoride/calcium fluoride eutectic is the thermal energy storage material. Thermal energy storage canisters are attached to the midsection of each heat pipe. The primary heat pipes pass through a secondary vapor cavity heat pipe near the engine and receiver interface. The secondary vapor cavity heat pipe serves three important functions. First, it smooths out hot spots in the solar cavity and provides even distribution of heat to the engine. Second, the event of a heat pipe failure, the secondary heat pipe cavity can efficiently transfer heat from other operating primary heat pipes to the engine heat exchanger of the defunct heat pipe. Third, the secondary heat pipe vapor cavity reduces temperature drops caused by heat flow into the engine. This unique design provides a high level of reliability and performance.

Baker, Karl W.↗

NASA NTRS1992

Estimation of the nucleation rate by differential scanning calorimetry

A realistic computer model is presented for calculating the time-dependent volume fraction transformed during the devitrification of glasses, assuming the classical theory of nucleation and continuous growth. Time- and cluster-dependent nucleation rates are calculated by modeling directly the evolving cluster distribution. Statistical overlap in the volume fraction transformed is taken into account using the standard Johnson-Mehl-Avrami formalism. Devitrification behavior under isothermal and nonisothermal conditions is described. The model is used to demonstrate that the recent suggestion by Ray and Day (1990) that nonisothermal DSC studies can be used to determine the temperature for the peak nucleation rate, is qualitatively correct for lithium disilicate, the glass investigated.

Kelton, Kenneth F.↗

DOE OSTI2021

MHD flow in liquid metal blankets: Major design issues, MHD guidelines and numerical analysis

The design of breeding blankets represents the major challenge for fusion reactor engineering because of performance requirements and severe operating conditions in terms of heat load and neutron flux. Liquid metal alloys such as lead-lithium, due to their lithium content, can be used to breed tritium, one of the plasma fuel components, and owing to their high thermal conductivity, they may serve as coolants. On the other hand, there are technical issues related to the fact that the liquid metals are electrically conducting and interact with the plasma-confining magnetic field. Induced electric currents and generated electromagnetic forces affect velocity and pressure distribution in the blankets. Magnetohydrodynamic (MHD) flows for fusion applications have been often investigated in simplified geometries, such as pipes, ducts, bends, with focus on their fundamental features. These analyses are essential, since results remain valid as background for the development of blanket designs, even when a concept is dismissed. However, the conceptual study of fusion blankets requires to take into account the global multiple effects, that arise when the full system is considered. Progress made in fusion-related MHD research results from combined numerical and experimental activities. In this paper we review and summarize features of 2D and 3D MHD flows that are typical in liquid metal blankets, together with available correlations for MHD pressure losses. This knowledge can provide simple design MHD guidelines that support a preliminary estimate of MHD effects in a blanket concept, in terms of pressure drop and flow distribution.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗