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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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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Image-based modeling of coupled electro-chemo-mechanical behavior of Li-ion battery cathode using an interface-modified reproducing kernel particle method

Abstract An interface-modified reproducing kernel particle method (IM-RKPM) is introduced in this work to allow for a direct model construction from image pixels of heterogeneous polycrystalline Li-ion battery microstructures. The interface-modified reproducing kernel (IM-RK) approximation is constructed through scaling of a kernel function by a regularized distance function in conjunction with strategic placement of interface node locations. This leads to RK shape functions with either weak or strong discontinuities across material interfaces, suitable for modeling various interface mechanics. With the placement of a triple junction node and distance-based scaling of kernel functions, the resulting IM-RK shape function also possesses proper discontinuities at the triple junctions. This IM-RK approximation effectively remedies the well-known Gibb’s oscillation in the smooth approximation of discontinuities. Different from the conventional meshfree approaches for interface discontinuities, this IM-RK approach is done without additional degrees of freedom associated with the enrichment functions, and it is formulated with the standard procedures in the RK shape function construction. This work focuses on identifying the accuracy and convergence properties of IM-RKPM for modeling the coupled electro-chemo-mechanical system. A linear patch test is formulated and numerically tested for the electro-chemo-mechanical coupled problem with a Butler–Volmer boundary condition representing the physical conditions in Li-ion battery microstructures. This is followed by verification of the optimal rates of convergence of IM-RKPM for solving the coupled problem with higher order solutions. The image-based modeling of Li-ion battery microstructures in the numerical examples demonstrates the applicability of the proposed method to realistic Li-ion battery materials modeling.

25 ENERGY STORAGE↗
DOE OSTI2022

Community Resilience through Low-Temperature Geothermal Reservoir Thermal Energy Storage

Submitted data include simulations related to underground thermal battery (UTB) simulations described in Modeling and efficiency study of large scale underground thermal battery deployment, presented at GRC, October 2021. The UTB is comprised of a tank of water, a helical heat exchanger in the center of tank and connected to a water source heat pump, and a phase change material (PCM). Compared to a conventional VBGHE, the UTB is designed to be installed at a much shallower depth, therefore, with a cheaper cost. In addition, the GSHP efficiency is improved due to natural convection of water and additional load capacity provided by PCM. The goal of this study is to explore factors that may affect the efficiency of large-scale UTB deployment. The simulations found in this submission relate to the report on UTB deployment.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Numerical modeling and parametric study of a dual purpose underground thermal battery

We report integrating thermal energy storage with building energy systems can enable flexible building electric demands at buildings to help mitigate the mismatch between electricity supply and demand. A novel building heating and cooling system that integrates a dual-source heat pump with hybrid thermal storage named dual-purpose underground thermal battery (DPUTB) has been developed for reshaping building electric demands. The proposed DPUTB integrated geothermal heat pump system is an original innovation that enables Grid-interactive Energy Efficient buildings. This paper focuses on the study of the novel DPUTB. The DPUTB works as both a thermal storage tank (an inner tank) and a ground heat exchanger (an outer tank separated from the inner tank by the insulation material). High fidelity and computationally effective models are needed to predict the performance of the novel DPUTB. This study has developed a simplified dynamic model for the DPUTB according to heat transfer and energy conservation principles and validated it by using experimental data obtained from testing a small-scale DPUTB apparatus. A parametric study was conducted to identify a design that can achieve the target thermal storage performance of load shift and energy efficiency. The parametric study results show that the inner tank shell thermal conductivity and the phase change material's melting point are the two most influencing factors on the performance of the DPUTB. One single full-size DPUTB with the identified design could provide 1-ton cooling (3.51 kW) with the supply temperature lower than 11 °C for 4 hours in summer after being fully charged in 8 hours. The inner tank filled with phase change material is for cooling thermal storage as a latent tank in the design. However, its capacity can be as high as 60 MJ as a sensible water tank for heating storage in winter. In the future study, the DPUTB model will be incorporated into the dual-source heat pump system for evaluating the overall system performance of demand side management in the long term.

25 ENERGY STORAGE↗
DOE OSTI2023

Acoustic signal based analysis of batteries

Systems and methods for acoustic signal based analysis, include obtaining acoustic response signal data of at least a portion of a battery cell, the acoustic response signal data comprising waveforms generated by transmitting one or more acoustic excitation signals into at least the portion of the battery cell and recording response vibration signals to the one or more acoustic excitation signals. One or more metrics are determined from at least the acoustic response signal data, the one or more metrics being determined based on correlation of the one or more metrics to one or more characteristics of battery cells and a reference model is generated from the one or more metrics. A test battery can be evaluated using the reference model. Actionable insights or recommendations can be generated based on the evaluation. The reference model can also be updated based on the evaluation.

Van Tassell, Barry J.↗
DOE OSTI2025

Insights Into Thermal Runaway Mechanisms: Fast Tomography Analysis of Metal Agglomerates in Lithium-Ion Batteries

Thermal Runaway (TR) in lithium-ion batteries (LIB) is a critical technological and social concern. Whilst such events are rare, TR is characterized by uncontrollable heating leading to catastrophic failures. To deepen the understanding of the failure process and subsequently develop more accurate TR prediction models and as a result safer battery systems, we present in this work high-speed X-ray tomography for in-depth investigations of the copper current collector melting and agglomeration during TR. The melting process presents valuable real-time internal information about heat evolution during TR, previously challenging to access but crucially important for validating TR models. In this work, controlled failure studies combined with high-speed X-ray tomography were performed on two different commercial LIB models, subjecting them to both external heating and nail penetration to induce TR. Through real-time observation via high-speed tomography, followed by segmentation, rendering, and analysis, the formation of copper agglomerates was qualitatively and quantitatively characterized and visualized for the first time. Agglomerates tended to form either from the battery's outermost layers or centrally, depending on the method of TR initiation, and gives an indirect insight into the internal temperature evolution and distribution. Moreover, an initial comparative analysis between the battery models also revealed differences in agglomerate size, which has been linked to the thicker copper current collectors of one of the cell models. We further discuss the impact of larger copper agglomerates on heat distribution and safety. This study not only sheds light on the intricate dynamics of TR in LIBs but also underscores the pivotal role of 'gold-standard' imaging techniques in advancing battery safety, crucial for the robust modeling of TR and the future design of electric vehicle safety systems.

25 ENERGY STORAGE↗
DOE OSTI2026

Multi-physics Preconditioning for Thermally Activated Batteries

Thermal batteries, also known as molten-salt batteries, are single-use reserve power systems activated by pyrotechnic heat generation, which transitions the solid electrolyte into a molten state. The simulation of these batteries relies on multiphysics modeling to evaluate performance and behavior under various conditions. This paper presents advancements in scalable preconditioning strategies for the Thermally Activated Battery Simulator (TABS) tool, enabling efficient solutions to the coupled electrochemical systems that dominate computational costs in thermal battery simulations. We propose a hierarchical block Gauss-Seidel preconditioner implemented through the Teko package in Trilinos, which effectively addresses the challenges posed by tightly coupled physics, including charge transport, porous flow, and species diffusion. The preconditioner leverages scalable subblock solvers, including smoothed aggregation algebraic multigrid (SA-AMG) methods and domain-decomposition techniques, to achieve robust convergence and parallel scalability. Strong and weak scaling studies demonstrate the solver’s ability to handle problem sizes up to 51.3 million degrees of freedom on 2048 processors, achieving near sub-second setup and solve times for the end-to-end electrochemical solve. These advancements significantly improve the computational efficiency and turnaround time of thermal battery simulations, paving the way for higher-resolution models and enabling the transition from 2D axisymmetric to full 3D simulations.

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 OSTI2021

Modeling Coupled Chemo-Mechanical Behavior of Randomly Oriented NMC811 Polycrystalline Li-Ion Battery Cathodes

This paper develops a three-dimensional, transient, chemo-mechanical model that predicts the performance of single secondary particle Li-ion battery cathodes. The secondary particles are composed of numerous (approximately 60) randomly oriented single-crystal primary particles. The model incorporates concentration-dependent and anisotropic material properties. As much as possible, electrochemical, transport, and structural properties for crystalline NMC811 (Li x Ni 0.8 Mn 0.1 Co 0.1 O 2 ) are taken from prior publications. Weak Van der Waals bonding between primary particles is modeled empirically using a spring analogy, which enables local primary-particle separations (disintegration) and subsequent reattachments. The model fully couples Li diffusion and the mechanical response. Results include predictions of local Li-concentrations and stresses. High stresses are found near grain boundaries, especially when the lattice orientations are greatly misaligned. Particle separations are characterized in terms of a damage parameter. The model is used to predict the effects of design and operating conditions, including charge/discharge rates, cycling scenarios, and particle sizes.

25 ENERGY STORAGE↗
DOE OSTI2021

Insight on electrolyte infiltration of lithium ion battery electrodes by means of a new three-dimensional-resolved lattice Boltzmann model

Electrolyte filling takes place between sealing and formation in Lithium Ion Battery (LIB) manufacturing process. This step is crucial as it is directly linked to LIB quality and affects the subsequent time consuming electrolyte wetting process. Although having fast, homogeneous and complete wetting is of paramount importance, this process has not been sufficiently examined and fully understood. For instance, experimentally available data is insufficient to fully capture the complex interplay upon filling between electrolyte and air inside the porous electrode. We report here for the first time a 3D-resolved Lattice Boltzmann Method (LBM) model able to simulate electrolyte filling upon applied pressure of LIB porous electrodes obtained both from experiments (micro X-ray tomography) and computations (stochastic generation, simulation of the manufacturing process using Coarse Grained Molecular Dynamics and Discrete Element Method). The model allows obtaining advanced insights about the impact of the electrode mesostructures on the speed of electrolyte impregnation and wetting, highlighting the importance of porosity, pore size distribution and pores interconnectivity on the filling dynamics. Furthermore, we identify scenarios where volumes with trapped air (dead zones) appear and evaluate the impact of those on the electrochemical behavior of the electrodes.

25 ENERGY STORAGE↗
DOE OSTI2022

The Importance of a Moving Boundary Approach for Modeling the SEI Layer Growth to Predict Capacity Fade

One of the contributing factors to the aging of lithium-ion batteries is the growth of the solid-electrolyte interphase (SEI) layer. The growth of the SEI layer leads to the irreversible loss of lithium available for cycling and increases the resistance of the battery. Physics-based models in literature model the kinetically limited or solvent diffusion-limited growth. In such models, the interface resistance is a constant, and the contribution to the overpotential of the intercalation reaction from the SEI layer is considered to be ohmic. In this study, we propose a model that describes the growth of the SEI layer on the electrode surface as a moving interface. The transport of lithium ions and the solvent in the electrolyte are affected by this moving interface. The equations that govern the species transport and the potential drop across the SEI layer are derived from dilute solution theory and solved by transforming the coordinates of the moving boundary. The ion transport induces changes in the conductivity across the SEI layer, which affects the potential drop that arises due to its growth. The effects of this potential on capacity fade are studied over cycling the battery.

25 ENERGY STORAGE↗
DOE OSTI2022

Data-Driven Simulation-Based Planning for Electric Airport Shuttle Systems: A Real-World Case Study

Many airports are adopting battery electric buses in their shuttle fleets due to concerns over air quality and regulations. This study proposes a simulation-based optimization modeling framework to help airport shuttle operators effectively deploy electric buses. We evaluated a planned airport electric shuttle system with an event-driven simulator. Empirical data collected from existing systems were used to drive the simulations. We then proposed a simulation-based optimization model to determine the battery capacity, charging power, and number of chargers so that predefined objective(s) (e.g., minimizing total capital cost, minimizing emissions) are optimized. Compared to existing studies, the primary contribution of the proposed method is that it can model the real-world stochastic nature of operations in an electric bus system with much higher fidelity. To demonstrate the proposed modeling framework, we study a real-world shuttle system at the Dallas-Fort Worth International Airport, and present extensive numerical studies. When considering partial fleet electrification, the model can provide a set of Pareto optimal solutions. When considering full fleet electrification, the optimal solution requires a 50-kWh battery capacity and four 210-kW chargers, resulting in a total capital cost of $26,744,000. The results demonstrate that the proposed modeling framework can effectively optimize the planning of electric airport shuttle systems with partial or full fleet electrification.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2024

Consumer-Oriented Energy Use and Range Metrics for Battery Electric Vehicles

The present study was motivated by a need to expand information for consumers offered through the FuelEconomy.Gov website. To that end, a power-based modeling approach has been used to examine the effect of steady-speed driving on estimated range for model year 2020 – 2023 battery electric vehicles (BEVs). This approach allowed rapid study of a broader range of BEV models than could be accomplished through vehicle tests. Publicly accessible certification test results and other data were used to perform a regression between cycle-average tractive power requirements and the resulting electrical power. Importantly, this regression enabled estimation of electric power and energy use over a range of steady highway speeds. These analyses in turn allowed projection of vehicle range at differing speeds. The projections agree within 6% with available 65 MPH manufacturer test data. Analyses of vehicles from model years 2020 – 2023 show that the 5-cycle range and energy use values from the window stickers of new vehicles are reasonable values for steady-speed driving at 65 MPH. Range decreases by a median value of approximately 15% for each 10 MPH increase in speed. The 5-cycle energy use (in kW-Hr / 100 miles) and energy economy (in miles / kW-Hr) derived from the 5-cycle energy use are reasonable estimates for 65 MPH steady speed driving. Energy economy decreases by about 0.5 miles / kW-Hr for every 10 MPH increase in speed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Parametric Study of Lithium-Ion Batteries using BatPaC (Final Report)

The Battery Performance and Cost Model (BatPaC) is a tool developed by Argonne National Laboratory to design lithium-ion battery (LIB) packs for automotive applications. The material demand and design specifications are used to estimate the cost of manufacturing the battery pack in a large volume production plant (5-50 GWh/year). With the option to select from various electrode chemistries and materials with their associated properties and prices, the resultant battery pack mass, volume, and cost can vary considerably. This report is the result of a parametric sensitivity study that helps identify the key parameters and prices that affect the battery metrics – the specific energy (Wh/kg) and the pack cost ($/kWh). The study was conducted with LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) and graphite (G) electrodes as the baseline materials used in a battery pack for a 300-mile range battery electric vehicle (BEV300) and a 50-mile range plug-in hybrid electric vehicle (PHEV50).

25 ENERGY STORAGE↗
DOE OSTI2024

Electrolyte Design for Silicon-Based Li-Ion Battery Guided by Chemical Reactivity of Solvents with a Model Silicon Anode

Here, the use of a model compound trimethylsilyllithium was demonstrated to study the chemical reactions of electrolyte with as a principal guide to design electrolyte for silicon-based Li-ion battery. Me 3 Si - anion initiates ring-opening polymerization of EC leading to the formation of poly(ethylene ether carbonate), which subsequently defragments into oligomers and dissolves in electrolyte. FEC was found to react differently, generating LiF and vinylene carbonate (VC). Further reaction of VC with Me 3 SiLi generated poly(hydroxymethylene), which is a nonsoluble polymer and the critical SEI component. The insights from this study have guided the new electrolyte design for the Si-based battery.

25 ENERGY STORAGE↗
DOE OSTI2022

A Comprehensive Numerical and Experimental Study for the Passive Thermal Management in Battery Modules and Packs

Cooling plates in battery packs of electric vehicles play critical roles in passive thermal management systems to reduce risks of catastrophic thermal runaway. In this work, a series of numerical simulations and experiments are carried out to unveil the role of cooling plates (both between cells and a bottom plate parallel to the cell stack) on the thermal behavior of battery modules and packs under nail penetrations. First, we investigated the role of side cooling plates on the thermal runaway propagation mitigation in battery modules (1S3P) and packs (3S3P) by varying the key parameters of the side cooling plates, such as plate thicknesses, thermal contact resistances, and materials. Then, three important factors for passive thermal management systems are identified: (i) thermal mass of side cooling plates, (ii) interfacial thermal contact resistances, and (iii) the effective heat transfer coefficients at exterior surfaces. The roles of bottom cooling plates on thermal runaway propagation mitigation in 1S3P and 1S5P battery modules are numerically investigated by comparing the thermal behavior of the modules with only side cooling plates and with both side and bottom cooling plates.

25 ENERGY STORAGE↗