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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Superior electrochemical performance and reduced heat generation in 3D printed vs. 2D tape-casted NMC622 electrodes

This study compares the charge storage mechanisms, thermodynamics behavior, ion transport, and heat generation in NMC622 electrodes fabricated using a novel 3D printing process and the conventional 2D tape casting process. First, potentiometric entropy measurements revealed that the charge storage mechanisms for both types of electrodes consisted of lithium deintercalation in a homogeneous solid solution of NMC622 followed by a transition from a hexagonal (H1) phase to another hexagonal (H2) phase through a monoclinic (M) phase. Both types of electrodes had similar thermodynamics behavior with overlapping entropic potential profiles. Furthermore, operando isothermal calorimetry at high C-rates indicated that the 3D printed electrodes featured larger specific capacity and better rate performance than the 2D tape-casted electrodes. The better performance of 3D printed electrodes was attributed to their larger electrode/electrolyte interfacial surface area and electrical conductivity as well as their faster lithium ion transport. As a result, the instantaneous heat generation rates were smaller in 3D printed electrodes than in 2D tape-casted electrodes, thus resulting in lower overall specific electrical energy and thermal energy dissipation per unit charge stored. Overall, additive manufacturing techniques offer great potential in producing electrodes with superior electrochemical performance and reduced heat generation for fast charging batteries.

25 ENERGY STORAGE↗
DOE OSTI2026

Flow dynamics and heat transfer in simplified battery energy storage systems with heated battery modules

Large-scale energy storage systems (ESSs) composed of batteries show promise in addressing current energy challenges, but dissipation of generated heat is important. Here, this paper focuses on buoyant convective flows in simplified ESS battery racks. Natural convection is not generally the primary cooling strategy but can be important in abnormal scenarios where there is module overheat or potentially thermal runaway. We use computational fluid dynamics to investigate the flow dynamics and heat transfer mechanisms in a simplified parameterized rack design. Despite its simplicity, this configuration produces many of the relevant features expected in real ESSs without details of module geometry or hardware, allowing broad conclusions independent of manufacture-specific designs. We start by providing visualizations of the flowfield and measurements of entrainment, heat flux, and pressure. To characterize the dependence on the system parameters, we develop an integral-scale analysis of the average temperature equation to highlight the dominant source terms. We use results from this analysis to derive a steady network model composed of simple algebraic expressions to provide first-order predictions of entrainment through the rack. The network model leads to a linear scaling of the Reynolds number based on convective mass flux with respect to the Grashof number based on the heat source. We deduce empirical relationships that relate the heat exchanged between modules using a surface-averaged Nusselt number as a function of the local Reynolds and Rayleigh numbers. Lastly, we investigate how space between the modules and rack in the spanwise direction creates flow bypass, resulting in different flow pathways.

Battery thermal management↗
DOE OSTI2020

Heat Generation Concerns Associated with Extreme Fast Charging

Present-day thermal management systems for battery electric vehicles are inadequate in limiting the maximum temperature rise of the battery during extreme fast charging. Incorrect thermal management designs for extreme fast charging conditions could result in cells reaching abuse temperatures and potentially sending the cells into thermal runaway. Furthermore, the cell and module design needs to be improved to meet the lifetime expectations of the consumer. Each of these aspects is explored and addressed as well as outlining where the heat is generated in a cell, the efficiencies of power and energy cells, and how to potentially measure the internal temperatures of a battery. Thermal management is not a limiting condition with regards to extreme fast charging, but many factors need to be addressed especially for future high specific energy density cells to meet U.S. Department of Energy cost and volume goals.

ADVANCED PROPULSION SYSTEMS↗
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 OSTI2025

Solid-state batteries enabled by ultra-high-frequency self-heating

Solid-state batteries (SSBs) are promising next-generation batteries due to their high energy density and enhanced thermal stability and safety. However, their sluggish kinetics and transport at room temperature result in high internal impedance and critically reduce the attainable discharge energy density. Taking advantage of their strong temperature-dependent ionic conductivity, here we introduce ultra-high-frequency (greater than 105 Hz) self-heating (UHFSH) of SSBs, which can rapidly warm up the batteries from room temperature to operating temperature (∼65°C) in less than a minute. As proof of concept, UHFSH experiments were conducted on symmetric solid-state cells with lithium aluminum germanium phosphate electrolyte in different configurations. Using an experimentally validated model, pack-level simulations predict fast heating (50 K/min) and minimized heating energy consumption (less than 4%). Without any modification of the materials or structure of the batteries, our non-intrusive self-heating strategy potentially enables SSBs to discharge more than 2-fold energy in 25°C ambient.

pulse heating↗
DOE OSTI2023

A New Analytical Expression for Estimating the Adiabatic Temperature Rise in Lithium-Ion Batteries During High-Power Pulses

A coupled, thermal-electrochemical model is used to explain why the Joule heating assumption (i.e., I 2 R) does not provide a good representation of the temperature rise during high power pulses in lithium-ion batteries, even in cases where the reversible heat generation can be neglected. The poor agreement occurs because the internal resistance changes during the pulse due to the opposing effects of mass transport in the electrolyte, which raises the resistance, and heat generation (temperature rise), which lowers the resistance. These insights are used to propose a new analytical expression for predicting the temperature rise during adiabatic pulses with limited experimental and physical data. The expression accounts for thermal effects using a Taylor series expansion of an Arrhenius-type equation. It accounts for transport effects using an approximate solution to the one-dimensional diffusion equation. The new expression is shown to accurately estimate the simulated, adiabatic temperature rise across a range of loadings (1 to 4 mAh cm -2 ) and C-rates (1C to 10C) for cells containing LiNi 0.5 Mn 0.3 Co 0.2 O 2 positive electrodes and graphite negative electrodes. In conclusion, it is also shown to accurately estimate the experimental, adiabatic temperature rise measured for cells with LiFePO 4 positive electrodes and mesocarbon negative electrodes with minimal changes to the fitted parameters.

25 ENERGY STORAGE↗
DOE OSTI2023

Chapter 6: Abuse Response of Batteries Subjected to Mechanical Impact

Electrochemical and thermal models to simulate nominal performance and abuse response of lithium-ion cells and batteries have been reported widely in the literature. Studies on mechanical failure of cell components and how such events interact with the electrochemical and thermal response are relatively less common. This chapter outlines a framework developed under the Computer Aided Engineering for Batteries program to couple failure modes resulting from external mechanical loading to the onset and propagation of electrochemical and thermal events that follow. Starting with a scalable approach to implement failure criteria based on thermal, mechanical, and electrochemical thresholds, we highlight the practical importance of these models using case studies at the cell and module level. The chapter also highlights a few gaps in our understanding of the comprehensive response of batteries subjected to mechanical crash events, the stochastic nature of some of these failure events, and our approach to build safety maps that help improve robustness of battery design by capturing the sensitivity of some key design parameters to heat generation rates under different mitigation strategies.

abuse simulations↗
DOE OSTI2025

200 h of discharge cycling with an all-aqueous copper thermally regenerative ammonia battery

Thermally regenerative ammonia batteries (TRABs) offer an approach to energy storage and electricity generation by harnessing low-grade heat (T < 150 °C). A TRAB discharge resembles that of a flow battery, where electrochemical reactions produce electrical power from energy stored within aqueous electrolytes. While there are many types of TRABs, the all-aqueous copper TRAB (Cu aq -TRAB) has produced the largest power and energy storage densities. Despite many improvements to TRAB performance, most tests have only lasted a few hours, which are not representative of operation times expected of these devices. Herein, we operated a Cu aq -TRAB for 200 h of constant current discharging to assess battery performance and component stability. After 200 h of testing, the average power density increased slightly to 7.2 mW cm -2 , which was within 0.01 % of starting conditions. Likewise, the average energy density for the final cycle was only 0.03 % lower than the initial cycle. The overall insensitivity of the power cell to cycling represents a major milestone in the advancement of TRAB systems. In conclusion, energy dispersive X-ray spectroscopy provides evidence to suggest that these small changes in power and energy density are likely to the membrane acclimating to TRAB electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2023

Development and testing of residential micro-CHP powered by opposed piston engine (CRADA Final Report)

A micro–combined heat and power (mCHP) prototype powered by innovative opposed piston engine technology was developed to simultaneously provide electricity and heat to residential or light commercial buildings. The mCHP prototype targeted at residential applications includes an opposed-piston four-stroke (OP4S) engine, generator, rectifier, inverter, battery energy storage system, 52 gal water tank, and application accessories for hot water supply and space heating. The OP4S engine can use renewable or regular natural gas, as well as hydrogen, to generate mechanical power and waste heat in form of hot coolant and exhaust gas simultaneously. The waste heat is recovered and stored in the water tank and can be used as a regular hot water supply and/or for space heating application. The tests show that the mCHP prototype enabled power outputs in the range of 3.2 –7.4 kW with up to 26.4% of AC electricity efficiency and up to 93.1% of the overall mCHP efficiency under stoichiometric combustion modes λ=~1.0. The mCHP was also run under lean combustion mode conditions at λ=~1.3. The lean mode operation enables more than 30% improvement in electrical energy efficiency. The maximum AC efficiency of the lean combustion mode attained was 35.2%, with the engine efficiency is approaching 40%. The exceptional electrical efficiency breaks the typical upper boundary of 30% for ICE-based mCHP. The engine exhaust temperatures in the lean modes are substantially less than in the stoichiometric modes. Moreover, the lean cases achieve high overall mCHP efficiencies: the overall mCHP efficiencies are all greater than 93%. Considering the mCHP prototype can achieve low-cost, flexible matching of thermal and electrical loads through reducing the complexity of distribution and installation, and high efficiency the novel technology will promote mCHP acceptance in the US residential and light commercial markets.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Effect of particle size on thermodynamics and lithium ion transport in electrodes made of Ti 2 Nb 2 O 9 microparticles or nanoparticles

This study compares the charging mechanisms, thermodynamics, lithium ion transport, and operando isothermal calorimetry in lithium-ion battery electrodes made of Ti 2 Nb 2 O 9 microparticles or nanoparticles synthesized by solid-state or sol-gel methods, respectively. First, electrochemical testing showed that electrodes made of Ti 2 Nb 2 O 9 nanoparticles exhibited larger specific capacity, smaller polarization, and better capacity retention at large currents than those made of Ti 2 Nb 2 O 9 microparticles. Furthermore, potentiometric entropy measurements revealed that electrodes made of either Ti 2 Nb 2 O 9 microparticles or nanoparticles showed similar thermodynamics behavior governed by lithium intercalation in solid solution, as confirmed by in situ XRD measurements. However, electrodes made of Ti 2 Nb 2 O 9 nanoparticles featured smaller overpotential and faster lithium ion transport than those made of Ti 2 Nb 2 O 9 microparticles. In fact, operando isothermal calorimetry revealed smaller instantaneous and time-averaged irreversible heat generation rates at electrodes made of Ti 2 Nb 2 O 9 nanoparticles, highlighting their smaller resistive losses and larger electrical conductivity. Finally, the measured total heat generation over a charging/discharging cycle matched the measured net electrical energy loss. Overall, Ti 2 Nb 2 O 9 nanoparticles synthesized by the novel sol-gel method displayed excellent cycling performance and reduced heat generation as a fast-charging lithium-ion battery anode material. These features present major advantages for actual battery systems including larger energy and power densities, simpler thermal management, and enhanced safety.

25 ENERGY STORAGE↗
DOE OSTI2026

Linking DSC/TGA to Cell Levels: Energetics, Evolved Gases, and Thermal Safety of NMC811‐Graphite Micro‐Cell

Thermochemical characterization of battery materials links intrinsic material properties to decomposition pathways, heat generation, and gas evolution that govern performance and safety. Despite extensive work on NMC811-Graphite, variability across partial configurations and the limited adoption of micro-cell architectures (cathode+anode+electrolyte+separator) hinder robust cell-scale interpretation. Accordingly, this work establishes a bottom-up, component-resolved methodology integrating DSC/TGA, evolved gas analysis (EGA), and in situ XRD to link decomposition pathways and energy release across partial and micro-cell configurations, providing a transferable assessment of safety and stability in emerging chemistries. In separator-free configurations, the gas–solid reaction between cathode-evolved O 2 and anode-leached Li dominates the net heat release (1139 J g −1 ). In contrast, in the micro-cell configuration, the separator hinders O 2 transport and alters the timing and pathways of other reactions, and reduces the net energy release to 618 J g −1 . Energy release was organized into defined temperature windows that provide a framework for a thermodynamic model combining quantified gas evolution with selected decomposition pathways and effective reaction enthalpies to estimate net specific energy release, with agreement between DSC and cell-level tests. Ex situ XPS of heat-treated samples extends post-mortem analysis to thermal-abuse regimes, supporting key pathway elements.

25 ENERGY STORAGE↗
DOE OSTI2020

Suppression of the Biermann Battery and Stabilization of the Thermomagnetic Instability in Laser Fusion Conditions

Magnetic field generated by the Biermann battery is thought to be one of the principal mechanisms behind the inhibition of heat flow in laser-plasma interactions, and is predicted to grow exponentially in some contexts due to the thermomagnetic instability [Tidman and Shanny, Phys. Fluids 17, 1207 (1974)]. In contrast to these predictions, however, here we have conducted Vlasov-Fokker-Planck simulations of magnetic field dynamics under a range of classically unstable laser-fusion conditions, and find field generation to be strongly suppressed, preventing magnetization of the transport, and stabilizing instability. By deriving new scaling laws, we show that this stabilization is a consequence of (i) heavy suppression of the Biermann battery under nonlocal conditions; (ii) rapid convection of magnetic field by the heat flow; and (iii) comparatively short field length scales. Our results indicate that classical models substantially overestimate the importance of magnetic fields generated by the Biermann battery, and the susceptibility of laser-fusion plasmas to the thermomagnetic instability.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Quantifying the Entropy and Enthalpy of Insertion Materials for Battery Applications Via the Multi-Species, Multi-Reaction Model

The entropy coefficient of a battery cell is the property that governs the amount of reversible heat that is generated during operation. In this work, we propose an extension of the Multi-Species, Multi-Reaction (MSMR) model to capture the entropy coefficient of a large format lithium-ion battery cell. We utilize the hybridized time-frequency domain analysis (HTFDA) method using a multi-functional calorimeter to probe the entropy coefficient of a large format pouch type lithium-ion battery with a NMC 811 cathode and a graphite anode. The measured entropy coefficient profile of the battery cell is deconvoluted into an entropy coefficient for each active material, which is then estimated using an extension of the MSMR model. Finally, we extend the entropy of a material to individual entropy for each gallery as treated by the model.

Electrochemistry↗
DOE OSTI2025

Spokane Eco-District Campus Performance Under Alternative Electricity Rates: Benefits for virtual power plant participants and suppliers

Here, the respective benefits for virtual power plant participants and suppliers are revealed and compared under alternative electricity rate structures, including conventional large commercial electricity rates, large commercial electricity rates with special rates for demand-side generation, and dynamic hourly transactive prices. These three scenarios were explored using the capabilities of the Eco-District campus, a virtual power plant in Spokane, Washington, that is supplied electricity by Avista Utilities. The Eco-District Campus was modeled to host solar power generation, battery energy storage, and thermal energy resources that must be coordinated with building heating and cooling needs. First, the electricity supplier’s costs for energy, infrastructure, and energy losses were modeled. Then, the virtual power plant’s performance was modeled while presuming that its manager would minimize its costs under its electricity rate structure. The demand charges of conventional commercial electricity rates managed monthly peak, as would be expected, but hourly dynamic transactive pricing resulted in a striking alignment between the costs incurred by the supplier and the virtual power plant’s energy costs.

Electricity rates↗
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↗
DOE OSTI2023

Distributed Energy Resource (DER) Reliability for Backup Electric Power Systems

Hospitals, emergency services, military bases, ports, airports, industries, commercial facilities, and others rely on backup power systems to provide electricity for their critical loads during grid outages. The purpose of this report it to provide accurate reliability information on commonly deployed distributed energy resources (DERs) to improve quantitative estimates for the reliability of these backup power systems during a grid outage. A backup power system consists of DERs, an electric distribution system with its associated switches and other devices, and mechanisms to control and manage the flow of electricity. Too often, facilities and campuses fail to properly quantify the reliability of their backup power systems. DERs are assumed to be 100% reliable, with the only concern being the availability of fuel. Such assumptions can lead to gross errors in the backup system's reliability estimates, particularly for long-duration outages. This report provides a set of estimates for reliability of emergency diesel generators (EDGs), natural gas prime generators and combined heat and power (CHP) prime movers, solar photovoltaics (PV), wind turbines, and Li-ion battery energy storage systems (BESS). The estimates are derived from empirical data when available and supplemented by modeling results when needed. These reliability estimates are for the DERs ability to provide power during a grid outage, ranging from an hour to 2 weeks.

14 SOLAR ENERGY↗
DOE OSTI2022

Integration of Heat Pumps With Solar Thermal Systems for Energy Storage

This chapter considers the combination of solar thermal systems with an energy storage device known as a Carnot Battery which charges thermal storage with a heat pump or electric heater. Integrating these systems can provide a variety of advantages, such as dispatchable renewable power generation and electricity storage services. In this chapter a variety of methods for hybridizing these systems are described, and ideal cycle analysis is used to assess their relative merits.

Carnot Battery↗
DOE OSTI2023

CHARACTERIZATION AND DEVELOPMENT OF THE ALL–AQUEOUS COPPER THERMALLY REGENERATIVE AMMONIA BATTERY

Low temperature thermal energy is an abundant and untapped energy source for large scale electrical power and energy production around the world. Many different stationary sources such as industrial and thermal power plants produce significant amounts of low temperature heat that goes unused. The primary reason for the energy loss is because the temperature of the heat is often too low for traditional systems to economically generate power from this waste heat. Many different technologies are being researched to produce grid–scale power from low temperature heat to increase grid efficiency, advance decarbonization efforts, and progress electrical power production to a more distributed system. A thermally regenerative battery (TRB) is one promising technology in this space, as it has large power and energy densities relative to competitive technologies and therefore has the potential to disrupt the current power generation mix. TRBs combine two unit operations (a redox flow battery and a distillation column) which are easily scalable and mature, meaning that if a viable TRB chemistry can be identified, its development to pilot and commercial scale can be streamlined. The all–aqueous, copper thermally regenerative ammonia battery (Cuaq–TRAB) was the first TRB that did not use an electrodeposition/dissolution reaction by stabilizing Cu(I) and Cu(II) in the electrolyte, allowing all electroactive species to be stable in an aqueous phase. Through these electrolyte modifications, coulombic efficiency, open circuit potential, and copper solubility all increased, resulting in large gains to power density, energy density, and energy efficiency.

Cross, Nicholas↗