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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 OSTI2026

Polymer-Grafted Nanoparticles as All-in-One Nanoplatforms

Polymer-grafted nanoparticles (PGNPs) represent a versatile class of hybrid nanomaterials, in which nanoparticle cores and tethered polymer coronas are integrated into structurally programmable building blocks. Rapid advances in nanoparticle surface functionalization and surface-initiated polymerization have enabled increasingly precise control over the nanoparticle core composition and brush architecture, greatly expanding the accessible structural and functional landscape of PGNPs. This review summarizes recent progress in the modular design and structural regulation of PGNPs, with an emphasis on nanoparticle platforms and associated surface functionalization strategies, polymer brush synthesis and architectural control, and the structure−property relationships that govern PGNP behavior. Emerging applications are further highlighted, including additive manufacturing, self-healing materials, membrane-based gas separations, and battery-related systems, where PGNPs provide unique opportunities to couple nanoscale interfacial design with macroscopic performance. Finally, future opportunities are discussed for extending PGNP concepts to increasingly complex, multifunctional, and application-oriented hybrid materials.

functional nanocomposites↗
DOE OSTI2026

Tabletop Testing for EV Charging Ecosystem PKI (Project T34PKI Final Report)

To test the communications and cybersecurity functionality, Electric Vehicle and charging station vendors have had to ship their products to in-person testing events. This is cumbersome, expensive, inefficient, and an impediment to rapid time-to-deployment. In this project Sandia used COTS hardware and Open-Source Software to develop and demonstrate a more agile, productive approach: testing low-voltage controllers independently from high-voltage power delivery sub-systems. This approach allows communications controllers to be transported easily (e.g. shipped at low cost, checked as airline baggage); set up on a table-top (“bench testing”); and use ordinary 120 VAC outlets to conduct agile testing. Table-top platforms become end nodes that can connect to laboratory and cloud-based servers to test communications and cybersecurity, specifically Public Key Infrastructure (PKI) functionality and interoperability, separately from EV battery charging (power/energy transfer) functionality.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Cost‐Effective and Scalable Approach for the Separation and Direct Cathode Recovery from End‐of‐Life Li‐Ion Batteries

Li-ion battery recycling presents a promising opportunity to decrease dependence on foreign sources of materials and harvest precious materials within the United States. Herein, a superior complete direct recycling process on individual end-of-life cells is reported where the recovered high-purity cathode active material, as well as electrolyte salt Li hexafluorophosphate (LiPF 6 ) can be reused without significant processing. This new process utilizes a series of mechanical separation steps that enable the separation of the cathode and anode active materials while they are still attached to their current collectors. Using this type of process can significantly reduce metal contamination and enable a clean cathode that can be directly recycled. The process if implemented commercially can greatly reduce the environmental burden of batteries as the greenhouse gas emissions of 8.25 kg CO 2 e kg −1 from the direct recycling process are 64% lower compared to those from virgin production of cathode material. During electrochemical testing of the recovered LiNi 0.6 Mn 0.2 Co 0.2 O 2 a discharge capacity of ≈160 mAh g −1 and good cyclability of over 250 cycles at 0.33C are achieved. This success paves a new pathway to explore and optimize existing Li-ion battery recycling procedures.

electrolyte reuse↗
DOE OSTI2024

Electrospun Nanofibers

Electrospun nanofibers have been considered promising separator candidates for lithium–sulfur (Li–S) batteries due to their unique properties, including but not limited to their high surface area, superior surface-to-volume ratio, excellent flexibility, good mechanical performance, etc. This chapter aims to provide an overview of research in electrospun nanofibers with their applications in Li–S batteries. It starts with a brief introduction to Li–S batteries, followed by the principle and advantages of electrospun nanofibers performed in this area. Applications of electrospun separators in Li–S batteries have been further discussed in detail. In the end, a future vision regarding challenges and perspectives is proposed to provide insightful comments in this field. It is believed that this chapter will provide an extensive and comprehensive reference to utilize this advanced technique to generate novel nanofiber separators for next-generation Li–S batteries.

Zhu, Jiadeng↗
DOE OSTI2025

Reinforced AEM Separators Based on Triblock Copolymers for Electrode-decoupled RFBs

Washington University in St. Louis (WUSTL), in collaboration with The University of Texas at San Antonio (UTSA) and Giner Inc. developed highly selective anion exchange membranes (AEMs) and a novel electrode-decoupled redox flow battery (RFB) for grid scale energy storage as part of the ARPA-E IONICS program (with connections to the DAYS program in the later part of the project). RFBs exhibit the crucial characteristic of system-level decoupled scaling of energy and power which makes them cost effective for the multi-GWh scales envisioned for grid-scale energy storage solutions. This has led to extensive (and deserved) research interest and attention. This project aimed to enhance the design space available for redox-flow batteries (RFBs) by enabling the long-term separation of disparate cationic (elemental) actives using a highly selective membrane separator, while concurrently permitting the transport of anions to balance charge. The approach proposed was to design and develop a highly selective anion-exchange membrane (AEM), which would in turn permit the design and development of electrode-decoupled RFBs. Pairs of (different element) cationic species with redox reactions exhibiting a large difference in their standard electrode potentials were identified to develop high voltage, high power RFBs while disrupting the existing paradigm of using a single element which can ionize to more than two soluble oxidation states (e.g.: Vanadium).

25 ENERGY STORAGE↗
DOE OSTI2025

Electrode Separation and Froth Flotation for the Recovery of Li-ion Battery Cathode Materials

Increasing use of Li-ion batteries (LIBs) will significantly increase the quantity of LIB waste generated from end-of-life batteries. Spent LiCoO 2 (LCO) battery cathodes contain significant quantities of valuable metals, making them good candidates for recycling. Typical recycling processes rely on high temperatures (pyrometallurgy) and chemical leachants (hydrometallurgy) to completely decompose the cathode and enable material recovery. Direct recycling processes and recovery of active material from electrode scrap do not benefit from such destructive recycling, and an efficient means of separating the cathode active material from the inactive components (e.g., polyvinylidene fluoride (PVDF) binder, conductive carbon) is needed. Here, we explore PVDF removal from LCO cathodes by two separate methods, evaluating their suitability for coupling to subsequent separation by froth flotation (FF). We show that washing electrodes in the solvent PolarClean (PC) dissolves PVDF away from LCO cathodes, enabling separation of the remaining LCO and conductive carbon by FF. The process is suitable for use with both pristine and cycled LCO electrodes, and the pristine recovered material can be used to prepare electrodes capable of cycling at 140 mAh/g. In conclusion, this demonstrates the suitability of coupled PC washing and FF separation for recycling both end-of-life batteries and scrap electrode material.

Batteries↗
DOE OSTI2025

Stress Corrosion Cracking of NaSICON Membranes in Aqueous Electrolytes for Redox-Flow Batteries

The sodium super-ionic conductor (NaSICON) has versatile applications as a ceramic electrolyte for energy storage, where it can serve as an impermeable separator in solid-state batteries and redox flow systems. In particular, NaSICON systems have been proposed to be relatively stable in contact with water, making them compatible with aqueous battery chemistries. However, owing to their brittle nature and metal oxide constituents, stress-corrosion cracking (SCC) is an important failure mechanism that has not been previously explored. In this study, we assess the fracture toughness of NaSICON membranes in contact with aqueous solutions that are relevant to redox flow systems. Microindentation was performed to generate visible surface cracks and residual stress, which were observed to grow in length after exposure to aqueous solutions. This allows for a quantitative measurement of fracture toughness, which decreases after exposure to water. To contextualize these results, we develop a simplified model of the fracture behavior in aqueous redox-flow batteries that incorporate NaSICON membranes, illustrating the importance of SCC in cell design. This work provides quantitative insights into SCC as a failure mode in NaSICON, enhancing our understanding of the chemo-mechanical behavior of ceramic electrolytes in contact with aqueous solutions.

Zhang, Mengyao↗
DOE OSTI2025

Diagnostic-free onboard battery health assessment

Diverse usage patterns induce complex and variable aging behaviors in lithiumion batteries, complicating accurate health diagnosis and prognosis. Separate diagnostic cycles are often used to untangle the battery’s current state of health from prior complex aging patterns. However, these same diagnostic cycles alter the battery’s degradation trajectory, are time-intensive, and cannot be practically performed in onboard applications. Here, in this work, we leverage portions of operational measurements in combination with an interpretable machine learning model to enable rapid, onboard battery health diagnostics and prognostics without offline diagnostic testing and the requirement of historical data. We integrate mechanistic constraints within an encoder-decoder architecture to extract electrode states in a physically interpretable latent space and enable improved reconstruction of the degradation path. The health diagnosis model framework can be flexibly applied across diverse application interests with slight fine-tuning.

battery aging reconstruction↗
DOE OSTI2025

Reciprocal Ternary Molten Salts Enable the Direct Upcycling of Spent Lithium‐Nickel‐Manganese‐Cobalt Oxide (NMC) Mixtures to Make NMC 622

Cathode active material is the most valuable component of spent lithium‐ion batteries, accounting for ≈30% of their overall value. Direct recycling of cathode materials involves recovering, regenerating, and reusing them without breaking down their chemical structure. This approach maximizes the added value of the cathode compound and reduces manufacturing costs by avoiding the need for virgin material production. However, one key challenge in scaling direct recycling from lab to industry is the requirement for highly purified cathode materials, contrasting with the low purity of black mass generated from battery shredding. No efficient separation process currently exists to isolate different lithium‐nickel‐manganese‐cobalt oxides (NMCs) from each other. Thus, direct recycling technologies that can operate with mixtures of multiple NMC stoichiometries will be best‐suited for industrial adoption. This study explores the direct recycling of NMC mixtures into NMC 622 using a “reciprocal ternary molten salts (RTMS)” system. Ionothermal relithiation and upcycling within the RTMS system successfully restore the layered structure, lithium content, and electrochemical performance of degraded NMCs, yielding results comparable to pristine NMC 622 (P‐NMC 622).

25 ENERGY STORAGE↗
DOE OSTI2025

What is the Role of Relative Humidity on Conductivity in Polymer Electrolytes?

Ion transport properties in polymer electrolytes have been widely studied under rigorously dry and highly water-swollen conditions. However, the transition between these extremes, i.e., the low hydration regime, is still poorly understood at the molecular level and relevant to applications ranging from battery electrolytes to electrophoretic separations. Here, in this study, we apply atomistic molecular dynamics simulations to probe the role of hydration on ion mobilities and conductivities in LiTFSI-doped polyethers at low water content (less than 10% water by volume), which corresponds to 0−80% relative humidity conditions. With increasing water content, Li + ions exhibit two distinct regimes in their mobilities. At low water content, the majority of the Li + ions are weakly hydrated (two or fewer water molecules per Li + ion), maintaining strong interactions with their polymer solvation cage, and therefore exhibit only a weak increase in mobility relative to dry conditions. As water content increases, Li + ions form complete hydration shells, residing within water-rich domains that promote faster mobilities. Further, Li + mobilities increase more significantly in polymer electrolytes composed of more hydrophilic polymers and higher salt concentrations due to the formation of larger water-rich domains. In contrast, TFSI − has comparatively weak interactions with both the polymer and water, exhibiting a monotonic increase in mobility as a function of water content. Overall, these results help clarify the molecular mechanisms underlying ionic mobilities and conductivities in polymer electrolytes at low water content.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Three-chamber electrochemical reactor for selective lithium extraction from brine

Efficient lithium recovery from geothermal brines is crucial for the battery industry. Current electrochemical separation methods struggle with the simultaneous presence of Na + , K + , Mg 2+ , and Ca 2+ because these cations are similar to Li + , making it challenging to separate effectively. We address these challenges with a three-chamber reactor featuring a polymer porous solid electrolyte in the middle layer. This design improves the transference number of Li + (t Li+ ) by 2.1 times compared to the two-chamber reactor and also reduces the chlorine evolution reaction, a common side reaction in electrochemical lithium extraction, to only 6.4% in Faradaic Efficiency. Employing a lithium-ion conductive glass ceramic (LICGC) membrane, the reactor achieved high t Li+ of 97.5% in LiOH production from simulated brine, while the concentrations of Na + K + , Mg 2+ , and Ca 2+ are below the detection limit. Electrochemical experiments and surface analysis elucidated the cation transport mechanism, highlighting the impact of Na + on Li + migration at the LICGC interface.

Science & Technology - Other Topics↗
DOE OSTI2024

Optimal Membrane Cascade Design for Critical Mineral Recovery Through Logic-based Superstructure Optimization

Critical minerals and rare earth elements play an important role in our climate change initiatives, particularly in applications related with energy storage. Here, we use discrete optimization approaches to design a process for the recovery of Lithium and Cobalt from battery recycling, through membrane separation. Our contribution involves proposing a Generalized Disjunctive Programming (GDP) model for the optimal design of a multistage diafiltration cascade for Li-Co separation. By solving the resulting nonconvex mixed-integer nonlinear program model to global optimality, we investigated scalability and solution quality variations with changes in the number of stages and elements per stage. Results demonstrate the computational tractability of the nonlinear GDP formulation for design of membrane separation processes while opening the door for decom-position strategies for multicomponent separation cascades. Future work aims to extend the GDP formulation to account for stage installation and explore various decomposition techniques to enhance solution efficiency.

Ovalle, Daniel↗
DOE OSTI2026

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗
DOE OSTI2026

Scalable High-Throughput Open-Air Spray-Plasma Manufacturing of Solid-State Lithium Batteries

This final technical report presents a comprehensive analysis of a novel plasma-based in-line manufacturing process for large-area, LLZO-separator-based, solid-state lithium-ion batteries, demonstrating both technical feasibility and economic advantages over conventional vacuum deposition methods. The technical validation shows that spray-deposition with plasma curing achieves comparable electrode and separator quality to vacuum techniques while enabling continuous processing of components and industrially relevant film areas. Critical material interfaces maintain low porosity and high ionic conductivities, which confirm the process's ability to overcome the primary limitation of conventional methods - the trade-off between deposition quality and economically-viable production scale.

25 ENERGY STORAGE↗
DOE OSTI2026

Battery Life Prediction Using Reduced-Order Physics Models and Machine Learning (CRADA Final Report)

Phase 1 (Original CRADA, plus no-cost extension modifications #1-3, 6/1/2017 to 3/13/2021): The Australian Department of Defence (AUDoD) is performing accelerated aging tests of Li-ion batteries to benchmark their reliability and degradation characteristics. Using its previously developed battery lifetime predictive model framework, the National Laboratory of the Rockies (NLR) will develop analytical models based the AUDoD data to predict lifetime of the multiple Li-ion battery chemistries under real-world use scenarios of interest to AUDoD. The NLR model is based on physical degradation mechanisms encountered by Li-ion batteries and has been previously validated. Phase 2 (CRADA modification #4, plus no-cost extension modification #5, 2/22/2021 to 3/30/2025): Train and support Australian Department of Defence personnel to use NLR software for model-based estimation of Li-ion battery lifetime using accelerated battery aging data collected by the Australian Department of Defence. Under separate DOE funding from 2019 to 2021, NLR enhanced its battery life-prediction software using machine learning algorithms to automate portions of the model-fitting process, requiring significantly less labor and expert judgment and also adding uncertainty quantification, increasing statistical rigor. Under Phase 2, NLR will customize NLR Software and provide it to AuDoD. NLR will enhance its NLR Model to capture aging modes of AuDoD's multi-cell modules, including cell-balancing effects. NLR will develop example single-cell and multi-cell models based on one AuDoD battery aging dataset. NLR will train AuDoD personnel on NLR Software. By the conclusion of the project, NLR will have provided AuDoD the training materials, a user manual and software needed to perform their own analysis of additional and/or future battery aging datasets.

33 ADVANCED PROPULSION SYSTEMS↗