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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 OSTI2020

Fast Determination of Lithium Content in Spent Cathodes for Direct Battery Recycling

Determination of the lithium ion content in cathode materials, which is currently performed by inductively coupled plasma mass spectrometry (ICP-MS), involves tedious procedures and error-prone preparation. This work introduces a new methodology to quickly determine the lithium content in spent cathode materials (LiNix Mny Coz O2, x + y + z = 1, NMC) using a thermalgravimetric analysis, which bypasses the use of ICP-MS and significantly reduces the cost and time required for determining the lithium content. Based on this new method, a new approach is developed to identify spent cathode materials suitable for direct relithiation recycling. Finally, these new methods have been applied to investigate the effectiveness of direct electrochemical-relithiation on recycling the spent cathodes, and provide insights for future development of direct battery materials recycling.

cathode recycling↗
DOE OSTI2025

Unveiling the Mechanism of Mn Dissolution Through a Dynamic Cathode‐Electrolyte Interphase on LiMn2O4

Abstract Understanding the formation and evolution of the cathode‐electrolyte interphase (CEI), which forms at the interface between the cathode and electrolyte, is crucial for revealing degradation mechanisms in cathode materials, especially for developing strategies to stabilize the interphase in the strongly oxidizing conditions that evolve at high operating voltages in next‐generation Li‐ion batteries. However, The present understanding of the CEI is challenged by its complex and dynamic nature. In this work, near‐edge X‐ray absorption fine structure spectroscopy, electrochemical characterization, and reactive molecular dynamics simulations are combined to reveal a mechanism for CEI formation and evolution above model LiMn 2 O 4 (LMO) thin‐film electrodes in contact with conventional carbonate‐based electrolytes. It is found that Mn dissolution from LMO can be understood in terms of repetitive Mn 3 O 4 formation and dissolution behavior during cycling, which is closely connected to electrolyte decomposition and a key aspect of the CEI formation and growth. The behavior of the CEI in this model system offers detailed insight into the dynamic chemistry of the interphase, underscoring the important role of electrolyte composition and cathode surface structure in interphase degradation.

Ou, Wenhan↗
DOE OSTI2025

Upcycling Mixed Spent Ni-Lean Cathodes into Ni-Rich Polycrystalline Cathodes

Sustainable battery recycling is vital for conserving resources and reducing environmental impacts. Current open- and closed-loop recycling strategies often focus on recovering individual components, making the reuse of mixed cathode materials a complex challenge. Meanwhile, the research on upcycling has been limited to using pristine cathode feedstocks and virgin materials for synthesis. Here, to address this issue, we present an upcycling approach for spent Ni-lean mixed cathode materials that integrate an upcycling hydrometallurgical recycling process with traditional hydrometallurgical methods. This strategy achieves a utilization of 92.31 mol % of recycled materials, enabling the regeneration of Ni-rich cathode materials while significantly reducing the reliance on virgin resources. The regenerated 83Ni cathode materials demonstrate physical properties comparable to those produced from virgin materials. Electrochemical evaluations using single-layer pouch cells show that both recycled and virgin cathodes exhibit initial specific capacity close to 201.1 mAh/g and maintain approximately 88 % capacity retention after 500 cycles. Additionally, 2Ah cells confirmed these findings, delivering 85 % capacity retention after about 900 cycles. Techno-economic analysis demonstrates notable environmental benefits, including reductions in greenhouse gas emissions and energy consumption, achieving 232.75 MJ/kg of product, which is 8.6 % lower than traditional methods and comparable to direct upcycling. Furthermore, the upcycling hydrometallurgical recycling process generates the highest profit, proving its economic viability. This scalable and versatile process is adaptable to varying transition metal compositions, facilitating a closed-loop recycling system that bridges mixed spent cathodes with next-generation cathode materials, and offers a sustainable solution for managing waste battery materials.

Hydrometallurgical recycling↗
DOE OSTI2020

Shaped Beams from Diamond Field-Emitter Array Cathodes

Diamond field-emitter arrays (DFEAs) are arrays of diamond pyramids with exquisitely sharp tips and micrometer-scale bases that produce high current densities. These arrays can be fabricated in arbitrary shapes, ranging from single tips to many millions of tips, so that they produce an inherently shaped electron beam. Each tip emits a modest current, but the large dense array can produce many Amps. We are investigating these cathodes for use in dielectric wakefield accelerators; however, they may also be applicable to vacuum microwave tubes. Recently, shaped beam production and transport have been demonstrated in the 1.3-GHz RF gun at the Argonne Cathode Test Stand at the Argonne National Laboratory. The charge was measured on a Faraday cup and the beam imaged on a YAG screen with peak electric field gradients on the cathode ranging from 12 to 35 MV/m. Three cathode geometries were tested: one 1-mm equilateral triangle with 7-mu m base pyramids and 10-mu m pitch, one 1-mm equilateral triangle with 10-mu m base and 25-mu m pitch, and one sparse 5 x 5 square array with 20-mu m base and 400-mu m pitch. The two triangular arrays emitted 35 nC in an RF macropulse at 35 MV/m and 13-nC charge at 27 MV/m, respectively, while the sparse array emitted 0.060-nC charge at 15 MV/m. This article presents the results of the triangular array experiments, including damage due to breakdown in the RF gun and initial models of tip-to-tip shielding.

Cathodes↗
DOE OSTI2021

Elucidating Cycling Rate-Dependent Electrochemical Strains in Sodium Iron Phosphate Cathodes for Na-ion Batteries

Battery electrodes materials undergo significant mechanical instabilities which affects their longevity and exert rate-limitations during the cycling process. In this study, we investigate the rate-dependent mechanical response of sodium iron phosphate (NaFePO4, NFP) cathodes during Na intercalation via galvanostatic cycling at different rates by employing digital image correlation, electrochemical methods, and mathematical model. The mechanical behaviour of the electrode shows strong dependance on the applied scan rate. At slower rates, electrode shows asymmetrical strain generation between anodic and cathodic cycles, which is attributed to the formation of cathode-electrolyte interface layers. The electrode undergoes smaller strain generation when cycled at slower rates when the same amount of Na ions is removed or inserted into the electrode. A mathematical model was developed to predict strain evolution in the composite electrode as well as the concentration profile of the Na ions in the electrode particles. Rate-dependent and time dependent factors on the strain generation in the electrode are attributed to the capacity-dependent intercalation strains, rate-dependent mismatch strains, and time-dependent irreversible strains. The combination of in situ strain measurements with the analytical model provided new insight into the electrochemically induced mechanical deformations in Na-ion cathode electrodes.

Ozdogru, Bertan↗
DOE OSTI2021

Influence of Calendering on the Electrochemical Performance of LiNi 0.9 Mn 0.05 Al 0.05 O 2 Cathodes in Lithium-Ion Cells

Electrode calendering is a necessary process used in industry to improve the volumetric capacity of lithium-ion batteries. However, calendering high-nickel cathodes leads to electrode particle pulverization, raising concerns of a reduced cycle life due to parasitic side reactions. We present here an investigation of the impact of calendering on the morphology and electrochemical performance of the cobalt-free layered oxide cathode LiNi 0.9 Mn 0.05 Al 0.05 O 2 (NMA-90). We find that secondary particle pulverization and fusion simultaneously occur at sufficiently high pressures. The initial surface area of the cathode is shown to increase with the degree of calendering, despite the higher likelihood of secondary particle fusion. Long-term cycling of full coin cells assembled with the NMA-90 cathode and the graphite anode indicates that cells with higher degrees of cathode calendering exhibit lower capacity fade compared to uncalendered cathodes. Hybrid pulse-power tests demonstrate that the usable capacity range of cells with calendered cathodes far exceeds those with uncalendered cells after long-term cycling. The improved capacity retention and pulse-power performance are attributed to the enhanced mechanical properties of the electrode after calendering that prevents loss of the primary particle contact during long-term cycling. As a result, we find that calendering high-nickel NMA-90 to industrially relevant densities does not have a detrimental effect on capacity fade, marking an important step toward commercial adoption.

25 ENERGY STORAGE↗
DOE OSTI2021

Vacancy‐Enabled O3 Phase Stabilization for Manganese‐Rich Layered Sodium Cathodes

Abstract Manganese‐rich layered oxide materials hold great potential as low‐cost and high‐capacity cathodes for Na‐ion batteries. However, they usually form a P2 phase and suffer from fast capacity fade. In this work, an O3 phase sodium cathode has been developed out of a Li and Mn‐rich layered material by leveraging the creation of transition metal (TM) and oxygen vacancies and the electrochemical exchange of Na and Li. The Mn‐rich layered cathode material remains primarily O3 phase during sodiation/desodiation and can have a full sodiation capacity of ca. 220 mAh g −1 . It delivers ca. 160 mAh g −1 specific capacity between 2–3.8 V with >86 % retention over 250 cycles. The TM and oxygen vacancies pre‐formed in the sodiated material enables a reversible migration of TMs from the TM layer to the tetrahedral sites in the Na layer upon de‐sodiation and sodiation. The migration creates metastable states, leading to increased kinetic barrier that prohibits a complete O3‐P3 phase transition.

Xiao, Biwei↗
DOE OSTI2021

Enabling stable and high-rate cycling of a Ni-rich layered oxide cathode for lithium-ion batteries by modification with an artificial Li⁺-conducting cathode-electrolyte interphase

Ni-rich LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM811) cathodes are investigated to realize high energy density Li ion batteries for long life electric vehicle applications. However, capacity decay and thermal instability due to cathode-electrolyte interfacial degradation remain challenges that require sophisticated surface stabilization methods to address. Here, we propose a strategy, for the first time, to form an artificial Li + -conducting cathode-electrolyte interphase (ALCEI) on the NCM811 cathode surface using a nucleophilic reaction between polysulfides and vinylene carbonate (VC). Furthemore, the as-formed ALCEI layer simultaneously protects the NCM particles from electrolyte corrosion and facilitates Li + ion transport, thus enabling stable and high rate cycling of NCM811. As a result, the ALCEI-modified NCM811 cathode exhibits a high capacity (211.6 mA h g -1 at 0.1C), notable rate capability (134 mA h g -1 at 10C), and superior cycle stability (94.2% over 200 cycles at 1C). These results underscore the use of interfacial engineering in high voltage cathode material development and provide a feasible strategy for stabilizing Ni-rich cathode interfaces in practical Li ion battery applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Unveiling the Stabilities of Nickel–Based Layered Oxide Cathodes at an Identical Degree of Delithiation in Lithium–Based Batteries

Bulk, surface, and interfacial instabilities that impact the cycle and thermal performances are the major challenges with high-energy-density LiNi 1–x–y Mn x Co y O 2 (NMC) cathodes with high nickel contents. It is generally believed that the instabilities and performance losses become exponentially aggravated as the nickel content increases. Disparate from this prevailing belief, it is herein demonstrated that NMC cathodes with higher Ni contents may imply better overall stability than “lower-Ni” cathodes under an identical degree of delithiation (charging) conditions. With two representative cathodes, LiNi 0.8 Mn 0.1 Co 0.1 O 2 and LiNiO 2 , a systematic investigation into their stabilities with control of the degree of delithiation is presented. Electrochemical tests indicate that LiNiO 2 displays better cyclability than LiNi 0.8 Mn 0.1 Co 0.1 O 2 at the same delithiation state. Comprehensive structural and interphase investigations unveil that the inferior cyclability of LiNi 0.8 Mn 0.1 Co 0.1 O 2 predominantly results from aggravated parasitic reactions, and the interphase stability may be more critical than lattice stability in dictating cyclability. Also, LiNiO 2 delivers similar or better thermal behavior than LiNi 0.8 Mn 0.1 Co 0.1 O 2 . Finally, the findings demonstrate a strong correlation of the stability of NMC cathodes to the degree of delithiation state rather than the Ni content itself, highlighting the importance of reassessing the true implications of Ni content and structural and interphasial tuning on the stabilities of NMC cathodes.

25 ENERGY STORAGE↗
DOE OSTI2021

Stabilizing Anionic Redox Chemistry in a Mn-Based Layered Oxide Cathode Constructed by Li-Deficient Pristine State

Li-rich cathode materials are of significant interest for coupling anionic redox with cationic redox chemistry to achieve high-energy-density batteries. However, lattice oxygen loss and derived structure distortion would induce serious capacity loss and voltage decay, further hindering its practical application. Herein, a novel Li-rich cathode material, O3-type Li 0.6 [Li 0.2 Mn 0.8 ]O 2 , is developed with the pristine state displaying both a Li excess in the transition metal layer and a deficiency in the alkali metal layer. Benefiting from stable structure evolution and Li migration processes, not only can high reversible capacity (≈329 mAh g -1 ) be harvested but also irreversible/reversible anionic/cationic redox reactions are comprehensively assigned via the combination of in/ex situ spectroscopies. Furthermore, irreversible lattice oxygen loss and structure distortion are effectively restrained, resulting in long-term cycle stability (capacity drop of 0.045% per cycle, 500 cycles). Altogether, tuning the Li state in the alkali metal layer presents a promising way for modification of high-capacity Li-rich cathode candidates.

anionic redox reactions↗
DOE OSTI2021

Origin, nature, and the dynamic behavior of nanoscale vacancy clusters in Ni-rich layered oxide cathodes

Oxygen and transition metal (TM) vacancies in transition metal oxides (TMOs) play an important role in materials functionalities. For TMO cathodes of Li-ion batteries, vacancies can be introduced, either deliberately or inevitably, during materials synthesis or upon electrochemical cycling. Effects of vacancies on the electrochemical properties of cathodes critically depend on the dynamic characteristics of vacancies during the battery cycling. However, a fundamental understanding of such characteristics in the layer structured cathode remains elusive. Here, using scanning transmission electron microscopy (STEM), we reveal a cycling-induced aggregation behavior of oxygen and TM vacancies in a Ni-rich layer structured cathode of secondary particles. We discover that during the initial charging, vacancies aggregate to form visible vacancy-rich nanoregions (vacancy clusters) firstly at the outer layer of the secondary particle, and then the vacancy-cluster populated region extends to the inner part of particle upon fully charged. The spatial distinction of preferential nucleation of vacancy clusters at the outer layer indicates that the vacancy migration and clustering is associated with Li migration flux, which is larger at the outer layer, as all the Li from the inner part has to go through the outer layer. With extended cycling (> 50), these vacancy clusters become immobilized. We further reveal that the generation of these vacancy clusters is correlated to the material-synthesis conditions. Our findings solve a long-standing puzzle on the origin, nature, and behavior of the commonly visible vacancy clusters in the NMC cathode, providing insights on correlation between properties and dynamic behaviors of atomic-scale defects in layered oxide cathodes.

Li-ion batteries, layered oxide cathodes, NMC, cat↗
DOE OSTI2024

Voltage Mining for (De)lithiation-Stabilized Cathodes and a Machine Learning Model for Li-Ion Cathode Voltage

Advances in lithium-metal anodes have inspired interest in discovery of Li-free cathodes, most of which are natively found in their charged state. This is in contrast to today's commercial lithium-ion battery cathodes, which are more stable in their discharged state. In this study, we combine calculated cathode voltage information from both categories of cathode materials, covering 5577 and 2423 total unique structure pairs, respectively. The resulting voltage distributions with respect to the redox pairs and anion types for both classes of compounds emphasize design principles for high-voltage cathodes, which favor later Period 4 transition metals in their higher oxidation states and more electronegative anions like fluorine or polyanion groups. Generally, cathodes that are found in their charged, delithiated state are shown to exhibit voltages lower than those that are most stable in their lithiated state, in agreement with thermodynamic expectations. Deviations from this trend are found to originate from different anion distributions between redox pairs. In addition, a machine learning model for voltage prediction based on chemical formulas is trained and shows state-of-the-art performance when compared to two established composition-based ML models for material properties predictions, Roost and CrabNet.

25 ENERGY STORAGE↗
DOE OSTI2020

Evolution of the Rate-Limiting step: From Thin Film to Thick Ni-rich Cathodes

Ni-rich NMC (LiNixMnyCo1-x-yO2, x = 0.6) has the attributes of high specific capacity (greater than 180 mAh g-1), high operating voltage (ca. 3.8 V) and low cost, which is therefore deemed as one of the most promising cathode candidates for next-generation high-energy Li-ion batteries (LIBs). However, challenges exist before the large-scale commercialization of Ni-rich cathode such as gas generation, capacity degradation especially at high rate or elevated temperatures. From thin film to densely pack high loading cathode, this work investigates the rate-limiting steps in Ni-rich cathodes e.g., phase structure, electronic and ionic conductivity to understand the reaction kinetics at different scales. This work provides new insights in understanding the electrochemical properties of Ni-rich cathode at different levels to inspire revolutionary ideas to address the fundamental issues of Ni-rich cathode from materials to relevant electrode levels.

Hu, Jiangtao↗
DOE OSTI2022

Gas Generation in Lithium Cells with High-Nickel Cathodes and Localized High-Concentration Electrolytes

High-nickel layered-oxide cathodes (LiNi x Mn y Co 1-x-y O 2 , x ≥ 0.8) exhibit high capacities, but also experience rapid capacity fade during cycling, and are susceptible to heat generation and gas release. Advanced electrolytes, such as localized high-concentration electrolytes (LHCE), substantially stabilize the cathode during cycling and have lower flammability than conventional electrolytes, but gas generation with these electrolytes is yet to be assessed. We demonstrate here that gas generation from a high-nickel cathode in an LHCE is half as much as in a conventional electrolyte at 4.4 V. The gas generation in LHCE is further reduced at 4.3 V, but the LHCE generates a similar amount of gas as the conventional electrolyte at 4.6 V. Neither electrolyte can prevent gas generation after cycling; cathodes after 200 cycles generate similar amounts of gas as pristine cathodes during high-voltage hold. Finally, it is shown that in both electrolytes, oxygen from the cathode lattice plays a critical role in gas generation.

25 ENERGY STORAGE↗
DOE OSTI2021

Crossover Effects in Batteries with High–Nickel Cathodes and Lithium–Metal Anodes

It is well understood that cathode-to-anode crossover, especially of transition-metal ions, can significantly impact the long-term cycling of lithium-ion batteries. The dissolved transition-metal ions in lithium-ion cells deposit on the graphite anode, disrupt the solid-electrolyte interphase (SEI), and catalyze further side reactions. Meanwhile, crossover effects in lithium-metal batteries have rarely been studied. This study is the first to investigate crossover effects in lithium-metal batteries with high-nickel layered-oxide cathodes. It is shown that the crossover of transition-metal ions from LiNi 0.9 Mn 0.05 Co 0.05 O 2 has minimal effect on the lithium-metal anode (LMA) due to the following reasons. The catalytic transition metals 1) have less effect on an inherently reactive LMA, 2) are diluted in a thicker SEI, and 3) are produced in overall lower quantity due to the limited cycle life of the LMA. Conversely, the LMA generates soluble decomposition products that cross over to the cathode even during early cycling. This crossover accelerates impedance growth and capacity fade at the cathode and is partially responsible for the mismatch between the performance of half and full-cells with layered-oxide cathodes. Finally, this study highlights the need for better battery design with LMA, potentially including electrolyte or cell modifications.

25 ENERGY STORAGE↗
DOE OSTI2021

Enhancing Oxygen Reduction Activity and Cr Tolerance of Solid Oxide Fuel Cell Cathodes by a Multiphase Catalyst Coating

Intermediate temperature solid oxide fuel cells (IT-SOFCs) are cost-effective and efficient energy conversion systems. Here, the sluggish oxygen reduction reaction (ORR) and the degradation of cathodes are critical challenges to the commercialization of IT-SOFCs. Here, a highly efficient multiphase (MP) catalyst coating, consisting of Ba 1–x Co 0.7 Fe 0.2 Nb 0.1 O 3–δ (BCFN) and BaCO 3 , to enhance the ORR activity and durability of the state-of-the-art lanthanum strontium cobalt ferrite (La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3–δ , LSCF) cathode is reported. The conformal MP catalyst-coated LSCF cathode shows a polarization resistance (R p ) of 0.048 Ω cm 2 at 650 °C, about one order of magnitude smaller than that of the bare LSCF. In an accelerated Cr-poisoning test, the degradation rate of the catalyst-coated LSCF electrode is 10 –3 Ω cm 2 h –1 (0.59% h –1 ) over 200 h, only one fifth of the degradation rate of the bare LSCF electrode at 750 °C. In addition, anode-supported single cells with the MP catalyst-coated LSCF cathode show a dramatically enhanced peak power density (1.4 W cm –2 vs 0.67 W cm –2 at 750 °C) and increased durability against Cr and H 2 O. Both experimental results and density functional theory-based calculations indicate that the BCFN phase improves the ORR activity while the BaCO 3 phase enhances the stability of the LSCF cathode.

solid oxide fuel cells↗