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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
NASA NTRS2018

Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Battery Assessment

In 2013, the Boeing Company model 787-8 Dreamliner commercial aircraft experienced three catastrophic lithium (Li) battery failures. The cause of each failure resulted in a single-cell thermal runaway (TR) condition, which propagated to adjacent battery cells. Two of the failures involved rechargeable lithium-ion (Li-Ion) batteries, and the third event involved a nonrechargeable lithium-manganese dioxide (Li-MnO2) battery. In response to these Li battery failures, the NASA Engineering and Safety Center (NESC) approved a technical assessment of the International Space Station Simplified Aid for Extra-Vehicular Activity Rescue (SAFER) Li non-rechargeable battery. This assessment was conducted to evaluate the SAFER Li nonrechargeable battery safety design features against Boeing 787 Dreamliner Li battery failure lessons learned. Specifically, this investigation focused on assessing the severity of a SAFER battery TR hazard conditions.

Iannello, Christopher J.↗
NASA NTRS2003

Polymer Energy Rechargeable System Battery Being Developed

Long description. Illustrations of discotic liquid crystals, rod-coil polymers, lithium-ion conducting channel dilithium phthalocyanine (Li2Pc) from top and side, novel star polyethylene oxide structures, composite polyethylene oxide materials (showing polyethylene oxide + lithium salt, carbon atoms and oxygen atoms), homopolyrotaxanes, and diblock copolymers In fiscal year 2000, NASA established a program to develop the next generation, lithium-based, polymer electrolyte batteries for aerospace applications. The goal of this program, known as Polymer Energy Rechargeable Systems (PERS), is to develop a space-qualified, advanced battery system embodying polymer electrolyte and lithium-based electrode technologies and to establish world-class domestic manufacturing capabilities for advanced batteries with improved performance characteristics that address NASA s future aerospace battery requirements.

Manzo, Michelle A.↗
NASA NTRS2002

Improved low temperature performance of lithium ion cells with quaternary carbonate-based electrolytes

In order to enable future missions involving the exploration of the surface of Mars with Landers and Rovers, NASA desires long life, high energy density rechargeable batteries which can operate well at very low temperature (down to 40(deg)C). Lithium-ion technology has been identified as being the most promising chemistry, due to high gravimetric and volumetric energy densities, as well as, long life characteristics. However, the state-of-art (SOA) technology is not sufficient to meet the needs of many applications that require excellent low temperature capabilities. To further improve this technology, work at JF'L has been focused upon developing electrolytes that result in lithium-ion cells with wider temperature ranges of operation. These efforts have led to the identification of a number of ternary and quaternary, all carbonate-based electrolytes that have been demonstrated to result in improved low temperature performance in experimental three-electrode MCMB carbon/LiNio.sCoo.zOz cells. A number of electrochemical characterization techniques were performed on these cells (i.e., Tafel polarization measurements, linear polarization measurements, and electrochemical impedance spectroscopy (EIS)) to further enhance our understanding of the performance limitations at low temperature. The most promising electrolyte formulations, namely 1 .O M LiPF6EC+DEC+DMC+EMC (1 : 1: 1 :2 v/v) and 1 .O M LiPF6 EC+DEC+DMC+EMC (1 : 1 : 1 :3 v/v), were incorporated into SAFT prototype DD-size (9 Ahr) lithium- cells for evaluation. A number of electrical tests were performed on these cells, including rate characterization as a function of temperature, cycle life characterization at different temperatures, as well as, many mission specific characterization test to determine their viability to enable future missions to Mars. Excellent performance was observed with the prototype DD-size cells over a wide temperature range (-50 to 4OoC), with high specific energy being delivered at very low temperatures (i.e, over 95 WHrKg being delivered at 40(deg)C using a C/10 discharge rate).

Li-ion low temperature electrolytes↗
NASA NTRS2003

Long Life, High Energy Silver-Zinc Batteries

This viewgraph presentation includes: 1) an introduction to RBC Technologies; 2) Rechargeable Zinc Alkaline (RZA(tm)) Systems which include MnO2/Zn, Ni/Zn, Ag/Zn, and Zn/Air; and 3) RZA Silver/Zinc Battery Developments. Conclusions include the following: 1)Issues with long term wet life and cycle life of the silver/zinc battery system are being overcome through the use of new anode formulations and separator designs; 2) Performance may exceed 200 cycles to 80% of initial capacity and ultimate wet-life of > 36 months; and 3) Rechargeable silver/zinc batteries available in prismatic and cylindrical formats may provide a high energy, high power alternative to lithium-ion in military/aerospace applications.

Kainthla, Ramesh↗
DOE OSTI2025

Defect-Engineered High-Entropy Spinel Oxide@Onion-Like Carbon Catalysts for High-Areal-Energy Rechargeable Zinc–Air Batteries

Rechargeable zinc-air batteries (ReZAB) have emerged as the next-generation batteries with several advantages over the conventional lithium-ion battery. In this work, single nanocrystals of inverse-type high-entropy spinel oxides (HESOx, particle size of 10−12 nm) confined in highly curved defective onion-like carbons (HESOx/OLC AT ) as efficient electrocatalysts for oxygen evolution reaction (OER), oxygen reduction reaction (ORR), and ReZAB, have been synthesized. The HESOx materials were thoroughly characterized using several analytical techniques, including X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning transmission electron microscopy (STEM), Raman, and electron paramagnetic resonance (EPR). HESOx/OLC AT catalyst was tested for ReZAB using literature-recommended parameters that would allow for real technological application. These parameters include a current loading of 10 mA cm −2 and a discharge areal energy density of 35 mWh cm geometric −2 , which maps a Li-ion battery pack-level specific energy of 120 Wh kg pack −1 . HESOx/OLC AT electrocatalysts allowed for continuous discharging and charging at a current loading of 10 mA cm −2 with discharge areal energy densities between 37 and 74 mWh cm geometric −2 , thus outperforming the recommended threshold of 35 mWh cm geometric −2 . Considering that most studies (>90%) hardly meet the recommended threshold for technological application of ReZAB, the present work represents one of the top-performing electrocatalysts for ReZAB. The excellent electrocatalytic properties of defect-rich HESOx/OLC AT toward ORR/OER and ReZAB are governed by the strong electronic modulation arising from d-π hybridization, the availability of multiple catalytic sites for intermediates, and weakened d-band centers of the rate-determining intermediates (i.e., *O adsorption for ORR and *OOH formation for OER) compared to the pristine HESOx. This work introduces an effective approach for the design and synthesis of single nanocrystals of high-entropy electrocatalysts for the development of low-cost, robust, and technologically relevant rechargeable zinc−air batteries.

25 ENERGY STORAGE↗
NASA NTRS2005

Nanostructured MnO2-Based Cathodes for Li-Ion/Polymer Cells

Nanostructured MnO2-based cathodes for Li-ion/polymer electrochemical cells have been investigated in a continuing effort to develop safe, high-energy-density, reliable, low-toxicity, rechargeable batteries for a variety of applications in NASA programs and in mass-produced commercial electronic equipment. Whereas the energy densities of state-of-the-art lithium-ion/polymer batteries range from 150 to 175 W h/kg, the goal of this effort is to increase the typical energy density to about 250 W h/kg. It is also expected that an incidental benefit of this effort will be increases in power densities because the distances over which Li ions must diffuse through nanostructured cathode materials are smaller than those through solid bulk cathode materials.

Skandan, Ganesh↗
DOE OSTI2025

Weakly solvating electrolytes: a solvation-centric paradigm for rechargeable metal batteries

Electrolyte design has long followed a solvation-first paradigm that prioritizes solvents capable of maximizing salt dissociation and ionic conductivity, while treating interfacial degradation and rheological limitations as secondary constraints. Although this approach has enabled significant progress in lithium-ion and sodium-ion batteries, it inherently favors solvent-dominated solvation structures that destabilize reactive metal interfaces. Weakly solvating electrolytes (WSEs) offer a fundamentally different strategy. By using solvents with intrinsically low donor strength and minimal electrostatic affinity for cations, WSEs suppress cation–solvent coordination and promote anion-rich solvation shells without relying on salt superconcentration. This shift lowers desolvation barriers, redirects interfacial decomposition pathways, and supports the formation of inorganic-rich, stable interphases. In this review, we discuss the molecular and solvation criteria that distinguish WSEs from conventional and concentrated or locally concentrated electrolyte systems, examine their implementation across different chemistries, and identify unresolved design challenges. WSEs are presented not as a niche formulation, but as a solvation-centric framework for rethinking electrolyte function in metal battery technologies.

Karbak, Mehdi [Pacific Northwest National Laborato↗
DOE OSTI2026

Zinc batteries for grid-scale energy storage: Challenges, opportunities, and future directions

The global electricity sector is undergoing rapid transformation, increasing demand for reliable stationary energy storage and intensifying the need for safe, cost-effective, and scalable technologies for grid-scale applications. While lithium-ion batteries currently dominate the market, concerns over cost, safety, and resource availability motivate the exploration of alternative chemistries. Zinc-based batteries have emerged as a promising option due to the abundance, low cost, and wide geographic distribution of zinc, combined with the inherent safety of aqueous electrolytes. This perspective examines the potential of zinc batteries for stationary energy storage, with particular focus on rechargeable zinc-air systems. We discuss the evolution of zinc battery technologies and compare zinc-air, zinc-bromine, nickel-zinc, and aqueous zinc-ion chemistries, highlighting their advantages for grid applications. Key challenges limiting rechargeable zinc battery performance are analyzed, including dendrite formation and corrosion at the zinc anode, electrolyte degradation from carbonation and evaporation, and sluggish oxygen electrocatalysis at the air cathode. Emerging strategies to address these limitations are reviewed, including advanced electrode architectures, electrolyte engineering, catalyst development, and system-level design improvements. Lastly, we outline future research directions and opportunities for developing durable, efficient, and economically viable zinc-based energy storage systems for grid-scale applications.

Aqueous electrolytes↗
NASA NTRS2004

Performance Characterization of a Lithium-ion Gel Polymer Battery Power Supply System for an Unmanned Aerial Vehicle

Unmanned aerial vehicles (UAVs) are currently under development for NASA missions, earth sciences, aeronautics, the military, and commercial applications. The design of an all electric power and propulsion system for small UAVs was the focus of a detailed study. Currently, many of these small vehicles are powered by primary (nonrechargeable) lithium-based batteries. While this type of battery is capable of satisfying some of the mission needs, a secondary (rechargeable) battery power supply system that can provide the same functionality as the current system at the same or lower system mass and volume is desired. A study of commercially available secondary battery cell technologies that could provide the desired performance characteristics was performed. Due to the strict mass limitations and wide operating temperature requirements of small UAVs, the only viable cell chemistries were determined to be lithium-ion liquid electrolyte systems and lithium-ion gel polymer electrolyte systems. Two lithium-ion gel polymer cell designs were selected as candidates and were tested using potential load profiles for UAV applications. Because lithium primary batteries have a higher specific energy and energy density, for the same mass and volume allocation, the secondary batteries resulted in shorter flight times than the primary batteries typically provide. When the batteries were operated at lower ambient temperatures (0 to -20 C), flight times were even further reduced. Despite the reduced flight times demonstrated, for certain UAV applications, the secondary batteries operated within the acceptable range of flight times at room temperature and above. The results of this testing indicate that a secondary battery power supply system can provide some benefits over the primary battery power supply system. A UAV can be operated for hundreds of flights using a secondary battery power supply system that provides the combined benefits of rechargeability and an inherently safer chemistry.

Reid, Concha M.↗
DOE OSTI2025

Station Impact Analysis 2025

As part of the U.S. DOE EVs@Scale consortium, the NextGen Profiles (NGP) project presents analysis and results from the study of High Power Charging Electric Vehicles and Battery Charging Infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. The intent of the project is to further understand the most recent technological capabilities of the electric mobility industry related to charging performance. The project aims to develop EV, EVSE, and Fleet characterization testing practices and comprehensive analysis with inputs from key industry stakeholders. The results published in this NextGen Profiles project report provide data and insight for use by numerous entities including modeling and simulation organizations, policy makers, fleet planners, industry stakeholders and the general public involved with the development, deployment and operation of electrified transportation technologies. The factors influencing Electric Vehicle (EV) Direct Current Fast Charging (DCFC), including EV battery specifications, temperature effects on lithium-ion battery and power electronics performance, lithium-ion battery SOC bounding and charging station design considerations are specifically investigated to analyze their impacts on charging station operation and recommendations are made to minimize charge station dwell time, reduce charging costs and mitigate electric grid and charge station congestion. Additional high-power charging results are anticipated in future publications in support of the U.S. DOE EVs@Scale consortium NextGen Profiles project.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Battery‐Grade Lithium Materials: Virgin Production and Recycling, a Techno‐Economic Comparison

Lithium has been identified as an essential mineral to the economic and national security of the United States. It is vital for rechargeable batteries that surround us daily from the personal electronics to large-scale energy storage. With a comprehensive techno-economic analysis, the cost of battery-grade lithium compounds production, i.e., lithium carbonate (LC) is evaluated and lithium hydroxide monohydrate (LHM), from both virgin (spodumene ore and brine) and recycled feedstocks (spent lithium-ion batteries). The goal of this study is to inform about the economics of lithium compounds production with comprehensive insights into differences in manufacturing routes and pave a pathway to explore more innovative, domestic manufacturing processes in future for their cost competitiveness and environmental impact. The study includes details on mining and extraction operations as well as unit level operation in the refining process. Moreover, process level information has been collected for pyrometallurgical and hydrometallurgical battery recycling routes. This analysis shows that brine and direct lithium extraction are the cheapest pathways to produce LC or LHM (between $\$3.39$ and 6.20 kg −1 ). The cost of production in the ore and recycling routes can range between $\$4.17$ and $\$53.41$ kg −1 and is highly depending on capital equipment investment, plant location, and the price of spodumene concentrate SC6.0.

battery recycling↗
DOE OSTI2025

Atomic Structural Features of Stacking Faults and Domain Connections in the Li- and Mn-Rich Cathode

Li- and Mn-rich layered oxides (LMRs), a class of earth-abundant materials for rechargeable Li-ion battery cathodes, crystallize into layered structures of two different symmetries: C2/m represented by Li 2 MnO 3 and R$\overline{3}$m represented by LiMn 0.5 Ni 0.5 O 2 . Fundamental questions about how the C2/m and R$\overline{3}$m domains spatially correlate within the same oxide grain and how the C2/m stacking faults arrange themselves when this happens still remain. Here, by using integrated differential phase contrast imaging in scanning transmission electron microscopy (STEM-iDPC), we probe the structural and compositional details of a prototypical, cobalt-free LMR material, 0.3Li 2 MnO 3 •0.7LiMn 0.5 Ni 0.5 O 2 (Li 1.13 Mn 0.57 Ni 0.3 O 2 ). The connection between the C2/m and R$\overline{3}$m domains is found to be abrupt, facilitated by the small lattice mismatch between the two structures. Stacking faults in the C2/m domains feature atomic plane shifting that accommodates stacking sequence changes, which explains why the stacking faults form in a random manner. Furthermore, a local disordering mechanism was identified to correlate with the C2/m stacking faults. Chemically, it is found that Ni coexists with Mn at the transition metal sites within the nominal Li 2 MnO 3 domain. As a result, this study demonstrates that STEM-iDPC is a very useful tool for capturing all the elements in a single image, revealing atomic details on domain connections and stacking faults in the LMRs.

Li-rich and Mn-rich oxides↗
DOE OSTI2025

Developing low-cost rechargeable batteries: beyond traditional layered oxide cathodes for Li-ion and beyond Li-ion batteries

Here, the rising demand for energy storage systems, driven by the rapid adoption of electric vehicles and the global shift toward renewable energy, necessitates continuous efforts to lower the cost of current lithium-ion batteries (LIBs) and enhance the sustainability of existing battery chemistries. This feature article examines the key challenges associated with Ni- and Co-containing LIB cathodes and compares advancements in cathode development for non-traditional Li-ion and beyond Li-ion chemistries. First, a review of earth-abundant element containing disordered rock-salt cathodes is presented, with a discussion of key strategies such as compositional tuning and carbon coating to improve their electrochemical performance. Hurdles in developing oxide-based cathodes for Na- and K-ion batteries are also highlighted, followed by an in-depth overview of polyanion and Prussian blue cathodes for Na- and K-ion systems. Overall, this article provides a systematic perspective on the design of earth-abundant, low-cost, and sustainable cathode materials for both LIB and beyond LIB technologies.

Lohani, Harshita [Lawrence Berkeley National Labor↗
NASA NTRS1994

Photocured Gelled Electrolytes For Secondary Li Cells

Class of photocured polymers exhibiting lithium-ion conductivities greater than those of well-studied polymers based on polyethylene oxide (PEO) show promise as polymeric electrolytes in rechargeable lithium cells. Increase in conductivity occasioned by use of electrolytes, coupled with amenability of electrolytes to formation into uniform thin (less than 25 micrometers thick), wide films, expected to result in cells with power densities greater than 100 W h/kg and charge/discharge rates exceeding currents equal, in amperes, to ampere-hour ratings. All-solid-state lithium batteries containing these electrolytes used as high-power, high-rate rechargeable power sources in commercial and aerospace applications.

Nagasubramanian, Ganesan↗
NASA NTRS1999

Performance Characteristics of Lithium-Ion Cells for Mars Sample Return Athena Rover

In contrast to the primary batteries (lithium thionyl chloride) on the Sojourner Mars Rover and the upcoming 2001 Mars Rover, the Mars Sample Return (MSR) Athena Rover will utilize rechargeable lithium ion batteries, following the footsteps of MSP 2001 Lander. The MSR Athena Rover will contain a rechargeable lithium ion battery of 16 V and a total energy of 150 Wh. The mass and volume of the projected power system will be a maximum of 3 kg and 2 liters, respectively. Each battery consists of twelve cells (6-7 Ah), combined in three parallel strings of four cells (16 V) each, such that the capability of the Rover shall be maintained even in the event of one string failure. In addition to the usual requirements of high specific energy and energy density and long cycle life (100 cycles), the battery is required to operate at wide range of temperatures, especially at sub-zero temperatures down to -20 C. In this paper, we report various performance characterization tests carried out on lithium ion cells, fabricated by different manufacturers under a NASA/DoD lithium ion battery consortium.

Ratnakumar, B. V.↗
NASA NTRS2005

Lithium-Ion Batteries Being Evaluated for Low-Earth-Orbit Applications

The performance characteristics and long-term cycle life of aerospace lithium-ion (Li-ion) batteries in low-Earth-orbit applications are being investigated. A statistically designed test using Li-ion cells from various manufacturers began in September 2004 to study the effects of temperature, end-of-charge voltage, and depth-of-discharge operating conditions on the cycle life and performance of these cells. Performance degradation with cycling is being evaluated, and performance characteristics and failure modes are being modeled statistically. As technology improvements are incorporated into aerospace Li-ion cells, these new designs can be added to the test to evaluate the effect of the design changes on performance and life. Cells from Lithion and Saft have achieved over 2000 cycles under 10 different test condition combinations and are being evaluated. Cells from Mine Safety Appliances (MSA) and modules made up of commercial-off-the-shelf 18650 Li-ion cells connected in series/parallel combinations are scheduled to be added in the summer of 2005. The test conditions include temperatures of 10, 20, and 30 C, end-of-charge voltages of 3.85, 3.95, and 4.05 V, and depth-of-discharges from 20 to 40 percent. The low-Earth-orbit regime consists of a 55 min charge, at a constant-current rate that is 110 percent of the current required to fully recharge the cells in 55 min until the charge voltage limit is reached, and then at a constant voltage for the remaining charge time. Cells are discharged for 35 min at the current required for their particular depth-of-discharge condition. Cells are being evaluated in four-cell series strings with charge voltage limits being applied to individual cells by the use of charge-control units designed and produced at the NASA Glenn Research Center. These charge-control units clamp the individual cell voltages as each cell reaches its end-of-charge voltage limit, and they bypass the excess current from that cell, while allowing the full current flow to the remaining cells in the pack. The goal of this evaluation is to identify conditions and cell designs for Li-ion technology that can achieve more than 30,000 low-Earth-orbit cycles. Testing is being performed at the Naval Surface Warfare Center, Crane Division, in Crane, Indiana.

McKissock, Barbara I.↗