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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Valuation of Anode Materials for High-Performance Lithium Batteries: From Graphite to Lithium Metal and Beyond

Lithium-ion batteries have revolutionized energy storage, yet advanced technologies such as electric vehicles and eVTOLs demand even higher performance and safety. Anodes, the negative electrodes, are crucial in enhancing batteries’ safety, lifespan, and fast-charging capabilities. This review paper comprehensively evaluates the progression of anode materials from traditional graphite to advanced anodes like lithium metal. Graphite anodes, with a capacity of 372 mAh g −1 , enabled the first commercial lithium-ion batteries, but future applications require higher energy densities and fast-charging capabilities. Emerging anode materials, including alloying, and conversion types, as well as lithium metal, offer significantly higher capacities, with lithium metal offering a theoretical capacity of 3 860 mAh g −1 . However, these advanced anodes face challenges such as volume expansion, high surface reactivity, sluggish Li+ kinetics, and unstable lithium deposition morphologies. Here, this review critically examines the electrochemical performance, interfacial properties, mechanical attributes, and stability issues of various anode materials. It further discusses solid electrolyte interphase (SEI) formation, strategies for enhancing interface stability, and the requirements of anodes for solid-state batteries. Additionally, the review explores potential solutions for limitations with each anode type, highlights innovative anode-free architectures, and evaluates the current and future trends of battery anode industries. Ultimately, this paper aims to guide the development of high-performance anode materials, paving the way for the next generation of efficient, reliable lithium batteries.

Alloying anodes↗
DOE OSTI2023

Nanoparticle Surface Passivation Strategies to Improve the Cycle and Calendar Lifetime of Silicon Anodes in Standard Carbonate Electrolytes

Silicon Lithium alloys (SiLix) as the anode active material in a Li-Ion battery configuration offer possible energy densities paralleled only by pure lithium metal. However, the extreme mechanical deformation of alloying and dealloying SiLix through charge/discharge cycles paired with the highly reactive interface of SiLix which generates an interfacial layer known as the solid-electrolyte-interphase are large barriers to industrial adoption of high-silicon-content negative electrodes. Moreover, these challenges are magnified when the thickness of the electrode is brought to relevant levels (>3 mg/cm2). Here, I describe our efforts to address these challenges by utilizing single-nanometer-scale silicon nanoparticles to reduce capacity fade related to mechanical failure. I also detail our efforts to modify the silicon surface through interfacial chemical engineering strategies to passivate the silicon surface. This development three different majority silicon electrodes (50-74 wt%) to achieve cycle capacity retention of greater than 73% through 1000 charge/discharge cycles against capacity-matched NMC-based cathodes and calendar lifetimes greater than one year. This research is a part of the multi-national lab Silicon Consortium Project.

anodes↗
DOE OSTI2020

Mechanical rolling formation of interpenetrated lithium metal/lithium tin alloy foil for ultrahigh-rate battery anode

To achieve good rate capability of lithium metal anodes for high-energy-density batteries, one fundamental challenge is the slow lithium diffusion at the interface. Here we report an interpenetrated, three-dimensional lithium metal/lithium tin alloy nanocomposite foil realized by a simple calendering and folding process of lithium and tin foils, and spontaneous alloying reactions. The strong affinity between the metallic lithium and lithium tin alloy as mixed electronic and ionic conducting networks, and their abundant interfaces enable ultrafast charger diffusion across the entire electrode. Furthermore, we demonstrate that a lithium/lithium tin alloy foil electrode sustains stable lithium stripping/plating under 30 mA cm -2 and 5 mAh cm -2 with a very low overpotential of 20 mV for 200 cycles in a commercial carbonate electrolyte. Cycled under 6 C (6.6 mA cm -2 ), a 1.0 mAh cm -2 LiNi 0.6 Co 0.2 Mn 0.2 O 2 electrode maintains a substantial 74% of its capacity by pairing with such anode.

25 ENERGY STORAGE↗
DOE OSTI2021

Engineering Approaches to Dendrite free Lithium Anodes

This is the Final Technical Report of the work that was completed related to development of dendrite free anodes for Li-metal batteries. The report contains full details of all the strategies that were employed to overcome this pernicious problems of dendrite formation of lithium metal during cycling of Li-metal and Li-ion batteries. Various approaches were developed to understand the formation of dendrites and mitigation strategies were then developed to overcome this severe problem. In doing so novel multi-component alloys as well as structurally isomorphous alloys have been developed. In addition coating strategies were also developed to overcome the formation of dendrites. The novel approaches related to development of novel alloys using economic cost effective and scalable approaches. The new approaches will easily advance the science of lithium metal alloys and dendrite free anodes including current collectors. Development of this new technology will have immense benefit to providing new high energy density batteries of tremendous benefit to the public since cost effective and safe high energy density batteries will be possible with this new technology.

25 ENERGY STORAGE↗
DOE OSTI2022

Mechanical and tribological properties of anodic Al coatings as a function of anodizing conditions

Enhanced wear and corrosion resistance properties are vital for numerous functional and decorative applications. Anodizing is a process frequently used to generate stable oxide coatings on metal surfaces, including aluminium (Al). In this work, we present an evaluation of process variables for optimized anodized coating properties using existing methods and as a baseline for novel coating development. A representative relatively pure Al alloy was chosen as a model system with a goal of finding conditions to achieve high wear coatings with retained ductility. AA5052 alloy coupons were anodized in two different electrolytes (sulfuric and phosphoric acid) to study the effects of anodizing conditions on the mechanical and tribological properties of the anodic coatings. Porosity was evaluated with microscopy, coating hardness was determined via nanoindentation, and tribological properties were characterized using a pin-on-disk tribometer. These measurements were correlated and a loading evaluation was performed to assess the optimum nanoindentation parameters for the use of representative coupons without the need for special processing prior to anodizing. The porosity and coating thickness were found to depend on the anodizing time and the type of electrolyte. Thicker and harder anodic coatings were generated in sulfuric acid compared to phosphoric acid. Porosity studies of the anodic coatings generated in phosphoric acid revealed that coating porosity decreased as the anodizing time increased. Both electrolytes generated anodic coatings with improved tribological properties (friction coefficient and dimensional wear rate), and an optimum processing time was identified for best wear properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Ce nanoparticles and sol-gel hybrid organic-inorganic coatings maximize corrosion protection in the anodized AA2024-T3

Herein we demonstrate that the corrosion resistance of the AA2024-T3 alloy can be maximized with the application of top protective sol-gel hybrid organic-inorganic coatings. Samples combining Ce nanoparticles within the pores of the anodic layer with the top sol-gel coatings were observed to outperform samples featuring only the coating. This research unravels the self-healing capability against corrosion of the sol-gel coating when Ce nanoparticles are present, as well as a good coverage of defective regions within the oxide by the hybrid layer. This research opens a paradigm aiming at maximizing the corrosion resistance for non-ferrous anodized alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Optimization of catholyte for halide-based all-solid-state batteries

Halide solid electrolytes gain significant attention due to their high ionic conductivity, low processing temperature, dry air compatibility, and high-voltage stability. However, low cathode active material (CAM) loading in the composite cathode constrains the realization of high energy density for halide-based all-solid-state batteries. In this study, three halide materials, raw Li 3 YBrCl 5 (LYBC-R, <30μm), milled LYBC (LYBC-M, <5 μm) and freeze-dried Li 3 InCl 6 (LIC, <500 nm), were used as catholytes, combined with LYBC-M as the electrolyte and LiIn alloy as the anode. The CAM:catholyte ratio was investigated as well as stack pressure and operating temperature. Our study demonstrates that particle size of the catholyte plays an important role only for high CAM loading or high C-rate cycling. At moderate CAM loading (65 and 70wt% LiNi 0.83 Mn 0.06 Co 0.11 O 2 ) and 0.1 C-rate, all the three catholytes perform well, providing initial discharge capacities >177 mAh/g. At high CAM loading (85wt%) and 0.1 C-rate, a cathode with the nano-scale LIC catholyte provides discharge capacity of 175 mAh/g, while the larger particle size catholytes suffer significantly reduced capacity. Both LYBC and LIC catholytes provided capacity retention >80% after 200 cycles at 0.5C. These results imply that cathode particle size is critically important for performance at high CAM loading. Furthermore, both electrolyte and cathode were tape cast to scale up size and prepare realistic layer thicknesses. A small amount of binder was used in both layers, to balance the electrochemical performance and mechanical properties. Further, the discharge capacity of a tape cell was 152mA h/g at 0.1C with a capacity retention of 81.8% after 20 cycles at 0.5C. The results demonstrate the excellent performance of LYBC as an electrolyte, and provide guidance for halide-based cathode design.

25 ENERGY STORAGE↗
DOE OSTI2026

Metallic Pd–Cu Alloy Phases Drive Selective Heterogeneous Electrochemical Ketonization of 1-Butene

Electrification of 2-butanone synthesis via ketonization of 1-butene offers a viable pathway to reduce emissions associated with its production as a commodity chemical and enhance its prospects as a clean carbon-based synthetic fuel. However, the direct electrochemical ketonization of alkenes remains underexplored, with previous studies largely limited to epoxides and glycols. Herein, we report an electrochemical heterogeneous system optimized for 1-butene ketonization, converting 1-butene to 2- butanone using a bimetallic PdCu catalyst in aqueous electrolytes. The system achieves a Faradaic efficiency of 20% and a partial current density of 0.6 mA/cm 2 at 1.8 V RHE . In comparison to monometallic Pd and oxidized PdCu analogs, the PdCu catalyst doubles the ketonization Faradaic efficiency and quadruples the production rate. Postelectrolysis characterization reveals that PdCu preserves the surface metallic alloy phase under anodic polarization, which likely accounts for the enhanced ketonization activity. This work demonstrates the significance of the Pd−Cu speciation dynamics and provides a framework for designing selective electrocatalysts for alkene ketonization.

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

In-situ anodic precipitation process for highly efficient separation of aluminum alloys

Electrorefining process has been widely used to separate and purify metals, but it is limited by deposition potential of the metal itself. Here we report in-situ anodic precipitation (IAP), a modified electrorefining process, to purify aluminium from contaminants that are more reactive. During IAP, the target metals that are more cathodic than aluminium are oxidized at the anode and forced to precipitate out in a low oxidation state. This strategy is fundamentally based on different solubilities of target metal chlorides in the NaAlCl4 molten salt rather than deposition potential of metals. The results suggest that IAP is able to efficiently and simply separate components of aluminum alloys with fast kinetics and high recovery yields, and it is also a valuable synthetic approach for metal chlorides in low oxidation states.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Design strategies for nonaqueous multivalent-ion and monovalent-ion battery anodes

The inability of current battery technologies to keep up with the performance requirements of industry is pushing forward developments in electrochemistry. Specifically, the battery's negative electrode, the anode, presents many unique chemical, physical and engineering challenges. Lithium-based battery technologies have dominated the past decade, but concerns about the limited supply of lithium in the Earth's crust have led researchers to look towards alternative metal-ion technologies. Furthermore, various alkali metals (such as sodium and potassium) and alkali earth metals (such as magnesium and calcium) have attracted significant research interest. In this Review, we analyse these technologies in a coherent manner, addressing the problems of each type of anode, rather than those of specific types of metal-ion batteries. Covering direct metal plating and stripping, intercalation-based, alloy-based and conversion-reaction-based anode technologies, this analysis will offer the reader a comprehensive understanding of the behaviour of different metal-ion anodes and of what can be learned by transferring knowledge between these different systems. Increasing demand for energy-storage systems will inevitably stress the Earth's lithium supply; thus, the research focus is shifting towards other alkali and alkali earth metals. In summary, this Review compares and connects strategies to enable different multivalent and monovalent metal-ion battery anodes, including metal anodes and intercalation-based, alloy-based and conversion-reaction-based anodes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High capacity, air-stable, structurally isomorphous lithium alloy multilayer porous foams

The invention relates to composite multilayer lithium ion battery anodes that include a porous metal alloy foam, and a lithium ion conductor coating applied to the metal alloy foam. The metal alloy foam can include structurally isomorphous alloys of lithium and, optionally, lithium and magnesium. The lithium ion conductor coating can include ternary lithium silicate, such as, lithium orthosilicate. Lithium ions from the ternary lithium silicate may be deposited within the pores of the metal alloy foam. Optionally, the lithium ion conductor coating may include a dopant. The dopant can include one or more of magnesium, calcium, vanadium, niobium and fluorine, and mixtures and combinations thereof.

Kumta, Prashant N.↗
DOE OSTI2022

Diffusional lithium trapping as a failure mechanism of aluminum foil anodes in lithium-ion batteries

Aluminum foils are an appealing anode for lithium-ion batteries due to high capacity and low-cost, but their viability has been limited due to poor cyclability arising from pulverization and solid-electrolyte interphase growth. Here, we show that significant capacity degradation of aluminum foil anodes during electrochemical cycling also occurs due to diffusional lithium trapping. Scanning electron microscopy of cross-sectioned, cycled foils in the delithiated state reveals large regions of β-LiAl that are passivated by a surface layer of α-Al, which has poor Li + diffusivity. It is found that lithium diffusion occurs preferentially along the β-LiAl grain boundaries, so the grain structure after initial lithiation significantly affects the trapping behavior. Diffusional lithium trapping is exacerbated by both higher delithiation rates and higher areal capacity, presenting a challenge towards commercialization of aluminum foil anodes. We further demonstrate that diffusional trapping in aluminum foil anodes can be mitigated through alloy design, with the addition of 2–3 wt% Li yielding improved first cycle efficiency, and the addition of 1 wt% Si yielding improved cycle life. These results provide a mechanistic understanding of diffusional lithium trapping in aluminum foil anodes and highlight compositional design of alloys as a promising strategy to overcome it.

25 ENERGY STORAGE↗
DOE OSTI2022

Fast and Simple Ag/Cu Ion Exchange on Cu Foil for Anode-Free Lithium-Metal Batteries

Lithium-metal batteries with zero excess lithium on the anode side paired with a fully lithiated cathode are regarded as a form of the highest energy-density configuration. Unfortunately, the continuous lithium loss over cycling from a limited amount of lithium reservoir significantly degrades the overall cell performance in the anode-free system. To mitigate the deterioration, modifying the current collector for enhanced lithium cycling is an indispensable route. Here, we apply a Ag/Cu ion exchange to precipitate micro-sized Ag particles on the Cu current collector to enhance the lithium reversibility via (de)alloying process. Further, we show a smoother morphology of lithium upon alloying, which leads to a lowered nucleation potential as well as increased average Coulombic efficiency in Li||Cu cells regardless of electrolyte formulation. The preferred lithium adsorption on Ag and AgLi over Cu is demonstrated with density functional theory calculations, which supports that Li is forming a gamma-phase alloy in the last stage rather than being deposited beneath the alloy. Lastly, this simple Cu foil modification enhances lithium reversibility and reduces its nucleation barrier, thus mitigating the capacity fade of a Cu||LiFePO 4 with reduced polarization.

25 ENERGY STORAGE↗
DOE OSTI2022

The Electrochemical Behavior of As-Prepared Aluminum Alloy A360 Produced by Selective Laser Melting Fabrication with and without a Trivalent Chromium Process Conversion Coating

In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization of Magnesium-Doped Lithium Metal Anode for High Performance Lithium Metal Batteries through Modeling and Experiment

Lithium (Li)-magnesium (Mg) alloy with limited Mg amount, which can also be called Mg-doped Li (Li-Mg), has been considered as a potential alternative anode for high energy density rechargeable Li metal batteries. However, the optimum doping-content of Mg in Li-Mg anode and the mechanism of the improved performance are not well understood. In this study, density functional theory (DFT) calculations are used to investigate the effect of Mg amount in Li-Mg anode. The Li-Mg with about 5 wt. % Mg (abbreviated as Li-Mg5) has the lowest absorption energy of Li, thus all the surface area can be “controlled” by Mg atoms, leading to the smooth and continuous deposition of Li on the surface around the Mg center. A localized high concentration electrolyte enables Li-Mg5 to exhibit the best cycling stability in Li metal batteries with high-loading cathode and lean electrolyte under 4.4 V high-voltage, which is approaching the demand of practical application. This electrolyte also helps generate an inorganic-rich solid electrolyte interphase, which leads to smooth, compact and less corrosion layer on the Li-Mg5 surface. Both theoretical simulations and experimental results prove that Li-Mg5 has optimum Mg content and gives best battery cycling performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Interfacial Engineering of Metal Chalcogenides‐based Heterostructures for Advanced Sodium‐Ion Batteries

Sodium-ion batteries (SIBs) have become one of the most promising candidates for large-scale energy storage applications. Metal chalcogenides anode materials based on alloying or conversion reactions are widely studied because of their high theoretical capacities and rich redox reactions. However, their intrinsic limitations such as high voltage hysteresis and large volume expansion hinder their further applications. The construction of heterostructures has become an attractive strategy to alleviate the above issues. Here, the formation of built in electric fields (BIEFs) at the heterointerfaces will accelerate the migration of Na + and electrons. Moreover, heterostructures can also enhance the structural stability, generate more active sites and provide additional capacity. It is worth noting that heterointerfacial properties play a significant role in promoting the overall electrochemical performance of the heterostructures. However, a systematic understanding of their interfacial engineering is currently lacking. This article reviews the research progress of metal chalcogenides-based heterostructure anode materials in the near term. First, the definition, classification and the roles of heterostructures are introduced. Second, the detailed research progress of the metal chalcogenide-based heterostructures anodes in SIBs is discussed. Finally, the future prospects and potential research directions of the heterostructures for batteries are discussed.

anode↗