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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Avoiding thermal runaway in lithium-ion batteries using ultrasound detection of early failure mechanisms

Thermal runaway leading to catastrophic failure has slowed the adoption of lithium-ion batteries, highlighting the need for early warning systems. In this work, ultrasound is used to detect physical changes in 0.950 Ah Li-ion battery cells by inducing conditions associated with thermal runaway. Ultrasound signal features are extracted as the batteries are cycled under baseline conditions and subsequently subjected to constant current and voltage overcharges. Two conditions identifying failure are defined: a warning to detect the start of overcharge and an emergency stop (E-stop), to immediately take the battery out of service. Using changes in ultrasound signal features, consistent warning and stopping classifications are applied to all failure experiments. On average, a warning notification was issued after 15% of the overcharge time and an E-stop was triggered after 35% of total overcharge duration before failure. Further testing suggests that it is possible to avoid thermal runaway by reacting to intermediate, warning notifications prior to an immediate E-stop. In other words, not only can detection derived by ultrasound identify battery failure before a catastrophic event, but can also provide early, actionable warnings so that overcharges can be detected and corrected quickly enough so the battery does not need to be decommissioned.

25 ENERGY STORAGE↗
DOE OSTI2022

Compressible battery foams to prevent cascading thermal runaway in Li-ion pouch batteries

Lithium-ion battery packs require thermal management to achieve optimum life and safety. This is becoming crucial for battery packs composed of high-energy-density cells. Pouch cells themselves achieve highest packaging efficiency but require additional structural support and thermal management when grouped into modules, especially under abusive conditions such as thermal runaway. Novel foam battery pads have demonstrated to cushion volume changes of pouch cells and are reengineered in this study to mitigate cell-to-cell thermal runaway propagation. The compressible pads are made of polyurethane foams incorporating flame-retardant additives or coatings, including intumescent and fire wall materials. Here their performances were evaluated by conducting nail penetration tests on modules composed of pouch cells at 100% state of charge (SOC), with the foams placed in between the cells. Experimental results show cascading thermal runaway was considerably delayed by polyurethane foams incorporating flame-retardant additives or coatings. Complete prevention of cascading failure was achieved with dense polyurethane foams with multilayered coatings of both fire wall and intumescent materials.

25 ENERGY STORAGE↗
DOE OSTI2024

Exploring thermal runaway propagation in Li-ion batteries through high-speed X-ray imaging and thermal analysis: Impact of cell chemistry and electrical connections

Battery safety design is important to consider from the individual Li-ion cell to the level of the macro-system. On the macro-level, failure in one single cell can lead to propagation of the thermal runaway and rapidly set a whole battery pack on fire. Factors that can impact the propagation outcome, such as cell model/chemistry and electrical connection are here investigated using a combination of measurements. Several abusive tests were conducted, combining two different cell models (Molicel P42A and LG M50, both 21700s) in series and parallel connections (16 tests per configuration). Overall, a propagation outcome of 56% was measured from the 32 conducted tests, a minimum temperature of 150 °C was required to initiate propagation, and the fastest propagation occurred in 123 s. Temperature measurements were higher in series connected cells, initiating the discussion of cell chemistry and internal resistance on this effect. The difference in current-flow during thermal runaway in series and parallel connections, and how this can affect the temperature evolution is further discussed. Spatio-temporal mapping of X-ray radiography allowed us to derive the speed of thermal runaway evolution inside the battery and has shown that series connected cells, in particular P42A, occur faster. It was further observed that deviant sidewall behaviors such as temperature-induced breaches and pressure-induced ruptures occurred in P42As only respective nail-penetrated cells only.

25 ENERGY STORAGE↗
DOE OSTI2026

Gas-driven short disconnection mitigates thermal runaway in Li-ion batteries under mechanical abuse

Mechanical abuse poses a critical safety risk to Li-ion batteries by inducing internal short circuits that initiate thermal runaway. Remarkably, voltage recovery frequently emerges during thermal runaway initiation, a phenomenon that conventional theories fail to explain. Here, our study develops a new multiphysics mechanism to explain voltage recovery, termed gas-driven short disconnection, whereby internal gas pressure mechanically disengages short-circuit contacts and causes the cell voltage to rebound. This mechanism incorporates gas generation and its structural impact on the short circuit. Real-time optical and thermal imaging and X-ray computed tomography reveal fluid-structure interaction between internal gas flow and adjacent shorting contacts. We establish a mechanistic framework linking gas-driven short disconnection to cell-level voltage and temperature responses, elucidating the extension–truncation pattern of voltage recovery. Furthermore, thermal regime maps show that a voltage recovery duration exceeding 5 s correlates with limited temperature rise below 150 °C, indicating that sustained short-circuit disconnection suppresses Joule heating. Additionally, a dimensionless criterion is deduced from scaling analysis for physical plausibility of gas-driven short disconnection in mechanically abused cells. This finding inspires smart venting control, which regulates gas release to maintain the internal pressure while dissipating gas enthalpy, thereby providing a device-level strategy for thermal runaway mitigation.

Gas-driven short disconnection↗
DOE OSTI2022

Lagrangian particle simulation of hydrogen pellets and SPI into runaway electron beam in ITER

Numerical studies of the ablation of pellets and shattered pellet injection (SPI) fragments into a runaway electron beam in ITER have been performed using a time-dependent pellet ablation code [Samulyak et al., Nucl. Fusion, 61(4), 046007 (2021)]. The code resolves detailed ablation physics near pellet fragments and large-scale expansion of ablated clouds. The study of a single-fragment ablation quantifies the influence of various factors, in particular, the impact ionization by runaway electrons and cross-field transport models, on the dynamics of ablated plasma and its penetration into the runaway beam. Simulations of SPI performed using different numbers of pellet fragments study the formation and evolution of the ablation clouds and their large-scale dynamics in ITER. In conclusion, the penetration depth of the ablation clouds is found to be of the order of 50 cm.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Nonlinear saturation of whistler modes driven by runaway electrons

Runaway electrons exhibit kinetic instabilities with potentially beneficial consequences. The anomalous Doppler resonance between the electrons and whistler modes is a primary underlying mechanism. These instabilities require a first-principle nonlinear theoretical analysis, which would ultimately enable assessment of their impact on disruption mitigation and diagnostics, especially in ITER-relevant conditions. This paper presents recent progress in developing the required theoretical framework for isolated nonlinear resonances. By employing the generic bump-on-tail model, we predict the wave saturation levels in both near-threshold and strongly driven regimes. Remarkably, for the waves of interest, the parallel component of the wave vector dictates the parallel momentum of the resonant particles. This feature, together with the expected wave saturation level, provides a complete description of the resonance impact on the runaway electron distribution function. We show that the parametric dependence of the nonlinearly saturated mode provides a way to recover certain features of the runaway momentum distribution function.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRSDate not supplied

Comparative Analysis of Thermal Runaway Heat Output as a Function of Trigger Mechanism and Cell Format

High demand for energy storage systems across many fields drives the need for safe and reliable Li-ion batteries. In order to assess the risk of using such batteries in various applications, many types of abuse tests have been developed to push battery cells to their limits and learn how they fail. In this work, internal short circuit (ISC) tests, nail penetration tests, and thermal tests were used to trigger thermal runaway in D-cell, 18650, and 21700 Li-ion cells. High-speed radiography was used to gain insight to the propagation of thermal runaway throughout the cell, while calorimetric and thermal data were recorded in real time. Post-test disassembly of the calorimeter allowed for any mass ejected from the cell to be analyzed and the distribution of mass through the calorimeter to be determined. The impact of cell geometry and trigger mechanism on post-test mass distribution, thermal runaway propagation and internal cell temperature are discussed.

Lithium-ion battery; thermal runaway; calorimetry;↗
DOE OSTI2024

The battery failure databank: Insights from an open-access database of thermal runaway behaviors of Li-ion cells and a resource for benchmarking risks

The thermal response of Li-ion cells can greatly vary for identical cell designs tested under identical conditions, the distribution of which is costly to fully characterize experimentally. The open-source Battery Failure Databank presented here contains robust, high-quality data from hundreds of abuse tests spanning numerous commercial cell designs and testing conditions. Data was gathered using a fractional thermal runaway calorimeter and contains the fractional breakdown of heat and mass that was ejected, as well as high-speed synchrotron radiography of the internal dynamic response of cells during thermal runaway. The distribution of thermal output, mass ejection, and internal response of commercial cells are compared for different abuse-test conditions, which when normalized on a per amp-hour basis show a strong positive correlation between heat output from cells, the fraction of mass ejected from the cells, their energy- and power-density. Ejected mass was shown to contain 10x more heat per gram than non-ejected mass. The causes of 'outlier' thermal and ejection responses i.e., extreme cases, are elucidated by high-speed radiography which showed how occurrences such as vent clogging can create more hazardous conditions. High-speed radiography also demonstrated how the time-resolved interplay of thermal runaway propagation and mass ejection influences the total heat generated.

25 ENERGY STORAGE↗
DOE OSTI2020

Structure and overstability of resistive modes with runaway electrons

In this paper, we investigate the effects of runaway electron current on the dispersion relation of resistive magnetohydrodynamic modes in tokamaks. We present a new theoretical model to derive the dispersion relation, which is based on the asymptotic analysis of the resistive layer structure of the modes. It is found that in addition to the conventional resistive layer, a new runaway current layer can emerge whose properties depend on the ratio of the Alfvén velocity to the runaway electron convection speed. Due to the contribution from this layer, both the tearing mode and kink mode will have a real frequency in addition to a growth rate. The derived dispersion relation has been compared with numerical results using both a simplified eigenvalue calculation and a M3D-C 1 linear simulation, and good agreement is found in both cases.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Pellet sublimation and expansion under runaway electron flux

This work provides a qualitative description of the pellet response to the ambient runaway electrons. For ITER-relevant parameters, our estimates suggest that the cryogenic pellets will be sublimated instantly at the edge of the runaway beam. The subsequent rapid expansion of the sublimated material spreads the impurities over the poloidal cross-section of a tokamak on a millisecond time scale prior to the complete ionization of the expanding cloud. Here, the injected solid pellet turns into a rapidly expanding gas cloud before it reaches the core of the runaway beam. As a result, the pellet acts similar to the massive gas injection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Toroidal modeling of runaway avalanche in DIII-D discharges

Abstract A toroidal modeling tool is developed to study the runaway electron (RE) avalanche production process in tokamak plasmas, by coupling the Rosenbluth–Putvinski avalanche model (Rosenbluth and Putvinski 1997 Nucl. Fusion 37 1355) with an n = 0 magneto-hydrodynamic (MHD) solver. Initial value numerical simulations are carried out for two DIII-D discharges with different plasma shapes (one near circular, and the other with high elongation). It is found that, assuming the same level of about 1% seed current level, the Rosenbluth–Putvinski model somewhat underestimates the RE plateau current for the circular-shaped plasma, as compared with that measured in DIII-D experiments. For an elongated, higher current plasma, simulations find strong runaway current avalanche production despite the lack of measured plateau RE current in experiments. A possible reason for this discrepancy is a lack of additional RE dissipation physics in the present two-dimensional model. Systematic scans of the plasma boundary shape, at fixed pre-disruption plasma current, find that the plasma elongation helps to reduce the RE avalanche production, confirming recent results obtained with an analytic model (Fülöp et al 2020 J. Plasma Phys. 86 474860101). The effect of the plasma triangularity (either positive or negative), on the other hand, has a minor effect. On the physics side, the avalanche process involves two competing mechanisms associated with the electric field. On the one hand, a stronger electric field produces a higher instantaneous avalanche growth rate. On the other hand, a fast growing RE current quickly reduces the fraction of the conduction current together with the electric field, and hence a faster dissipation of the poloidal flux. As a final result of these two dynamic processes, the runaway plateau current is not always the largest with the strongest initial electric field. These results lay the foundation for future self-consistent inclusion of the MHD dynamics and the RE amplification process.

Physics↗
DOE OSTI2022

Runaway electron deconfinement in SPARC and DIII-D by a passive 3D coil

The operation of a 3D coil—passively driven by the current quench (CQ) loop voltage—for the deconfinement of runaway electrons (REs) is modeled for disruption scenarios in the SPARC and DIII-D tokamaks. Nonlinear magnetohydrodynamic (MHD) modeling is carried out with the NIMROD code including time-dependent magnetic field boundary conditions to simulate the effect of the coil. Further modeling in some cases uses the ASCOT5 code to calculate advection and diffusion coefficients for REs based on the NIMROD-calculated fields, and the DREAM code to compute the runaway evolution in the presence of these transport coefficients. Compared with similar modeling in Tinguely et al (2021 Nucl. Fusion 61 124003), considerably more conservative assumptions are made with the ASCOT5 results, zeroing low levels of transport, particularly in regions in which closed flux surfaces have reformed. Of three coil geometries considered in SPARC, only the n = 1 coil is found to have sufficient resonant components to suppress the runaway current growth. Without the new conservative transport assumptions, full suppression of the RE current is maintained when the thermal quench MHD is included in the simulation or when the RE current is limited to 250kA, but when transport in closed flux regions is fully suppressed, these scenarios allow RE beams on the order of 1–2 MA to appear. Additional modeling is performed to consider the effects of the close ideal wall. In DIII-D, the CQ is modeled for both limited and diverted equilibrium shapes. In the limited shape, the onset of stochasticity is found to be insensitive to the coil current amplitude and governed largely by the evolution of the safety-factor profile. In both devices, prediction of the q-profile evolution is seen to be critical to predicting the later time effects of the coil.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

The SN Ia runaway LP 398-9: detection of circumstellar material and surface rotation

ABSTRACT A promising progenitor scenario for Type Ia supernovae (SNeIa) is the thermonuclear detonation of a white dwarf in a close binary system with another white dwarf. After the primary star explodes, the surviving donor can be spontaneously released as a hypervelocity runaway. One such runaway donor candidate is LP 398-9, whose orbital trajectory traces back ≈105 yr to a known supernova remnant. Here, we report the discovery of carbon-rich circumstellar material around LP 398-9, revealed by a strong infrared excess and analysed with follow-up spectroscopy. The circumstellar material is most plausibly composed of inflated layers from the star itself, mechanically and radioactively heated by the past companion’s supernova. We also detect a 15.4 h periodic signal in the UV and optical light curves of LP 398-9, which we interpret as surface rotation. The rotation rate is consistent with theoretical predictions from this supernova mechanism, and the brightness variations could originate from surface inhomogeneity deposited by the supernova itself. Our observations strengthen the case for this double-degenerate SNIa progenitor channel, and motivate the search for more runaway SNIa donors.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Utilizing the deuterium-tritium fusion resonance to diagnose thermal runaway in igniting plasmas

For high-efficiency inertial confinement fusion implosions, it is predicted that a burning hot spot will successfully encompass all surrounding fuel and then transition into a thermal runaway where the internal energy increase from fusion occurs on a timescale faster than the expansion of the fuel is able to quench the fusion chain reaction after ignition occurs. Observation of this dynamic phase transition would indicate distinct burn properties and indicate an implosion's robustness. A technique for diagnosing the presence of thermal runaway from measurements of nuclear reaction history is presented. The technique is based on taking the logarithmic derivative of the nuclear reaction history, called the 𝛼 curve, and allowing a mathematical decoupling of the mass, volume, and thermal reactivity in the fusion reaction rate equation. During thermal runaway, where the thermal temperature dominates the burn dynamics, a maximum in the 𝛼 curve is found where there is a maximum in the first derivative of the thermal fusion reactivity, an effect to the deuterium-tritium (DT) fusion cross-section resonance. This provides a distinct signature related to the fundamental nature of the DT fusion nuclear resonance and signifies the transition into the fusion thermal instability. Impacts of charged particle transport on the effect are also assessed and the analytical formulas are compared and found to be in agreement with radiation hydrodynamic codes.

high-energy-density plasmas↗
DOE OSTI2022

Thermal Runaway of Li-Ion Cells: How Internal Dynamics, Mass Ejection, and Heat Vary with Cell Geometry and Abuse Type

Thermal runaway of lithium-ion batteries can involve various types of failure mechanisms each with their own unique characteristics. Using fractional thermal runaway calorimetry and high-speed radiography, the response of three different geometries of cylindrical cell (18650, 21700, and D-cell) to different abuse mechanisms (thermal, internal short circuiting, and nail penetration) are quantified and statistically examined. Correlations between the geometry of cells and their thermal behavior are identified, such as increasing heat output per amp-hour (kJ Ah −1 ) of cells with increasing cell diameter during nail penetration. High-speed radiography reveals that the rate of thermal runaway propagation within cells is generally highest for nail penetration where there is a relative increase in rate of propagation with increasing diameter, compared to thermal or internal short-circuiting abuse. For a given cell model tested under the same conditions, a distribution of heat output is observed with a trend of increasing heat output with increased mass ejection. Finally, internal temperature measurements using thermocouples embedded in the penetrating nail are shown to be unreliable thus demonstrating the need for care when using thermocouples where the temperature is rapidly changing. All data used in this manuscript are open access through the NREL and NASA Battery Failure Databank.

25 ENERGY STORAGE↗
DOE OSTI2020

Gas Generation Models for Thermal Runaway in Lithium Ion Batteries

A numerical model is implemented to study cell venting, internal pressure, and gas-phase dynamics behavior of Li-ion cells undergoing thermal runaway. A k-ɛ Reynolds-Averaged Navier-Stokes (RANS) model is adopted to describe the turbulent flow out of the cells, while the fluid dynamics inside the cells is described by Darcy-Forchheimer’s equation. Thermal abuse reactions and gas generation kinetics are described by a single-step lumped reaction model. A series of computational fluid dynamics (CFD) simulations are conducted on a single cell at various states-of-charge (100%, 50%, 25%) to demonstrate detailed flow and thermal behavior as a function of quantity of gas generated during cell venting. Venting events are categorized into two stages: i) breaching of the cell container and ii) thermal runaway reactions. It is shown that the cell response is dominated by the second stage since most of the gases are generated during thermal runaway. Also, the propensity for propagation is highly affected by state-of-charge (SOC). Cells at higher SOCs produce more heat and gas during the venting event, owing to higher mass and concentrations of reacting gases, and consequently reach higher internal cell pressures which increase the risk of side-wall breaching.

Kim, Jinyong↗
DOE OSTI2021

A laser inverse Compton scattering diagnostic to study runaway electron dynamics during tokamak disruptions

The goal is to design a new diagnostic based on laser inverse Compton scattering (LICS) to study the dynamics of runaway electron formation and their subsequent loss during triggered disruptions in DIII-D. It is known that better measurements of the runaway electron population, throughout the evolution of a disruption, is critical for mitigating the impact of energetic electron beams especially in high plasma current discharges such as those in reactor relevant burning plasmas. The goal of the LICS approach being designed for DIII-D is to measure the timeresolved spatial profile and energy distribution of the runaway electrons while they are in the core of the tokamak plasma. During the last year, a code was developed to simulate the signals from a new laser scattering diagnostic for DIII-D, which will measure the relativistic electron population expected in DIII-D after disruptions triggered by argon pellet injection.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

LIM1TR: Lithium-Ion Modeling with 1-D Thermal Runaway (V.1.0)

LIM1TR (Lithium-Ion Modeling with 1-D Thermal Runaway) is an open-source code that uses the finite volume method to simulate heat transfer and chemical kinetics on a quasi 1-D domain. The target application of this software is to simulate thermal runaway in systems of lithium-ion batteries. The source code for LIM1TR can be found at https://github.com/ajkur/lim1tr. This user guide details the steps required to create and run simulations with LIM1TR starting with setting up the Python environment, generating an input file, and running a simulation. Additional details are provided on the output of LIM1TR as well as extending the code with custom reaction models. This user guide concludes with simple example analyses of common battery thermal runaway scenarios. The corresponding input files and processing scripts can be found in the “Examples” folder in the on-line repository, with select input files included in the appendix of this document.

25 ENERGY STORAGE↗