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DOE OSTI2023

Rechargeable metal-metal alkaline batteries: Recent advances, current issues and future research strategies

Over the past few decades, remarkable advancement has been attained in the field of rechargeable metal–metal alkaline batteries (RABs). In terms of safety, energy density, charge-discharge capacity, and long-term storage capability, metal-metal RABs (e.g., Ni–Zn, Ni–Fe, Ni–Bi, Ni–MH, Ag–Zn, Co–Zn, Cu–Zn, and Bi–Zn systems) are contemplated as the promising energy storage devices for the applications in electric vehicles (EVs), hybrid EVs, grid-scale energy storage, as well as various implantable and wearable electronic devices. Especially, Ni-MH batteries become competitive with Li-ion batteries for EVs and hybrid EVs applications due to their high tolerance against mechanical abuse, stability under wide temperature ranges, and considerable charge/discharge capacity. Meanwhile, earlier works reviewed only specific topics, so, as a rapidly growing research topic, providing a deep understanding on metal–metal RABs is timely and worthwhile. So here, in this work, we discuss the electrochemistry of all metal-metal RABs, then full cell designing with their performance will be discussed thoroughly. Further, issues associated with the existing metal–metal RABs and corresponding improvement approaches will be provided for future advances in high-performance and reliable metal-metal RABs.

25 ENERGY STORAGE↗

NASA NTRS2011

Development and Demonstration of Sustainable Surface Infrastructure for Moon/Mars Exploration

For long-term human exploration of the Moon and Mars to be practical, affordable, and sustainable, future missions must be able to identify and utilize resources at the site of exploration. The ability to characterize, extract, processes, and separate products from local material, known as In-Situ Resource Utilization (ISRU), can provide significant reductions in launch mass, logistics, and development costs while reducing risk through increased mission flexibility and protection as well as increased mission capabilities in the areas of power and transportation. Making mission critical consumables like propellants, fuel cell reagents and life support gases, as well as in-situ crew/hardware protection and energy storage capabilities can significantly enhance robotic and human science and exploration missions, however other mission systems need to be designed to interface with and utilize these in-situ developed products and services from the start or the benefits will be minimized or eliminated. This requires a level of surface and transportation system development coordination not typically utilized during early technology and system development activities. An approach being utilized by the US National Aeronautics and Space Administration and the Canadian Space Agency has been to utilize joint analogue field demonstrations to focus technology development activities to demonstrate and integrate new and potentially game changing. mission critical capabilities that would enable an affordable and sustainable surface infrastructure for lunar and Mars robotic and human exploration. Two analogue field tests performed in November 2008 and February 2010 demonstrated first generation capabilities for lunar resource prospecting, exploration site preparation, and oxygen extraction from regolith while initiating integration with mobility, science, fuel cell power, and propulsion disciplines. A third analogue field test currently planned for June 2012 will continue and expand the fidelity and integration of these surface exploration and infrastructure capabilities while adding Mars exploration technologies, improving remote operations and control of hardware, and promoting the use of common software, interfaces, & standards for control and operation for surface exploration and science. The next field test will also attempt to include greater involvement by industry, academia, and other countries/space agencies. This paper will provide an overview of the development and demonstration approach utilized to date, the results of the previous two ISRU-focused field analogue tests in Hawaii, and the current objectives and plans for the 3rd international Hawaii analogue field test.

Sanders, Gerald B.↗

NASA NTRS2017

Personal Rotorcraft Design and Performance with Electric Hybridization

Recent and projected improvements for more or all-electric aviation propulsion systems can enable greater personal mobility, while also reducing environmental impact (noise and emissions). However, all-electric energy storage capability is significantly less than present, hydrocarbon-fueled systems. A system study was performed exploring design and performance assuming hybrid propulsion ranging from traditional hydrocarbon-fueled cycles (gasoline Otto and diesel) to all-electric systems using electric motors generators, with batteries for energy storage and load leveling. Study vehicles were a conventional, single-main rotor (SMR) helicopter and an advanced vertical takeoff and landing (VTOL) aircraft. Vehicle capability was limited to two or three people (including pilot or crew); the design range for the VTOL aircraft was set to 150 miles (about one hour total flight). Search and rescue (SAR), loiter, and cruise-dominated missions were chosen to illustrate each vehicle and degree of hybrid propulsion strengths and weaknesses. The traditional, SMR helicopter is a hover-optimized design; electric hybridization was performed assuming a parallel hybrid approach by varying degree of hybridization. Many of the helicopter hybrid propulsion combinations have some mission capabilities that might be effective for short range or on-demand mobility missions. However, even for 30 year technology electrical components, all hybrid propulsion systems studied result in less available fuel, lower maximum range, and reduced hover and loiter duration than the baseline vehicle. Results for the VTOL aircraft were more encouraging. Series hybrid combinations reflective of near-term systems could improve range and loiter duration by 30. Advanced, higher performing series hybrid combinations could double or almost triple the VTOL aircrafts range and loiter duration. Additional details on the study assumptions and work performed are given, as well as suggestions for future study effort.

electric motors↗

NASA NTRSDate not supplied

Energy Efficient Large-Scale Storage of Liquid Hydrogen

The world’s largest liquid hydrogen storage tanks were constructed in the mid-1960sat the NASA Kennedy Space Center. These two vacuum-jacketed, perlite powder insulated tanks, still in service today, have 3,200 m3 of useable capacity. In 2018, construction began on an additional storage tank at Launch Complex 39B. This new tank will give an additional storage capacity of 4,700 m3 for a total on-site storage capacity of roughly 8,000 m3. NASA’s new Space Launch System (SLS) heavy lift rocket for the Artemis program includes an LH2tank that makes up the bulk of the vehicle, holding 2,033 m3 of LH2 in its 8.4-m diameter by40-m height. The new storage tank includes two new energy-efficient technologies: a glass bubbles insulation system in lieu of perlite, and an Integrated Refrigeration and Storage (IRAS)heat exchanger for controlled storage capability. The evacuated glass bubbles insulation system is based on the prior two decades of research to prove the thermal performance benefits as well as the mechanical and vacuum integrity; and has been shown to reduce LH2 boiloff by 46%versus perlite in field demonstrations. The IRAS capability is centered on a heat exchanger system that is built within the inner vessel to reject heat from the bulk liquid through the future implementation of an external helium refrigerator. Controlled storage via IRAS, when fully implemented, will provide full control of the ullage pressure, zero boiloff, and even production of densified LH2 pending its adoption on future launch vehicles. The design basics are described along with main construction and testing processes involved. The key features of the new technology items and implications on simplified operations and long-term energy savings are addressed

cryogenics↗

NASA NTRS2017

Development of Lightweight CubeSat with Multi-Functional Structural Battery Systems

This collaborative multi-disciplinary effort aims to develop a lightweight, 1-unit (1U) CubeSat (10x10x10 cm) which utilizes improved and fully integrated structural battery materials for mission life extension, larger payload capability, and significantly reduced mass.The electrolytic carbon fiber material serves the multifunctional capacitive energy system as both a lightweight, load bearing structure and an electrochemical battery system. This implementation will improve traditional multifunctional energy storage concepts with a highly effective energy storage capability.

Light-weight CubeSat↗

DOE OSTI2020

Technical Performance of Refractory Liners for Molten Chloride Salt Thermal Energy Storage Systems

A chloride-based molten-salt system that uses a ternary blend of MgCl2/KCl/NaCl is investigated to provide higher temperature thermal energy storage capability. Despite higher thermal stability, molten chlorides present several unique challenges, including the design of internal refractory-ceramic liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the refractory material at the molten salt interface (hot face). The down-selected hot face candidate limits permeation of salt through the material and forms a highly stable secondary surface phase in equilibrium with the molten salt. A mortar is created using the corrosion resistant hot face brick. Brick and mortar composite are subjected to mechanical stress/strain analysis, in order to calculate composite material properties and better inform thermomechanical models. The U.S. Department of Energy Generation 3 (DOE Gen3) program seeks to develop higher efficiency CSP plants that can provide cost-competitive, flexible power in the U.S. electric grid. The proposed Gen3 Liquid Pathway CSP plant closely resembles the configuration of current nitrate salt power towers with two-tank storage (Gen2). The differences between Gen2 and Gen3 include the types of compatible materials used in salt storage tank construction. Stainless steel loses strength at Gen3 temperatures, and although nickel superalloys would be capable of withstanding sustained high temperatures, these materials are prohibitively expensive at scale. Uninsulated tank shells also pose a significant risk as common steels are highly susceptible to chemical attack from molten chloride salt. To address these concerns, refractory-ceramic based containment materials are proposed to line the inside of the hot and cold storage tanks. In doing so, stainless or carbon steel shells may be used in construction depending on the level of insulation provided. The composition of the internal liner requires careful consideration to maximize the efficacy of multiple parameters including corrosion resistance, strength at operating temperature, durability, and cost. This is particularly true for the material at the interface with the salt, known as the "hot face", which is responsible for protecting the insulating layers between the tank shell and the hot face brick layer. The molten salt in this system is superheated over 300 °C above its freeze temperature. Therefore, unlike other industrial processes which use refractory-lined vessels, it is not expected that a freeze plane will develop in the hot face. Therefore, the hot face must be designed to withstand chemical corrosion and inhibit permeation of molten salt into the insulating layers. A down selection was performed to identify a hot face candidate best equipped to maintain thermal, mechanical, and chemical integrity when exposed to molten salt over extended periods of time. Long-duration chemical capability experiments were conducted with the down selected hot face refractory fully immersed in molten chloride salt for up to 3000 hours. The average salt penetration does not exceed 100 microns. When extrapolated to 20 and 30 years of continuous exposure, the expected salt penetration depth is approximately 2.0 mm and 2.9 mm, respectively. A magnesium-rich secondary phases develops at the salt/refractory interface. X-ray diffraction identifies the material as forsterite (Mg2SiO4), which is reported to form synthetically in molten chloride salt solutions. These results suggest the selected hot face will adequately inhibit salt permeation. While there is optimism that the hot face brick will inhibit salt permeation, mortar joints are typically the weakest point of a refractory brick liner. From a thermochemical perspective, differing thermal expansion coefficients may result in the mortar and brick to grow independent of each other, creating gaps through which molten salt can penetrate. To address this issue, NREL has developed an in-house mortar composed of the down selected hot face brick that has been shown to be compatible with the salt. Compressive stress/strain analyses have been performed on the brick/ mortar composites to generate stress/strain curves. Modulus of elasticity and Poisson's ratio of the composite may be calculated from the stress/strain curves, in order to provide more representative data to finite element mechanical models for accurate approximation of stress on the tank shell and the amount of thermal expansion expected within the tank liner.

41 EE - Solar Energy Technologies Office (EE-4S)↗

NASA NTRS1991

Flywheel energy storage for electromechanical actuation systems

The authors describe a flywheel energy storage system designed specifically to provide load-leveling for a thrust vector control (TVC) system using electromechanical actuators (EMAs). One of the major advantages of an EMA system over a hydraulic system is the significant reduction in total energy consumed during the launch profile. Realization of this energy reduction will, however, require localized energy storage capable of delivering the peak power required by the EMAs. A combined flywheel-motor/generator unit which interfaces directly to the 20-kHz power bus represents an ideal candidate for this load leveling. The overall objective is the definition of a flywheel energy storage system for this application. The authors discuss progress on four technical objectives: (1) definition of the specifications for the flywheel-motor/generator system, including system-level trade-off analysis; (2) design of the flywheel rotor; (3) design of the motor/generator; and (4) determination of the configuration for the power management system.

Hockney, Richard L.↗

NASA NTRS1996

NASA SSTI CLARK 3-meter imaging satellite

Within the framework of NASA's Small Satellite Technology Initiative (SSTI) CLARK program, the development of a high technology small satellite is reported on. The satellite will provide 3 m resolution panchromatic and 15 m resolution multispectral image capabilities. The satellite, programmed for launch in 1996, will be in a sun-synchronous orbit and includes the following systems: three-axis zero momentum attitude control; hydrazine propulsion for stationkeeping; Global Positioning System satellite position and star tracker attitude determination; and onboard image storage capability. The objectives of the SSTI CLARK program, the technical characteristics of the satellite, the techniques employed to reduce costs, and the image processing, archiving and distribution are described.

Sebestyen, George↗

DOE OSTI2025

Improving Resiliency in Planning MW-Scale Medium and Heavy Duty EV Charging Stations Considering TSCOTS Optimization

Electrification of heavy-duty (HD) vehicles marks an important milestone and technical challenge in the electric vehicle (EV) industry and the public grid. However, implementing EV charging at this scale will necessitate that traditional truck stops be updated with EV charging infrastructure that could represent 10's of MW in electricity consumption. Furthermore, as the transportation sector is represented as critical infrastructure, supporting resiliency considerations in EV charging infrastructure will be critical. This paper proposes an optimization-based approach for optimally designing a MW-scale microgrid charging network. This approach transforms conventional designed truck stops into a reliable HDEV charging stations capable of overnight slow charging and 30-minute to 1 hour fast charging. Using a mixed-integer linear program formulation blending capacity planning and reliability constraints, an optimal network configuration can be solved for a proposed EV charging station that includes photovoltaic and battery energy storage capabilities.

Ponce, Moises [University of Tennessee, Knoxville ↗

DOE OSTI2024

Hydrogel-Salt Hydrate Composite for Highly Stable Heat Energy Storage with Reduced Supercooling

Phase change materials (PCM) have potential for use in thermal energy storage in buildings, medical devices, and water heat pumps. Sodium sulfate hydrate (SSD) is appealing due to its high energy storage capability and affordability. However, SSD has issues including high supercooling (> 15°C) and low thermal cyclic stability. In this study, we introduced an ionic molecular nucleating agent that decreases the supercooling temperature to under 2°C. When this SSD was combined with a hydrogel, it maintained its thermal energy storage capacity for over 100 cycles without any decline. The success is attributed to the polymer confining the SSD crystals, preventing large-scale phase separation and the nucleating agent which resulted in nucleation of many small SSD crystals at small undercoolings rather than a small number of larger crystals. As a proof-of-application, we synthesized this composite at a kg scale and demonstrated its properties in a close to real-world demonstration.

chemical composition, thermodynamics↗

DOE OSTI2025

A combined experimental and machine learning exploration of Ti 2-x Zr x MnCrFeNi high entropy Laves hydrides

A series of high entropy AB 2 -type Ti 2-x Zr x MnCrFeNi alloys (x = 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 and 1.2) were synthesized to investigate their potential for hydrogen storage and chemical compression. The influence of the Ti/Zr ratio was explored in terms of structural, microstructural and thermodynamic properties. The storage capacity together with the reaction enthalpy and entropy changes of the synthesized high entropy alloys were compared to predictions from Machine Learning (ML) to investigate changes in these properties across the explored composition space. The results revealed that a decreasing Zr content consistently lowered the hydride formation enthalpy and increased the plateau pressure from 8 to >90 bar H 2 at 25 °C, in good agreement with ML predictions. Selected compositions (x = 1.0 and 1.2) demonstrated reversible hydrogen storage capability over 150 cycles, with capacities of 1.34–1.40 wt % H 2 and remarkable reaction kinetics (<4 min) at ambient temperature. These experimental and computational findings highlight the potential of this Laves-HEA system as tuneable, stable, and cost-effective materials suitable for long-term operations in stationary hydrogen storage and compression applications.

36 MATERIALS SCIENCE↗

NASA NTRS1992

Autonomous support for microorganism research in space

A preliminary design for performing on-orbit, autonomous research on microorganisms and cultured cells/tissues is presented. An understanding of gravity and its effects on cells is crucial for space exploration as well as for terrestrial applications. The payload is designed to be compatible with the COMmercial Experiment Transported (COMET) launch vehicle, an orbiter middeck locker interface, and with Space Station Freedom. Uplink/downlink capabilities and sample return through controlled reentry are available for all carriers. Autonomous testing activities are preprogrammed with inflight reprogrammability. Sensors for monitoring temperature, pH, light, gravity levels, vibration, and radiation are provided for environmental regulation and experimental data collection. Additional experiment data acquisition includes optical density measurement, microscopy, video, and file photography. Onboard full data storage capabilities are provided. A fluid transfer mechanism is utilized for inoculation, sampling, and nutrient replenishment of experiment cultures. In addition to payload design, representative experiments were developed to ensure scientific objectives remained compatible with hardware capabilities. The project is defined to provide biological data pertinent to extended duration crewed space flight including crew health issues and development of a Controlled Ecological Life Support System (CELSS). In addition, opportunities are opened for investigations leading to commercial applications of space, such as pharmaceutical development, modeling of terrestrial diseases, and material processing.

Luttges, M. W.↗

DOE OSTI2023

Pouch cells with 15% silicon calendar-aged for 4 years

Small amounts of high-capacity silicon-based materials are already used in the anode of commercial Li-ion batteries, helping increase their energy density. Despite their remarkable storage capability, silicon continu-ously reacts with the electrolyte, accelerating time-dependent cell performance fade. Nevertheless, very limited information is available on the specific consequences of this reactivity for the calendar aging of Li-ion cells. Here, we analyze aging effects on 450 mAh pouch cells containing 15 wt% of Si (and 73 wt% graphite) after storage at 21 °C for four years. We show that severe losses of Si capacity occurred due to particle isolation when cells were stored at high states of charge (SOC), but not when cells were fully discharged prior to storage. Impedance rise was also significantly higher when cells were kept at high SOCs and was mostly due to phenomena taking place at the cathode; the continuous electrolyte reduction at the anode did not lead to a major increase in bulk electrode resistance. A series of post-test characterization provided additional information on the effects of time and SOC on the calendar aging of Si-containing cells. In conclusion, our study highlights the many challenges posed by Si during calendar aging and can inform future studies in the field.

25 ENERGY STORAGE↗

NASA NTRS1992

Autonomous support for microorganism research in space

A preliminary design for performing on orbit, autonomous research on microorganisms and cultured cells/tissues is presented. An understanding of gravity and its effects on cells is crucial for space exploration as well as for terrestrial applications. The payload is designed to be compatible with the Commercial Experiment Transporter (COMET) launch vehicle, an orbiter middeck locker interface, and with Space Station Freedom. Uplink/downlink capabilities and sample return through controlled reentry are available for all carriers. Autonomous testing activities are preprogrammed with in-flight reprogrammability. Sensors for monitoring temperature, pH, light, gravity levels, vibrations, and radiation are provided for environmental regulation and experimental data collection. Additional experimental data acquisition includes optical density measurement, microscopy, video, and film photography. On-board full data storage capabilities are provided. A fluid transfer mechanism is utilized for inoculation, sampling, and nutrient replenishment of experiment cultures. In addition to payload design, representative experiments were developed to ensure scientific objectives remained compatible with hardware capabilities. The project is defined to provide biological data pertinent to extended duration crewed space flight including crew health issues and development of a Controlled Ecological Life Support System (CELSS). In addition, opportunities are opened for investigations leading to commercial applications of space, such as pharmaceutical development, modeling of terrestrial diseases, and material processing.

Fleet, Mary L.↗

NASA NTRS1998

Smart Optical RAM for Fast Information Management and Analysis

Statement of Problem Instruments for high speed and high capacity in-situ data identification, classification and storage capabilities are needed by NASA for the information management and analysis of extremely large volume of data sets in future space exploration, space habitation and utilization, in addition to the various missions to planet-earth programs. Parameters such as communication delays, limited resources, and inaccessibility of human manipulation require more intelligent, compact, low power, and light weight information management and data storage techniques. New and innovative algorithms and architecture using photonics will enable us to meet these challenges. The technology has applications for other government and public agencies.

Liu, Hua-Kuang↗

NASA NTRS2008

FPGA Coprocessor for Accelerated Classification of Images

An effort related to that described in the preceding article focuses on developing a spaceborne processing platform for fast and accurate onboard classification of image data, a critical part of modern satellite image processing. The approach again has been to exploit the versatility of recently developed hybrid Virtex-4FX field-programmable gate array (FPGA) to run diverse science applications on embedded processors while taking advantage of the reconfigurable hardware resources of the FPGAs. In this case, the FPGA serves as a coprocessor that implements legacy C-language support-vector-machine (SVM) image-classification algorithms to detect and identify natural phenomena such as flooding, volcanic eruptions, and sea-ice break-up. The FPGA provides hardware acceleration for increased onboard processing capability than previously demonstrated in software. The original C-language program demonstrated on an imaging instrument aboard the Earth Observing-1 (EO-1) satellite implements a linear-kernel SVM algorithm for classifying parts of the images as snow, water, ice, land, or cloud or unclassified. Current onboard processors, such as on EO-1, have limited computing power, extremely limited active storage capability and are no longer considered state-of-the-art. Using commercially available software that translates C-language programs into hardware description language (HDL) files, the legacy C-language program, and two newly formulated programs for a more capable expanded-linear-kernel and a more accurate polynomial-kernel SVM algorithm, have been implemented in the Virtex-4FX FPGA. In tests, the FPGA implementations have exhibited significant speedups over conventional software implementations running on general-purpose hardware.

Pingree, Paula J.↗

NASA NTRS1979

Fuel spray data with LDV

Droplet size and two component velocities in the severe environment of an operating gas turbine combustor system can be measured simultaneously using the solar laser morphokinetomer (SLM) which incorporates the following capabilities: (1) measurement of a true two-dimensional velocity vector with a range of + or - (0.01-200 m/sec); (2) measurement of particle size (range 5 to 300 micron m) simultaneously with the measurement of velocity; (3) specification of probe volume position coordinates with a high degree of accuracy (+ or - 0.5 mm); (4) immediate on-line data checks; and (5) rapid computer storage of acquired data. The optical system of the SLM incorporates an ultrasonic beam splitter to allow the measurement of a two-dimensional velocity vector simultaneously with particle size. A microprocessor with a limited storage capability permits immediate analysis of test data in the test cell.

Rohy, D. A.↗

NASA NTRS1981

Adaptive control system for large annular momentum control device

A dual momentum vector control concept, consisting of two counterrotating rings (each designated as an annular momentum control device), was studied for pointing and slewing control of large spacecraft. In a disturbance free space environment, the concept provides for three axis pointing and slewing capabilities while requiring no expendables. The approach utilizes two large diameter counterrotating rings or wheels suspended magnetically in many race supports distributed around the antenna structure. When the magnets are energized, attracting the two wheels, the resulting gyroscopic torque produces a rate along the appropriate axis. Roll control is provided by alternating the radiative rotational velocity of the two wheels. Wheels with diameters of 500 to 800 m and with sufficient momentum storage capability require rims only a few centimeters thick. The wheels are extremely flexible; therefore, it is necessary to account for the distributed nature of the rings in the design of the bearing controllers. Also, ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. An adaptive control system designed to handle these problems is described.

Montgomery, R. C.↗