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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 127 records · Page 7

Enhancing Li + Transport in NMC811||Graphite Lithium–Ion Batteries at Low Temperatures by Using Low–Polarity–Solvent Electrolytes

LiNi x Co y MnzO 2 (x+y+z=1)||graphite lithium-ion battery (LIB) chemistry promises practical applications. However, its low-temperature (≤ –20°C) performance is poor because the increased resistance encountered by Li + transport in and across the bulk electrolytes and the electrolyte/electrode interphases induces capacity loss and battery failures. Though tremendous efforts have been made, there is still no effective way to reduce the charge transfer resistance (R ct ) which dominates low-temperature LIBs performance. In this work, we propose a strategy of using low-polarity-solvent electrolytes which have weak interactions between the solvents and the Li + to reduce R ct , achieving facile Li + transport at sub-zero temperatures. The exemplary electrolyte enables LiNi 0.8 Mn 0.1 Co 0.1 O 2 ||graphite cells to deliver a capacity of ≈113 mAh g –1 (98% full-cell capacity) at 25°C and to remain 82% of their room-temperature capacity at –20°C without lithium plating at 1/3C. They also retain 84% of their capacity at –30°C and 78% of their capacity at –40°C and show stable cycling at 50°C.

25 ENERGY STORAGE↗

Dynamic In‐Plane Heterogeneous and Inverted Response of Graphite to Fast Charging and Discharging Conditions in Lithium‐Ion Pouch Cells

Solutions for improving fast charging of lithium‐ion batteries have largely focused on alleviating through‐plane lithiation gradients while little is understood about in‐plane heterogeneities and how to resolve them. Herein, high‐speed synchrotron X‐ray diffraction (XRD) resolves graphite lithiation spatially and temporally during 6 C charging and 2 C discharging. At every point during operation, considerable differences in the state of lithiation across the pouch cell are present. Some regions are more responsive to operation than others, reaching full lithiation early during charge and full delithiation during discharge. Other regions within the cell never fully delithiate during discharge, despite a prolonged voltage hold at 2.8 V. Using time‐resolved XRD data, the calculated local current density (mA cm −2 ) at the graphite surface shows an unexpected occurrence of local inverted current densities where regions of graphite are observed to delithiate during charging and lithiate during discharging. A pseudo‐3D model is developed for the graphite electrode with spatially varying microstructural tortuosity to show how microstructural heterogeneity could influence spatial charge dynamics. The model could not predict the complex in‐plane charge behavior observed within the cell. Consequently physics‐based charging protocols based on homogeneous electrode assumptions may underestimate the local variations in charge dynamics and occurrence of lithium plating.

25 ENERGY STORAGE↗

Unraveling capacity fading in lithium-ion batteries using advanced cyclic tests: A real-world approach

Battery lifespan estimation is essential for effective battery management systems, aiding users and manufacturers in strategic planning. However, accurately estimating battery capacity is complex, owing to diverse capacity fading phenomena tied to factors such as temperature, charge-discharge rate, and rest period duration. In this work, we present an innovative approach that integrates real-world driving behaviors into cyclic testing. Unlike conventional methods that lack rest periods and involve fixed charge-discharge rates, our approach involves 1000 unique test cycles tailored to specific objectives and applications, capturing the nuanced effects of temperature, charge-discharge rate, and rest duration on capacity fading. This yields comprehensive insights into cell-level battery degradation, unveiling growth patterns of the solid electrolyte interface (SEI) layer and lithium plating, influenced by cyclic test parameters. Here, the results yield critical empirical relations for evaluating capacity fading under specific testing conditions.

25 ENERGY STORAGE↗

Electrode Modification by Laser Ablation to Overcome Mechanical and Scalability Limitations of Solid-State Prealkylation of Electrode Architectures

In this work, laser ablation of Si electrode surfaces is utilized to provide localized strain relief during the Solid State Prealkylation of Electrode Architectures (SPEAR) process, in addition to volumetric expansion relief in the form of free volume channels across the electrode. A hexagonal mesh patterning was employed via laser ablation, where the hexagonal diameter (pitch) was varied from 250 to 1000 µm. It was demonstrated that these channels serve as expansion voids, accommodating the increase in electrode thickness observed during SPEAR and preventing cracking at the electrode surface. Optical microscopy and Raman mapping confirm that Li diffusion is the rate-limiting solid-state process, requiring a 24 h rest period to achieve homogeneous LixSi alloying through the electrode bulk. Electrochemical evaluations in full cells show that a 1000 μm pitch pattern yields a high initial discharge capacity of 2485 mA h g–1 and 86.4% capacity retention after 80 cycles, whereas smaller pitches (<500 μm) result in lithium plating at 4.1 V in full cells paired with NMC 811 due to excessive current collector exposure from the ablation process. XPS analysis reveals that the laser treatment modifies the electrode surface by increasing the Si–O and C–O species, changing the SEI composition observed via an increase in fluorophosphates upon cycling.

Musgrove, Amanda [ORNL] (ORCID:0009000220910389)↗

Operando Analysis of Gas Evolution in TiNb 2 O 7 (TNO)-Based Anodes for Advanced High-Energy Lithium-Ion Batteries under Fast Charging

TiNb 2 O 7 (TNO) is regarded as one of the promising next-generation anode materials for lithium-ion batteries (LIBs) due to its high rate capabilities, higher theoretical capacity, and higher lithiation voltage. Furthermore, this enables the cycling of TNO-based anodes under extreme fast charging (XFC) conditions with a minimal risk of lithium plating compared to that of graphite anodes. Here, the gas evolution in real time with TNO-based pouch cells is first reported via operando mass spectrometry. The main gases are identified to be CO 2 , C 2 H 4 , and O 2 . A solid–electrolyte interphase is detected on TNO, which continues evolving, forming, and dissolving with the lithiation and delithiation of TNO. The gas evolution can be significantly reduced when a protective coating is applied on the TNO particles, reducing the CO 2 and C 2 H 4 evolution by ~2 and 5 times, respectively, at 0.1C in a half-cell configuration. The reduction on gas generation in full cells is even more pronounced. The surface coating also enables 20% improvement in capacity under XFC conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

High Li + Transference Number Electrolyte Enabled by Fluoride Acceptor for Low-Temperature Li-Ion Batteries

To enable wide-temperature operation of lithium-ion batteries (LIBs), new electrolyte formulations have been developed to enhance the performance, particularly at low temperatures. A key challenge lies in achieving both high ionic conductivity and a high lithium-ion transference number due to their inherent trade-off. In this study, we designed an electrolyte system comprising tris(pentafluorophenyl)borane (TPFPB), a fluoride acceptor, and LiF salt in ethylene carbonate (EC)-free solvents. TPFPB, with its electron-deficient boron center, facilitates fluoride transfer reactions that promote the dissociation of otherwise insoluble LiF. When methyl acetate (MA) was used as the solvent, the electrolyte exhibited a high transference number (t Li + = 0.85) and ionic conductivity (σ = 5.0 × 10 –3 S cm –1 ). The optimized electrolyte demonstrated excellent performance at −20 °C, with no evidence of lithium plating. This work presents a new strategy for electrolyte design by leveraging cation desolvation to achieve high-performance LIBs for low-temperature and high-power applications.

anions↗

Heterogeneous doping via nanoscale coating impacts the mechanics of Li intrusion in brittle solid electrolytes

Lithium dendrite intrusion in solid-state batteries limits fast charging and causes short-circuiting, yet the underlying regulating mechanisms are not well-understood. Here, in this work, we discover that heterogeneous Ag + doping dramatically affects lithium intrusion into Li 6.6 La 3 Zr 1.6 Ta 0.4 O 12 (LLZO), a brittle solid electrolyte. Nanoscale Ag + doping is achieved by thermally annealing a 3-nm-thick metallic coating on LLZO, inducing Ag–Li ion exchange and Ag diffusion into grains and grain boundaries. Density functional theory calculations and experimental characterization show negligible impact on the electronic properties and surface wettability from Ag + incorporation. Mechanically, nanoindentation experiments show a fivefold increase in the mechanical force required to fracture the surface Ag + -doped LLZO, indicating substantial doping-induced surface toughening. Operando microprobe scanning electron microscopy experiments show that the Ag + -doped LLZO surface exhibits improved lithium plating at >250 mA cm −2 and an electroplating diameter that is expanded by over fourfold, even under an extreme indentation stress of 3 GPa. This demonstrates enhanced defect tolerance in LLZO, rather than electronic or adhesion effects. Our study reveals a chemo-mechanical mechanism via surface heterogeneous doping, complementing present bulk design rules to minimize mechanical failures in solid-state batteries.

36 MATERIALS SCIENCE↗

Pathways towards managing cost and degradation risk of fast charging cells with electrical and thermal controls

The charging rate of Li-ion batteries is limited by the risks of lithium plating and thermal damage, both of which negatively affect lifetime of the batteries. This work analyzes how to minimize charge time and manage the risk of degradation using both electrical and thermal controls. To accomplish this, an electrochemical-thermal model is developed to introduce a constant-risk fast charging protocol which maximizes the charging current while maintaining the cell within pre-defined design limits selected to minimize the risk of degradation. Results indicate 80%-charging of a typical NMC/graphite cell can be achieved within 10 minutes with a cell cost under $100 kW –1 h –1 (corresponding to an 80 μm thick anode) when charged at moderate allowable risks of degradation. Here, we also demonstrate how stretching the allowable risk (i.e., higher temperatures, larger C-rates, and lower anode potential limits) allows affordable design of fast charging cells.

25 ENERGY STORAGE↗

Investigation of the Electrode-Electrolyte Interphase in Ester-Based Electrolytes in NCM523/Graphite Cells

The use of methyl acetate (MA) and methyl propionate (MP) as co-solvents in carbonate/LiPF 6 electrolytes have been investigated in LiNi 0.5 Co 0.2 Mn 0.3 O 2 (NCM523)/graphite cells to improve electrochemical performance at low temperature (−20 °C). Consistent with previous investigations, improved low temperature performance was observed with all electrolyte formulations containing esters. Detailed ex situ surface analysis of the surface films generated with the ester-based electrolytes containing electrolyte additives reveal significant changes to the SEI on graphite upon cycling at moderately elevated temperature (45 °C). In the presence of vinylene carbonate (VC) lithium plating is observed upon cycling at low temperature (−20 °C) which leads to a thicker solid electrolyte interface (SEI) upon cycling at 45 °C. Incorporation of fluoroethylene carbonate (FEC) as an electrolyte additive results in the generation of a thin SEI and alters the structure of the surface film on the NCM523 cathode resulting in stable cycling over a wide temperature range.

Rodrigo, Nuwanthi D. (ORCID:0000000343129536)↗

Modeling Losses in a Three Electrode System Towards Fast Charge Control

In this work we demonstrate the applicability of a versatile separator-reference mounted electrode in a three-electrode setup to accurately capture the primary current pathway in the battery cell during operation, calibrate a porous electrode model to the individual anode and cathode potential signals, and assign the various resistances to electrochemical phenomena in the battery cell. This calibrated electrochemical model is validated using continuous rate discharges associated with highway driving scenarios in an electric vehicle, and in turn utilized to predict the local anode potential and proximity to lithium plating onset. Finally, we demonstrate the strategy associated with utilization of the model to estimate constant anode potential charging during fast charge scenarios at various rates and starting conditions as a future look to fast charge calibration development and controls.

Garrick, Taylor R. (ORCID:0000000322518129)↗

Highly Ordered Hierarchical Anodes for Extreme Fast Charging Batteries (Final Report)

The goal of this project is to enable extreme fast charging (XFC) of Li-ion batteries, which was accomplished through a combination of 1) rational design and manufacturing of hierarchically structured anode architectures; 2) blending graphite/hard carbon into a bulk hybrid anode; 3) engineering artificial solid-electrolyte interphase (SEI) coatings with reduced interphase impedance; 4) computational modeling of coupled transport, kinetic, and electrochemical phenomena; and 5) improved fundamental understanding of lithium plating through operando analysis. This work integrated structural, compositional, and surface modification of graphite anodes, multi-physics modeling of ion transport, electrochemical activity, and heat transfer, advanced strategies to detect Li plating, and semi-automated roll-to-roll cell assembly. The unique facilities at the University of Michigan (UM) and Sandia National Laboratories (SNL) were leveraged to manufacture, prototype, and characterize commercially relevant >2Ah and >180 Wh/kg cells with a target of <20% capacity fade over 500 XFC cycles.

25 ENERGY STORAGE↗

Research and Development on Advanced Electrochemical Energy Storage Devices Enabling a Spectrum of Electrified Vehicles

The USABC Advanced Battery development plan had the following three focus areas: 1. Existing technology validation, implementation, and cost reduction 2. Identification of the next viable technology with emphasis on the potential to meet USABC cost and energy density goals. 3. Support high-risk, high-reward battery technology R&D The primary aim of this project was focused on the barriers that most impede wider public adoption of electrification in vehicles-cost, energy density, low-temp performance, calendar life, and improvements in abuse tolerance. The specific objectives are as follows: Cost Reduction: drive to significantly reduce battery cost to be in-line with the $\$$100/kWh or less (by the end of calendar year 2020) DOE cost goals. Additionally, goals of $\$$75/KWh were set for 2023 aligned with fast charge and some offset of energy density. Energy Density Increase: focus on improving the cell-level specific energy and energy densities to >350 watt hours per kilogram (Wh/kg) and >750Wh/L. Low Temperature Performance Increase: strive toward developments that improve the discharge power and eliminate or dramatically reduce the life limiting lithium plating associated with regenerative braking at low temperatures, during the program. Calendar Life Increase: drive to achieve a 15-year calendar life. Abuse Tolerance Improvement: strive to develop improvements in Li-ion abuse tolerance and/or development of electrochemical energy storage technologies with inherently better response to abuse circumstances. Emerging Areas: initiate new programs that address emerging technologies that arise during the contract period.

25 ENERGY STORAGE↗

Preliminary Evaluations of Polymer-based Lithium Battery Electrolytes Under Development for the Polymer Electrolyte Rechargeable Systems Program

A component screening facility has been established at The NASA Glenn Research Center (GRC) to evaluate candidate materials for next generation, lithium-based, polymer electrolyte batteries for aerospace applications. Procedures have been implemented to provide standardized measurements of critical electrolyte properties. These include ionic conductivity, electronic resistivity, electrochemical stability window, cation transference number, salt diffusion coefficient and lithium plating efficiency. Preliminary results for poly(ethy1ene oxide)-based polymer electrolyte and commercial liquid electrolyte are presented.

Manzo, Michelle A.↗

Weld repair method for aluminum lithium seam

Aluminum-lithium plates are butt-welded by juxtaposing the plates and making a preliminary weld from the rear or root side of the seam. An initial weld is then made from the face side of the seam, which may cause a defect in the root portion. A full-size X-ray is made and overlain over the seam to identify the defects. The defect is removed from the root side, and rewelded. Material is then removed from the face side, and the cavity is rewelded. The procedure repeats, alternating from the root side to the face side, until the weld is sound.

McGee, William Floyd↗

Materials Processes (MP) Engineering Internship Projects

This poster illustrates my major and minor projects worked on during my entire time interning at KSC in the Materials Science Branch. My major projects consist of three Failure Analyses, a research project on Magnesium Alloys, and the manufacturing and mechanical testing of the Advanced Plant Habitat. My three Failure Analyses are Umbilical Testing Ground Plates, Lithium Ion Battery Locking Spring Blade, and a Liquid Oxygen Poppet.

Tomsik, Elizabeth↗

Development of Solid State Electrolytes for Li-Metal Based High Capacity Battery

NASA future missions demand safe, high specific energy (>400 Wh/kg) batteries. Current state-of-the-art (SOA) lithium-ion batteries (LIBs) can only provide ~150-200 Wh/kg in energy capacity, which is unable to meet NASA's future energy goals, and also pose safety issues due to the use of liquid flammable electrolyte. There are intense on-going development activities to increase battery energy density. The use of Li metal as an anode material has emerged as one highly attractive option for achieving high-energy, next generation batteries. This is because Li has many advantages. It is the lightest metal, but also has the highest theoretical capacity. It also has the lowest potential, which boosts whole cell voltage, and Li metal is 100% active material and requires no binder. Thus, Li metal is an ideal anode material for high energy battery chemistries. Lithium metal based advanced battery chemistries are envisioned to be mission enhancing and, in many cases, mission enabling for future space and aeronautic applications. However, the reliable use of this exceptionally high capacity anode in a commercial rechargeable battery has not been achieved due to safety and reliability concerns resulting from thermal runaway and short-circuit issues due to dendritic growth on the Li metal anode from lithium plating during charge-discharge cycles. A solid state electrolyte, such as garnet/ceramic or solid polymer nanocomposite electrolyte, is a promising approach to make Li metal safely cycling. The solid state electrolyte is non-flammable and eliminates leakage and fire hazard by replacing the liquid flammable electrolyte. However, the low-ionic conductivity and high interfacial impedance are the key issues to be overcome. In this presentation, the research activities on solid state electrolyte development funded by the NASA Advanced Energy Storage System program and by the NASA Center Innovative Fund will be presented, and the progress and results will be also discussed.

Wu, James J.↗

Fundamental Understanding of Dynamic Interfacial Phenomena in Solid State Batteries

Solid-state batteries (SSBs) are considered as one of the most promising battery technologies for resolving the intrinsic limitations of current lithium-ion batteries, such as safety and insufficient energy density. However, the degradation associated with interfaces in SSBs is still a critical issue leading to short cycle life. To get fundamental understanding of the failure mechanism of the interfaces, we first developed a comprehensive set of in situ diagnostic techniques combined with atomic/continuum modeling schemes to investigate and understand the coupled mechanical/chemical degradation associated with dynamic interfacial phenomena in SSBs. Specifically, we focused on in situ observations and characterizations of lithium plating-stripping processes, lithium dendrite formation, interphase formation, and the induced interfacial stresses, as well as the mechanical and electrochemical properties of interfaces and interphases. The final project report first gives an overview of the project background, objectives, technical approaches, and final deliverables for all the budget periods; then follows with a summary on main accomplishments based on main tasks. We particularly would like to highlight some capabilities developed from this project which can also be implemented to our advanced battery development.

25 ENERGY STORAGE↗

Plating and Stripping of Lithium Metal Stabilized by a Block Copolymer Electrolyte: Local Current Density Measurement and Modeling

Here, plating and stripping of lithium protrusions in lithium metal symmetric cells containing a solid block copolymer electrolyte was studied as a function of time in 3D using time-resolved X-ray tomography. These measurements enabled determination of the spatial variation in current densities at the plating and stripping electrodes. The initial interelectrode distance was 27 μm. Correlation functions were calculated to reveal the relationships between current densities at the two electrodes and local electrolyte thickness. Current densities at opposing electrode locations during protrusion growth is uncorrelated until the local interelectrode distance decreases to less than 6 μm, just before the cell shorts. Mass balance was used to determine the area from which lithium ions that form a protrusion were stripped. Computational modeling of the plating and stripping process reveals the interplay between electrochemical and mechanical driving forces and their effect on nonuniform current distribution. Model predictions were compared with experiments without resorting to any adjustable parameters. The computed correlation functions were in qualitative agreement with experiments. Finally, the model was used to calculate contour plots of electrochemical potential within the electrolyte, shedding light on how geometry, salt concentration, interelectrode distance, and mechanical stress influence local rates of electrochemical reaction.

36 MATERIALS SCIENCE↗