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DOE OSTI2021

Sensitivity and reliability of key electrochemical markers for detecting lithium plating during extreme fast charging

Lithium plating is one of the key challenges for enabling extreme fast charging (XFC, ≤10 to 15 min charging at ≥6C) in graphite-based lithium-ion batteries. Significant R&D effort has been focused on how to mitigate Li plating. Parallel effort is also being devoted to developing methods to detect Li plating when and if it happens during fast charging. In that regard, electrochemical (EC) signature-based detection techniques are less resource intensive, more convenient, and more practical from an end-user application perspective. However, a comprehensive understanding of key plating related EC signatures for extreme fast charging is presently unavailable. In particular, there exist distinct issues of unreliability with key plating-related EC signatures—e.g., incremental capacity (dQ.dV -1 ), differential OCV (dOCV.dt -1 ), end of lithiation (EOL) rest voltage—at XFC conditions, and the underlying reasons have not been explored and identified methodically. Using a comprehensive test matrix and XFC conditions with Li/graphite half cells, this article highlights the unreliability issues associated with the EC Li plating diagnostics and explains the underlying root cause. This study finds distinct sensitivity and unreliability issues with plating related dQ.dV -1 , dOCV.dt -1 , and EOL rest voltage signatures with charging rates. Furthermore, the complex interaction between graphite and plated Li that happens through multiple competing mechanisms —Li stripping and chemical intercalation— at different charging rates is at the core of the sensitivity and unreliability issue.

25 ENERGY STORAGE↗

DOE OSTI2026

Ultra-low thermal resistance and pressure drop copper and copper-tungsten diamond-shaped pin fin cold plates for liquid cooling of electronics

Modern and future data centers face increasing cooling challenges due to increasing chip thermal design power and die size, along with the need to reduce energy consumption used for cooling. High performance cooling solutions that maintain a low chip junction temperature are needed to ensure electronics reliability. This work develops an ultra-low thermal resistance and low pressure drop 75 mm × 75 mm cold plate, intended for next-generation electronics cooling. The cold plate features an array of diamond-shaped pin fins and integrated copper tungsten heat spreader, selected for its low coefficient of thermal expansion which reduces thermomechanical deformation and allows for closer integration of the cold plate with silicon dies. Starting with 300 candidate designs, three-dimensional computational fluid dynamics simulations predict the thermal-hydraulic performance of cold plate subsections. The highest performing geometries are evaluated with high fidelity simulations. Four cold plates are manufactured for experiments: three with diamond-shaped pin fins and one with straights fins for comparison purposes. The cold plates are fabricated from copper-tungsten (CuW), copper (Cu), or aluminum-silicon-magnesium alloy (AlSi10Mg). The diamond-shaped pin fins achieve a roughly 15 % lower thermal resistance compared to the conventional straight fin microchannel. The highest performing design achieves a chip-to-coolant (including thermal interface material) thermal resistance of 9.0 K/kW in CuW and 6.9 K/kW in Cu under a 1 kW heat load with an inlet-to-outlet pressure drop of 9.0 kPa and water as the working fluid. This work demonstrates ultra-low thermal resistance and pressure drop cold plates for large die, high heat load applications, and shows that CuW is an attractive cold plate material for improved reliability in next generation data center cooling.

Coefficient of thermal expansion↗

DOE OSTI2025

Microstructure Scale Lithium-Ion Battery Modeling: Part III. When and Where Lithium Plating Occurs and its Correlation with the Electrode Microstructure

Li-ion battery performance and degradation are closely related to the cell’s underlying electrode microstructure. Electrode microstructures are typically characterized with volume-averaged properties that neglect the impact of local heterogeneities. However, local heterogeneities create hot spots that can trigger degradation onset. Herein, a microstructure scale electrochemical model is used to investigate the impact of microstructure heterogeneity on lithium plating. The model predicts lithium plating is not uniform, even when considering a relatively small portion of the electrode (a cross-sectional area of 154×144 µm 2 ), preferring to plate on larger particles as compared to smaller particles. While local heterogeneities control where plating occurs, the model predicts that volume-averaged properties control when plating occurs. Additionally, the model predicts that the active material specific surface area has a linear relationship with the plating onset. However, the linear relationship between increased active material surface area and delayed plating response appears to be sensitive to the microstructure feature used to increase the active interface area. Here, a comparative case-study is explored where the specific surface area is increased by either reducing the active material particle diameter, adding open-porosity cracks, or increasing the active material surface roughness. The model predicts that increasing the specific surface area by reducing the active material particle diameter is the most effective strategy for delaying lithium plating. At 6C, reducing particle size is shown to be 3 and 20 times more effective than, respectively, adding open-porosity cracks and increasing surface roughness. A dual-layer electrode architecture combining gradations both for average properties and uniformities is eventually proposed to improve homogeneous material utilization and reduce degradation at high charge rates.

25 ENERGY STORAGE↗

DOE OSTI2021

Quantification of heterogeneous, irreversible lithium plating in extreme fast charging of lithium-ion batteries

Realization of extreme fast charging (XFC, ≤15 minutes) of lithium-ion batteries is imperative for the widespread adoption of electric vehicles. However, dramatic capacity fading is associated with XFC, limiting its implementation. To quantitatively elucidate the effects of irreversible lithium plating and other degradation mechanisms on the cell capacity, it is important to understand the links between lithium plating and cell degradation at both the local and global (over the full cell) scales. Here, we study the nature of local lithium plating after hundreds of XFC cycles (charging C-rates ranging from 4C to 9C) in industrially-relevant pouch cells using spatially resolved X-ray diffraction. Our results reveal a spatial correlation at the mm scale between irreversible lithium plating on the anode, inactive lithiated graphite phases, and local state-of-charge of the cathode. In regions of plated lithium, additional lithium is locally and irreversibly trapped as lithiated graphite, contributing to the loss of lithium inventory (LLI) and to a local loss of active anode material. The total LLI in the cell from irreversibly plated lithium is linearly correlated to the capacity loss in the batteries after XFC cycling, with a non-zero offset originating from other parasitic side reactions. Finally, at the global (cell) scale, LLI drives the capacity fade, rather than electrode degradation. We anticipate that the understanding of lithium plating and other degradation mechanisms during XFC gained in this work will help lead to new approaches towards designing high-rate batteries in which irreversible lithium plating is minimized.

25 ENERGY STORAGE↗

DOE OSTI2024

Interplay of intercalation dynamics and lithium plating in monolithic and architectured graphite anodes during fast charging

Fast charging of high-capacity anodes is challenging due to lithium plating reactions, which lead to poor cycling performance and safety concerns. Thus, accurate predictions of plating onset and an understanding of this electrochemical process are crucial for robust battery design. However, the most commonly used models, based on porous electrode theory (e.g., the pseudo-2D model), are notoriously difficult to calibrate due to their complexity, limiting their predictive power. This work studies the process of lithium plating during fast charging of (small-particle) graphite half-cells by measuring local reaction progression and plating behavior using optical operando techniques. These experiments employ a realistic 1D graphite electrode geometry with commercially-relevant mass loading charged at fast charge rates. It is demonstrated that the local reaction progression and plating onset can not only be predicted accurately with a p2D numerical model, but that these processes follow a simple scaling law. Remarkably, the entire reaction histories of different electrodes charged at different rates (e.g., 160 μm thickness at 0.5C, 111 μm at 1C or 66 μm at 4C) were observed to have self-similar intercalation profiles. It is demonstrated that plating onset is in turn governed by the reaction profile which explains why both processes exhibit the same scaling behavior. Finally, operando measurements of local reaction dynamics are conducted for the first time in electrodes with channeled architectures, quantitatively determining how channels affect reaction uniformity and plating onset. Together, these results reveal underlying simplicity in the complex electrochemical environment of fast charging and lithium plating, improving understanding of this process. These fundamental insights are broadly applicable for design processes, modeling and experimental evaluation of lithium ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Flow resistance of phloem sieve plates revisited using an experimental model

Sieve plate resistance has been identified as the key to understanding the efficiency of phloem transport of carbohydrates in trees. These plates with small holes connecting sieve tubes are responsible for the largest resistance to flow in the phloem. Their structure determines how fast sugars can be transported through the phloem with certain pressure differences and what the limits for phloem transport in different plants are. Because experiments with the phloem are very challenging, our understanding of sieve plate resistance is mostly based on anatomical studies and hydrodynamic modeling of flow through sieve plates. These models calculate the resistance of the entire sieve tube–sieve plate system using the Hagen–Poiseuille flow resistance for the sieve cell lumen and a combination of the Hagen–Poiseuille resistance and Sampson flow resistance through the sieve pores. The resistance of the entire sieve plate is calculated by summing the Hagen–Poiseuille and Sampson flow resistances of each pore. To test the validity of this model formulation, an experimental model with aspect parameters similar to phloem sieve tubes was built using polyvinyl chloride (PVC) piping and plastic straws of different diameters and lengths. This system was used to measure flow rates and calculate flow resistance at Reynolds numbers 0.5–300. The results suggest that the current models may significantly overestimate the flow resistance caused by sieve plates and that the resistance might be better described by formulations used for perforated plates.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Involute Working Group – FSI Analysis of Fuel Plates Using Finite Volume and Finite Element Methods

The three involute plate research reactors RHF, HFIR, and FRM II have expressed an interest in using computational software to carry their steady-state safety analysis. Since these tools represent a significant departure from the methods used currently (one-dimensional), the acceptability of the new approach by regulators requires thorough verification and validation of these tools. Therefore, Argonne National Laboratory and the three involute-plate reactors formed an informal group called the Involute Working Group aiming at qualifying computational tools to perform steady-state safety analysis. The present report focuses on a comparison of finite volume and finite element methods to model solids in fluid-structure interaction problems with the goal to estimate the coolant flow-induced fuel plate deflections obtained with the two methods. The finite volume method will be obsoleted in STARCCM+ by the end of 2021, nevertheless, this evaluation is important because the method was used by ANL researchers to model the response of the fuel plates, despite its drawbacks, which are discussed in the report. It was essential to check how those estimates compare to the results obtained with the finite element method that is considered superior for structural analysis. Various geometries, i.e., flat, cylindrical and circle-involute fuel plates, as well as coolant flow speed, were considered. The comparison shows that, independently of the plate geometry, the finite volume method significantly underestimates the deflection as compared to finite element method for coarser meshes. When the discretization is developed as a result of a mesh sensitivity study using finite element method, the result obtained using finite volume method can be a few times smaller than the corresponding finite element method solution. A code-to-code comparison , between STAR-CCM+ and LS-DYNA was included in the analysis. Within the LS-DYNA models, two types of finite element formulations were used: solid and shell finite elements. Mesh sensitivity study showed that both approaches converge to a similar value that was obtained with STAR-CCM+ finite element solver. The evaluation of the computational solvers was extended by adding two benchmark cases from the STAR-CCM+ Verification Suite and presented in the Appendix A. The selected cases are: (1) bending of a cantilever beam under external load, and (2) cylindrical shell deformation analysis, known in the literature as ‘Scordelis-Lo roof’. The problems were solved with finite volume, and finite element methods, and the results confirmed the previously discussed findings. The analysis shows that the finite element solver is superior to the finite volume solver in terms of representation of model geometry and estimating the structural behavior of fuel plates. Depending on the ratio of the load to the flexibility of the plate, the finite volume solver can greatly under- or overestimate the structural response if a very carefully selected mesh is not used.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1971

Theoretical buckling loads of boron/aluminum and graphite/resin fiber composite anisotropic plates

Theoretical results are presented for the buckling of anisotropic plates. The plates are subjected to simple and combined in-plane loading. The plates are made from fiber composite material of boron/aluminum or high-modulus graphite/resin. The results are presented in nondimensional form as buckling load against fiber orientation angle for various plate aspect ratios. The results indicate that buckling loads of boron/aluminum plates are independent of fiber direction if the plate aspect ratios are greater than about 1, and moderately dependent when this ratio is less than about 1. In addition, the results indicate that the buckling loads are independent of aspect ratio for plates with aspect ratios greater than about 2. Boron/ aluminum composite plates can resist buckling loads more efficiently than graphite/resin composites on a specific buckling stress basis. The numerical algorithm and a listing of the computer code used to obtain the results are included.

Chamis, C. C.↗

NASA NTRS1985

Noise Transmission Loss of a Rectangular Plate in an Infinite Baffle

An improved analytical procedure was developed that allows for the efficient calculation of the noise transmission characteristics of a finite rectangular plate. Both isotropic and symmetrically laminated composite plates are considered. The plate is modeled with classic thin-plate theory and is assumed to be simply supported on all four sides. The incident acoustic pressure is assumed to be a plane wave impinging on the plate at an arbitrary angle. The reradiated pressure is assumed to be negligible compared with the blocked pressure, and the plate vibrations are calculated by a normal-mode approach. A Green's function integral equation is used to link the plate vibrations to be transmitted far-field sound waves, and transmission loss is calculated from the ratio of incident to transmitted acoustic powers. The result is a versatile research and engineering analysis tool that predicts noise transmission loss and enables the determination of the modal behavior of the plate.

Roussos, Louis A.↗

NASA NTRS1986

Buckling behavior of compression-loaded symmetrically-laminated angle-ply plates with holes

An approximate analysis for buckling of a rectangular specially-orthotropic plate with a central circular hole is applied to symmetrically-laminated angle-ply plates. Results obtained from finite element analyses and experiments indicate that the approximate analysis predicts accurately the buckling loads of (+/-theta sub m)s plates with integer values of m not below 6 and with hole diameters up to 50 percent of the plate width. Moreover, the results indicate that the approximate analysis can be used to predict the buckling trends of plates with hole diameters up to 70 percent of the plate width. Results of a parametric study indicate the influence of hole size, plate aspect ratio, loading conditions, boundary conditions, and orthotropy on the buckling load. Results are also presented that indicate the relationship of the bending stiffness and the prebuckling load distribution to the buckling load of a plate with a hole.

Nemeth, M. P.↗

NASA NTRS1988

Dual passband dichroic plate for X-band

A need arose in the Deep Space Network for a dichroic plate that would simultaneously pass two desired frequency bands in the X-band region. In addition, the plate must be totally reflective for S-band frequencies. A dielectrically loaded dichroic plate is described that was developed to meet this need. The unique microwave properties that the new dichroic plate had to possess were: (1) insertion losses of less than 0.04 dB for X-band uplink frequencies centered at 7167 MHz and for X-band downlink frequencies centered at about 8425 MHz; (2) insertion losses that met the low loss requirements at 30 deg incidence angle simultaneously for both parallel and perpendicular polarizations; (3) total reflectivity at S-band frequencies; and (4) ability to maintain these electrical characteristics while passing 100 kW of CW power at X-band or while reflecting 100 kW of CW power at S-band. The dual passband dichroic plate is a thick metallic plate having an array of periodic round holes filled with Teflon plugs. Test results on an experimental prototype plate indicate that it is technically possible to design a dielectrically filled dichroic plate that meets all of the technical requirements.

Otoshi, T. Y.↗

NASA NTRS1990

Power flow analysis of two coupled plates with arbitrary characteristics

In the last progress report (Feb. 1988) some results were presented for a parametric analysis on the vibrational power flow between two coupled plate structures using the mobility power flow approach. The results reported then were for changes in the structural parameters of the two plates, but with the two plates identical in their structural characteristics. Herein, limitation is removed. The vibrational power input and output are evaluated for different values of the structural damping loss factor for the source and receiver plates. In performing this parametric analysis, the source plate characteristics are kept constant. The purpose of this parametric analysis is to determine the most critical parameters that influence the flow of vibrational power from the source plate to the receiver plate. In the case of the structural damping parametric analysis, the influence of changes in the source plate damping is also investigated. The results obtained from the mobility power flow approach are compared to results obtained using a statistical energy analysis (SEA) approach. The significance of the power flow results are discussed together with a discussion and a comparison between the SEA results and the mobility power flow results. Furthermore, the benefits derived from using the mobility power flow approach are examined.

Cuschieri, J. M.↗

NASA NTRS1990

On the tones of round choked jets impinging on normal flat plates

An experimental investigation of the sound produced by an axisymmetric supersonic jet impinging on plates with variable size and nozzle-to-plate spacings was performed. Spectral analysis and schlieren photography were used to determine the sound characteristics and flow disturbances associated with the production of discrete tones. Two classes of tones, associated with small and large plates, existed for pressure ratios above 2.70. For lower pressure ratios, however, only large plate tones occurred for all plate sizes with choked jet screech appearing at the largest spacings. Reflector tests indicated that both classes of tones were part of a feedback loop to the nozzle. Schlieren photography revealed both symmetric and asymmetric disturbances in the large plate jet flows which corresponded to symmetrical and helical modes of oscillation in the cross-spectrum studies. In addition to this, both symmetric and asymmetric oscillations of the shock waves occurred in the large plate case while symmetric oscillations of the shock wave occurred in the small plate case.

Powell, Alan↗

NASA NTRS1990

Present-day kinematics of the Rivera plate and implications for tectonics in southwestern Mexico

A model for the present-day motion of the Rivera plate relative to the North America, Cocos, and Pacific plates is derived using new data from the Pacific-Rivera rise and Rivera transform fault, together with new estimates of Pacific-Rivera motions. The results are combined with the closure-consistent NUVEL-1 global plate motion model of DeMets et al. (1990) to examine present-day deformation in southwestern Mexico. The analysis addresses several questions raised in previous studies of the Rivera plate. Namely, do plate motion data from the northern East Pacific rise require a distinct Rivera plate? Do plate kinematic data require the subduction of the Rivera plate along the seismically quiescent Acapulco trench? If so, what does the predicted subduction rate imply about the earthquake recurrence interval in the Jalisco region of southwestern Mexico?

Demets, Charles↗

NASA NTRS1992

Photometric calibration of NGS/POSS and ESO/SRC plates using the NOAO PDS measuring engine. I - Stellar photometry

The PDS/Monet measuring engine at the National Optical Astronomy Observatory was used to obtain photometry of nearly 10,000 stars on the NGS/POSS and 2000 stars on the ESO/SRC Survey glass plates. These measurements have been used to show that global transformation functions exist that allow calibration of stellar photometry from any blue or red plate to equivalent Johnson B and Cousins R photoelectric magnitudes. The four transformation functions appropriate for the POSS O and E and ESO/SRC J and R plates were characterized, and it was found that, within the measurement uncertainties, they vary from plate to plate only by photometric zero-point offsets. A method is described to correct for the zero-point shifts and to obtain calibrated B and R photometry of stellar sources to an average accuracy of 0.3-0.4 mag within the range R between values of 8 and 19.5 for red plates in both surveys, B between values of 9 and 20.5 on POSS blue plates, and B between values of 10 and 20.5 on ESO/SRC blue plates. This calibration procedure makes it possible to obtain rapid photometry of very large numbers of stellar sources.

Cutri, Roc M.↗

NASA NTRS1989

Comparison of full 3-D, thin-film 3-D, and thin-film plate analyses of a postbuckled embedded delamination

Strain-energy release rates are often used to predict when delamination growth will occur in laminates under compression. Because of the inherently high computational cost of performing such analyses, less rigorous analyses such as thin-film plate analysis were used. The assumptions imposed by plate theory restrict the analysis to the calculation of total strain energy, G(sub t). The objective is to determine the accuracy of thin-film plate analysis by comparing the distribution of G(sub t) calculated using fully three dimensional (3D), thin-film 3D, and thin-film plate analyses. Thin-film 3D analysis is the same as thin-film plate analysis, except 3D analysis is used to model the sublaminate. The 3D stress analyses were performed using the finite element program NONLIN3D. The plate analysis results were obtained from published data, which used STAGS. Strain-energy release rates were calculated using variations of the virtual crack closure technique. The results demonstrate that thin-film plate analysis can predict the distribution of G(sub t) quite well, at least for the configurations considered. Also, these results verify the accuracy of the strain-energy release rate procedure for plate analysis.

Whitcomb, John D.↗

NASA NTRS1993

Kinematics of the New Zealand plate boundary: Relative motion by GPS across networks of 1000 km and 50 km spacing

The NASA/DOSE 'Kinematics of the New Zealand Plate Boundary' experiment is a four-year cooperative Global Positioning System (GPS) experiment involving 6 universities and institutions in New Zealand and the United States. The investigation covers two scales, the first on the scale of plates (approximately 1000 km) and the second is on the scale of the plate boundary zone (approximately 50 km). In the first portion of the experiment, phase A, the objective is to make direct measurements of tectonic plate motion between the Australian and Pacific plates using GPS in order to determine the Euler vector of this plate pair. The phase A portion of this experiment was initiated in December 1992 with the first-epoch baseline measurements on the large scale network. The network will be resurveyed two years later to obtain velocities. The stations which were observed for phase A are shown and listed. Additional regional stations which will be used for this study are listed and are part of either CIGNET or other global tracking networks. The phase A portion of the experiment is primarily the responsibility of the UNAVCO investigators. Therefore, this report concentrates on phase A. The first year of NASA funding for phase A included only support for the field work. Processing and analysis will take place with the second year of funding. The second part of the experiemnt measured relative motion between the Australian and Pacific plates across the pate boundary zone between Hokitika and Christchurch on the South Island of New Zealand. The extent and rate of deformation will be determined by comparisons with historical, conventional surveys and by repeated GPS measurements to be made in two years. This activity was the emphasis of the LDGO portion of the study. An ancillary experiment, phase C, concentrated on plate boundary deformation in the vicinity of Wellington and was done as part of training during the early portion of the field campaign. Details of the objectives of the field investigations are given in the appendix. An overview of the 1992 GPS field program is also given in the appendix.

Meertens, Charles M.↗

NASA NTRS1993

On the effect of acoustic coupling on random and harmonic plate vibrations

The effect of acoustic coupling on random and harmonic plate vibrations is studied using two numerical models. In the coupled model, the plate response is obtained by integration of the nonlinear plate equation coupled with the nonlinear Euler equations for the surrounding acoustic fluid. In the uncoupled model, the nonlinear plate equation with an equivalent linear viscous damping term is integrated to obtain the response of the plate subject to the same excitation field. For a low-level, narrow-band excitation, the two models predict the same plate response spectra. As the excitation level is increased, the response power spectrum predicted by the uncoupled model becomes broader and more shifted towards the high frequencies than that obtained by the coupled model. In addition, the difference in response between the coupled and uncoupled models at high frequencies becomes larger. When a high intensity harmonic excitation is used, causing a nonlinear plate response, both models predict the same frequency content of the response. However, the level of the harmonics and subharmonics are higher for the uncoupled model. Comparisons to earlier experimental and numerical results show that acoustic coupling has a significant effect on the plate response at high excitation levels. Its absence in previous models may explain the discrepancy between predicted and measured responses.

Frendi, A.↗