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This presentation covers work to be presented at the 2024 VTO Annual Merit Review in June 2024 for the Battery500 project. The presentation will cover work related to aging in Li metal batteries. All content will have been submitted for publication, published or be appropriate for public release prior to June. This presentation compiles information from other presentations.
Mechanical metamaterials have demonstrated exceptional impact performance while remaining lightweight. Impact resistance has traditionally been investigated using quasi-static simulations, often with the assumption that performance will translate to high-velocity impact scenarios. However, critical crash protection parameters—such as peak stress and absorbed energy—are highly sensitive to impact velocity, leading to inconsistent performance under dynamic loading. To address this, we introduce a strain-rate-aware, active deep learning framework that enables multi-objective optimization of impact protection metrics across a wide range of impact velocities. Our framework captures the strain-rate sensitivity of architected lattices by learning to control spatial gradation in cellular metamaterials, resulting in over 200 % enhancement in impact protection relative to state-of-the-art designs such as Voronoi and re-entrant lattices. We demonstrate its practical utility by designing next-generation lattice structures for automotive bumper systems that satisfy multiple, velocity-specific safety criteria—capabilities beyond those of conventional designs. More than just a predictive tool, this framework marks the first step towards enabling adaptable impact-resistant structures across dynamic regimes.
Carbon fiber (CF)-reinforced epoxy composites are widely used in vehicle applications, where early damage detection is crucial for reliability and safety. To address this need, we developed a self-sensing epoxy/CF composite by embedding a PVDF-MoS 2 nanosensor via an embedded 3D printing method. By harnessing the intrinsic curing kinetics of epoxy, we tailored its rheological properties to optimize the embedded printing process, enabling precise and reliable support for sensor filaments without compromising the composite’s structural and functional integrity. Through comprehensive rheological and kinetic analysis, we established a quantitative relationship among curing temperature, conversion rate, and resulting yield modulus─defining a narrow processing window essential for successful sensor integration. Specifically, we identified that an epoxy yield modulus range of 180–294 Pa and a conversion rate below 10% are critical to support the PVDF-MoS 2 filament architecture. Here, this embedded 3D printing method produces complex and multimaterial PVDF-MoS 2 sensors within an epoxy matrix with minimal deformation and reduced postprocessing, which is scalable and adaptable for industrial applications. Under cyclic loading, the embedded sensors exhibited stable signals under constant loads and increased voltage signals in response to crack formation (17–35% higher) and catastrophic failure (1 order of magnitude higher), effectively capturing structural changes in real time. This study demonstrates the potential of PVDF-MoS 2 nanocomposite sensor materials for real-time structural health monitoring in epoxy–CF composite systems, enabling early detection of defects and stress anomalies, significantly reducing the risk of unexpected failures, and enhancing structural reliability.
Plug-in electric vehicles (EVs) are reshaping the transportation energy landscape, providing a practical alternative to petroleum fuels for a growing number of applications. EV sales grew 55x in the past decade (2014-2024) and 6x since 2020, driven by technological progress enabled by policies to reduce transportation emissions as well as industrial plans motivated by strategic value of EVs for global competitiveness, jobs and geopolitics. In 2024, 22% of passenger cars sold globally were EVs and opportunities for EVs beyond on-road applications are growing, including solutions to electrify off-road vehicles, maritime and aviation. This Review updates and expands our 2020 assessment of the scientific literature and describes the current status and future projections of EV markets, charging infrastructures, vehicle-grid integration and supply chains in the USA. EV is the lowest-emission motorized on-road transportation option, with life-cycle emissions decreasing as electricity emissions continue to decrease. Charging infrastructure grew in line with EV adoption but providing ubiquitous reliable and convenient charging remains a challenge. EVs are reducing electricity costs in several US markets and coordinated EV charging can improve grid resilience and reduce electricity costs for all consumers. The current trajectory of technology improvement and industrial investments points to continued acceleration of EVs.
Thermodynamic, aerodynamic, mechanical, and systems studies of lift fan concepts for V/STOL TRANSPORT and supersonic fan-in-wing fighter aircraft
Research and development at the National Renewable Energy Laboratory supports the U.S. Department of Energy's Vehicle Technologies Office in advancing efficient and sustainable transportation technologies that will improve energy efficiency, fuel economy, and mobility energy productivity, and will enable America to achieve a resilient, secure, clean, and affordable transportation future.
Research and development at the National Renewable Energy Laboratory supports the U.S. Department of Energy's Vehicle Technologies Office in advancing efficient and sustainable transportation technologies that will improve energy efficiency, fuel economy, and mobility energy productivity, and will enable America to achieve a resilient, secure, clean, and affordable transportation future.
Research and development at the National Renewable Energy Laboratory supports the U.S. Department of Energy's Vehicle Technologies Office in advancing efficient and sustainable transportation technologies that will improve energy efficiency, fuel economy, and mobility energy productivity, and will enable America to achieve a resilient, secure, clean, and affordable transportation future.
Research and development at the National Renewable Energy Laboratory supports the U.S. Department of Energy's Vehicle Technologies Office in advancing efficient and sustainable transportation technologies that will improve energy efficiency, fuel economy, and mobility energy productivity, and will enable America to achieve a resilient, secure, clean, and affordable transportation future.
Research and development at NLR supports the U.S. Department of Energy's Vehicle Technologies Office in advancing low-cost, abundant, and secure energy technologies to accelerate a more affordable, reliable, efficient, and globally competitive U.S. transportation system.