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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Ultra Long-Lived, Self-Surveying Autonomous Air Quality Sensing - Executive Summary

We set out to evolve ultra-low power air quality sensing technologies developed at JSC to add a highly accurate positioning sensor based on SBIR technology to give a self-surveying air quality monitoring platform with years-long lifetime on a small, disposable coin cell battery. Using Radio Frequency Identification (RFID) technology for data transport, the system can take advantage of RFID-based inventory management systems in place on lunar exploration assets to provide this capability with extremely small SWAP impacts. Years-long operational lifetimes enable flexible, autonomous environmental monitoring during lengthy intervals between and unprecedented situational awareness during crewed missions. Software integration of the localization system into the JSC RFID sensing platform was advanced, but the COVID-19 pandemic complicated and slowed maturation of the localization system SBIR product, and center closure indefinitely deferred a final hardware integration and system demonstration. In the meantime, progress was made to mature the air-quality sensing platform for flight, including hardware, software, antenna, and mechanical improvements. The underlying RFID sensing capability was also adapted to a drawer motion sensing system, which is currently (FY21) being taken toward an ISS flight demonstration as part of the RFID Enhanced Autonomous Logistics Management (REALM)-3 experiment.

Raymond Summers Wagner↗
NASA NTRSDate not supplied

Ultra Long-Lived, Self-Surveying Autonomous Air Quality Sensing

Environmental sensing will be key to autonomous vehicle operation and crew health monitoring in tended/untended long-duration habitats for Human Space Exploration in deep space. Small wireless sensors, based on Radio Frequency Identification (RFID) technology, can provide unprecedented capacity to monitor crew/habitat health. We develop a next-generation, path-to-flight wireless air quality sensor capable of operating for years on a small coin-cell battery without crewmember intervention. Initial steps are taken to integrate a self-surveying capability under development as a NASA Small Business Innovative Research (SBIR) project, though final integration was prevented due to COVID-19 center closure.

Raymond S Wagner↗
NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗
DOE OSTI2020

Hybrid electrolytes for group 2 cation-based electrochemical energy storage device

This invention relates to the field of energy storage devices, and especially electrochemical energy storage devices including electrolytes comprising an ionic liquid, one or more solvents, and one or more salts of a Group 2 element. Effects on electrochemical performance of the electrolyte of each of the components of the electrolyte were systematically determined. In addition, interactions between the electrolytes and separator films were dissected to optimize electrochemical performance of coin cell batteries.

25 ENERGY STORAGE↗
DOE OSTI2021

Methodologies for Design, Characterization and Testing of Electrolytes that Enable Extreme Fast Charging of Lithium-ion Cells

Selection, testing and validation of electrolyte candidates for Li-ion cells are discussed, based on a 10-minute target for extreme fast charge (XFC). A combination of modeling and laboratory measurements create a timely and synergistic approach to identifying candidate electrolyte formulations. Multi-solvent systems provide a balanced set of properties, wherein lower molecular-weight solvents offer reduced viscosity, increased species diffusivity, and mitigation of concentration polarization at high charge rates. Carefully selected formulations can exhibit peak conductivity and usable conductivity range of two to three times that of the baseline EC-EMC (3:7, wt.) + LiPF 6 . Candidates are also chosen based on stability and longevity within the cell environment. Lab testing coincides with property predictions from the Advanced Electrolyte Model (AEM) and a macro-scale cell model. Furthermore, cell testing utilized coin and pouch cells having NMC532 or NMC811 cathodes with graphite electrodes. Results indicate combinations of low-molecular weight solvents are key for fast-charge electrolytes as they extend the useful conductivity range to both low and higher salt concentrations, and possess higher self-diffusivities compared to conventional solvents. This reduces impacts from concentration polarization. The choice of electrolyte also influences the tendency for lithium metal deposition at the anode, as showcased by experimental and modeling results herein.

25 ENERGY STORAGE↗
NASA NTRS2006

Self-Passivating Lithium/Solid Electrolyte/Iodine Cells

Robust lithium/solid electrolyte/iodine electrochemical cells that offer significant advantages over commercial lithium/ iodine cells have been developed. At room temperature, these cells can be discharged at current densities 10 to 30 times those of commercial lithium/iodine cells. Moreover, from room temperature up to 80 C, the maximum discharge-current densities of these cells exceed those of all other solid-electrolyte-based cells. A cell of this type includes a metallic lithium anode in contact with a commercial flexible solid electrolyte film that, in turn, is in contact with an iodine/ graphite cathode. The solid electrolyte (the chemical composition of which has not been reported) offers the high ionic conductivity needed for high cell performance. However, the solid electrolyte exhibits an undesirable chemical reactivity to lithium that, if not mitigated, would render the solid electrolyte unsuitable for use in a lithium cell. In this cell, such mitigation is affected by the formation of a thin passivating layer of lithium iodide at the anode/electrolyte interface. Test cells of this type were fabricated from iodine/graphite cathode pellets, free-standing solid-electrolyte films, and lithium-foil anodes. The cathode mixtures were made by grinding together blends of nominally 10 weight percent graphite and 90 weight percent iodine. The cathode mixtures were then pressed into pellets at 36 kpsi (248 MPa) and inserted into coin-shaped stainless-steel cell cases that were coated with graphite paste to minimize corrosion. The solid-electrolyte film material was stamped to form circular pieces to fit in the coin cell cases, inserted in the cases, and pressed against the cathode pellets with polyethylene gaskets. Lithium-foil anodes were placed directly onto the electrolyte films. The layers described thus far were pressed and held together by stainless- steel shims, wave springs, and coin cell caps. The assembled cells were then crimped to form hermetic seals. It was found that the solid electrolyte films became discolored within seconds after they were placed in contact with the cathodes - a result of facile diffusion of iodine through the solid electrolyte material (see figure).

Bugga, Ratnakumar↗
DOE OSTI2020

In-Situ Characterization of Dynamic Morphological and Phase Changes of Selenium-doped Germanium Using a Single Particle Cell and Synchrotron Transmission X-ray Microscopy

The dynamic information of lithium-ion battery active materials obtained from coin cell-based in-situ characterizations might not represent the properties of the active material itself because many other factors in the cell could have impacts on the cell performance. To address this problem, a single particle cell was developed to perform the in-situ characterization without the interference of inactive materials in the battery electrode as well as the X-ray-induced damage. In this study, the dynamic morphological and phase changes of selenium-doped germanium (Ge 0.9 Se 0.1 ) at the single particle level were investigated via synchrotron-based in-situ transmission X-ray microscopy. The results demonstrate the good reversibility of Ge 0.9 Se 0.1 at high cycling rate that helps understand its good cycling performance and rate capability. This in-situ and operando technique based on a single particle battery cell provides an approach to understanding the dynamic electrochemical processes of battery materials during charging and discharging at the particle level.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Operando FTIR Studies of Electrolyte Solution Structures and Dynamics at Electrode-Electrolyte Interfaces

The well-stabilized electrode-electrolyte interface (EEI) is critical to battery performance and safety, thus understanding the electrolyte solution structures (e.g., ion solvation and ionic association) and dynamics within EEI is an important area of study. Unfortunately, due to the sensitive nature of the electrodes, ex-situ characterization methods are limited and challenging to interpret as chemical and structural changes occur upon deconstructing the cell. In this work, we present operando characterization of near-surface electrolyte solution structures and dynamics by ATR-FTIR spectroscopy during battery cycling. We studied two selected model electrodes, a lithium nickel manganese cobalt oxide (NMC) or a planar silicon (Si), in a standard Gen2 electrolyte of 1.2 M LiPF6 in ethylene carbonate (EC):ethyl methyl carbonate (EMC) (3:7 wt%). In the former case, the composite cathode on aluminum foil is placed face-down on an ATR crystal. A ring of lithium metal serves as the counter/reference electrode and no separator is required. In the latter case, a lightly doped p-type silicon wafer is phosphorous-doped at the surface to increase the conductivity of the sample without compromising infrared transparency. The ATR crystal is then pressed on the back of the silicon with a minimal air gap to ensure sufficient optical contact between the two materials. The front of wafer is then placed in a modified coin-type cell geometry with a minimal electrolyte, a separator, and a lithium metal counter/reference electrode. In both experiments, we analyze the electrolyte solution structures within the EEI and find similar patterns as a function of potential. Firstly, we find that EMC decomposes faster than EC -suggesting that EMC plays a greater role in the electrochemical reactions on the electrode surface (e.g., formation of a protective layer to prevent further electrolyte decomposition). Secondly, we monitor the increase/decrease of the vibrational absorption peaks attributed to carbonates coordinated with Li+ ions relative to the decrease/increase of their uncoordinated counterparts, as expected when changing the local concentration of Li+ ions near the electrode surface during deintercalation/intercalation into the electrode. Finally, we observe that the features assigned to the Li+-PF6 -/-solvent molecules contact ion pair relative to the uncoordinated PF6 - anion. These observations give important information regarding the electrolyte solution structures and dynamics near the electrode surfaces. We look forward to applying these techniques to additional lithiumion battery systems with different cathode or anode materials and beyond lithium-ion systems to characterize surface chemistry/evolution (on-going research) and solution structures/dynamics (in particular, (de)solvation behaviors) within the EEI, which can be a bottleneck to efficient ion transfer from the electrolyte to the electrode.

14 SOLAR ENERGY↗
NASA NTRS1974

A study of degradation of plates for nickel-cadmium spacecraft cells

The relative merits of coining and not coining of sintered nickel oxide and cadmium plates was investigated. Sample plate materials from most commercial cell suppliers were obtained and characterized for properties that may correlate with the tendency toward physical disintegration during handling and over long periods of time in the cell. Special test methods were developed to obtain comparative data in a short time. A wide range of physical properties and coining thickness was observed, resulting in a range of responses. The stronger materials resisted loss of sinter better than weaker materials whether or not coined. Coining improved handling and resistance to electrochemical cycling of weaker materials. The mechanism of break-down of positive plate edges under cycling appears to be the same as that of thickening and blistering. Brittle, nonadherent sinter, resulting from certain impregnation processes, is the most vulnerable to degradation. It is concluded that the latter type of materials should be coined, but coining of strong materials is optional.

Scott, W. R.↗
NASA NTRS1973

A study of degradation of plates for nickel-cadmium spacecraft cells

The relative merits of coining and not coining of sintered nickel-oxide and cadmium plates was investigated. A survey of the industry including cell manufactures and users was made and results summarized. Sample plate materials from most commercial cell suppliers were obtained and characterized for properties that may correlate with the tendency toward physical disintegration during handling and over long periods of time in the cell. Special test methods were developed to obtain comparative data in a short time. A wide range of physical properties and coining thicknesses was observed, resulting in a range of responses. The stronger, less brittle materials resisted loss of sinter better than weaker materials whether or not coined. Coining improved handling and resistance to electrochemical cycling in all materials tested. An apparent exception was found to be due to improper coining of a tapered edge.

Scott, W. R.↗
DOE OSTI2025

Improving Ionic Conformality Across Polymer Electrolyte|Electrode Interfaces

Maintaining uniform ionic transport at electrode|electrolyte interfaces, i.e., ionic conformality, remains challenging in polymer electrolyte (PE)-based solid-state batteries. Morphological conformality does not necessarily imply ionic conformality. In PEs, which typically consist of a mechanically supporting component and distinct ionically conductive components, the rearrangement or depletion of mobile ion-conductive domains at interfaces can disrupt ionic transport pathways. Such localized ionic depletion contributes to interfacial instability and capacity degradation in high-voltage lithium-metal batteries. Herein, an electrolyte design approach aimed at minimizing interfacial heterogeneities is demonstrated through compositional adjustments, characterized by spatially resolved structural and chemical X-ray techniques and NMR diffusometry to elucidate ion transport dynamics. This approach improves ionic conformality at electrode interfaces, enhancing cycling stability in Li||LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NMC811) coin and pouch cells cycled at high voltages. These results contribute to understanding interfacial behaviors in multiphase PEs and inform strategies for improving stability across solid-state battery interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Lithium-Ion Battery Testing Capable of Simulating “Ultralow” Lunar Temperatures

The first-ever lithium-ion battery cycler capable of testing the coin and pouch cells under ultralow (≤40 °C) temperatures down to -175 °C to simulate extreme climates found in the lunar and space missions, high-altitude air vehicles, polar regions of Earth, and military expeditionary missions is enthusiastically reported. The extremely cold temperatures are achieved through a tailored extreme low-temperature system (ELTS) with liquid nitrogen flow and the ability to reach temperatures between -175 and 25 °C, using 1 kΩ and 1 MΩ resistors at varying currents of 1–4 mA and 1–4 μA, respectively, is validated. Employing the ELTS, Li 4 Ti 5 O 12 (LTO)||Li cells with 1 m lithium bis(fluorosulfonyl)imide in cyclopentyl methyl ether as an electrolyte developed in this research group are charged and discharged at room temperature (cycling rate C/5), -20 (C/10), -40 (C/40), and -60 °C (C/50), which exhibited discharge capacities of 159.04, 119.12, 101.79, and 33.06 mAh g -1 , respectively. Moreover, the LTO||Li cell produced a reversible capacity of 7.12 mAh g -1 tested at -100 °C for the first time.

25 ENERGY STORAGE↗
DOE OSTI2021

Effect of temperature on capacity fade in silicon-rich anodes

Coin half-cells containing 80 wt% silicon electrodes are assembled and cycled at the similar to C/10 rate in the temperature range of 25-55 degrees C. To the best of our knowledge, this is the first time that the effect of temperature is reported for such high-silicon-containing cells. Two different electrolytes are used in this study, a baseline electrolyte and the baseline electrolyte +10 wt% fluoroethylene carbonate (FEC). Analysis of the capacity vs. cycle count data by curve fitting reveals that the addition of FEC markedly affects the capacity loss mechanism. Without FEC, the kinetic rate law for the capacity loss mechanism can be described as the sum of two logistic growth models. With the addition of FEC, the rate law depends on ln(t). Clearly, the addition of FEC has a profound effect on the mechanism of capacity loss. Interestingly, X-ray photoelectron spectroscopy (XPS) shows that the composition of the solid electrolyte interphase (SEI) layer changes markedly from mostly organic to mostly inorganic in the presence of FEC and how it varies at the different temperatures tested, especially in the absence of FEC.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Investigating Ternary Li–Mg–Si Zintl Phase Formation and Evolution for Si Anodes in Li-Ion Batteries with Mg(TFSI) 2 Electrolyte Additive

Improved electrochemical performance of Si was recently reported by adding multivalent cation salts (such as Mg 2+ , Al 3+ , Ca 2+, etc.) in the electrolyte. This is achieved via the formation in an in situ manner of relatively more stable Li-M-Si ternary phases with less chemical reactivity. These phases stabilize Si anions and thus reduce side reactions with electrolytes at the surface and eventually benefit the overall electrochemistry. To understand the mechanism of ternary Zintl phase formation and its dynamics upon lithiation/delithiation, high-resolution solid-state 7 Li and 29 Si nuclear magnetic resonance (NMR) are utilized to directly probe the local Li and Si environments on Si electrodes harvested from coin and pouch cells at various states of (de)lithiation. The NMR spectra along with the electrochemical characterization reveal that lithiation of Si starts from the surface Si-O layer further confirmed by 7 Li– 29 Si cross-polarization NMR. Lithiation progresses with heterogeneous silicon clustering with Si -4 anions at high states of lithiation. At a fully lithiated state, the formation of overlithiated Si species is detected. At a low-voltage region (below 100 mV), direct evidence for Mg-ion insertion is found, postulated by two possible mechanisms: ion exchange with fully or overlithiated binary domains (Li 3.75+x Si) and/or a coinsertion with slightly underlithiated domains (similar to Li 3.55 Si). Upon delithiation, Li extraction starts from overlithiated Si domains. No evidence is found for electrochemical Mg removal. Evidence for a lithium-deficient Li y Mg 0.1 Si phase is found as a result of Li removal during charging. This investigation sheds light on the possible mechanisms of a new Si anode chemistry, which could enable the development of stable Si-based anodes for lithium-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2019

Effective Electrochemical Charge Storage in the High-Lithium Compound Li8ZrO6

Li8ZrO6 is a pseudolamellar compound with high lithium content. Even though it is intrinsically a poor conductor and does not contain a transition metal with easily variable oxidation states, a new synthetic approach to preparing it in nanocomposite form with intimate contact to a conductive carbon by mechanical delamination enabled galvanostatic cycling of coin half-cells containing Li8ZrO6/C as the cathode and Li-metal as the anode at 221 mAh/g (which corresponds to extracting 2 Li per formula unit) over at least 140 cycles. With a higher capacity limit, a discharge capacity of 331 mAh/g (which corresponds to extracting 3 Li per formula unit) was maintained over 15–20 cycles. Ex-situ and operando X-ray diffraction (XRD) studies of galvanostatically cycled cells showed that at these levels of charge, delithiation follows a reversible, topotactic path with only small distortions around Zr atoms. During this process, crystalline grain sizes decrease continuously, shortening diffusion lengths within grains but increasing the number of grain boundaries and electrode/electrolyte interfaces. Charge storage in Li8ZrO6 appears to involve partial oxidation of oxygen atoms and production of small-polaron holes, as supported by XRD, X-ray photoelectron spectroscopy, and pair-distribution function studies and predicted by quantum mechanical calculations. At higher depths of charge, delithiation results in amorphization of the active electrode material. The charge storage mechanism in Li8ZrO6 is unusual among lithium-ion battery electrode materials and involves a combination of mechanisms that resemble intercalation and conversion reactions. With further refinement, Li8ZrO6/C based materials open up opportunities to develop new cathode materials for lithium-ion batteries that may improve on currently existing capacity barriers.

Li diffusion↗
DOE OSTI2025

Quantitative insights for diagnosing performance bottlenecks in lithium–sulfur batteries

Lithium–sulfur (Li–S) batteries hold significant promise for electric vehicles and aviation due to their high energy density and cost-effectiveness. However, understanding the root causes of performance degradation remains a formidable challenge, as the interplay of multiple factors obscures key failure mechanisms. A major limitation has been the inability to quantify soluble sulfur species within practical detection limits accurately and to correlate electrochemical processes with associated physical inventory changes. Here, we introduce the high-performance liquid chromatography-ultraviolet spectroscopy and gas chromatography sequential characterization (HUGS) toolkit, capable of precisely quantifying seven distinct sulfur and polysulfide species at concentrations as low as 40 ppb. HUGS has been successfully applied to practical coin and pouch cells without requiring cell modification. Furthermore, our self-developed software, Dr HUGS, enhanced the data analysis speed by over 30 times, enabling multi-source data integration and delivering comprehensive analysis results within minutes. Using HUGS, we identify significant capacity losses from inactive lithium and sulfur during initial cycles and sulfide-rich solid–electrolyte interphase (SEI) formation on the anode during later cycles. Notably, our findings reveal that soluble polysulfides have minimal contributions to capacity loss, challenging long-standing assumptions. Moreover, HUGS demonstrates that constant-pressure setups in Li–S pouch cells improve compositional uniformity compared to constant-gap configurations. For sulfurized polyacrylonitrile (SPAN) cathodes, unique issues such as non-sulfide SEI formation and lithium pulverization are observed, which can be mitigated through localized high-concentration electrolytes to enhance lithium inventory retention. By enabling precise quantification of critical inventory components, HUGS provides transformative insights into failure mechanisms across various electrolytes and cathode chemistries, guiding rational design strategies for next-generation energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2017

Economically Viable “Green” Carbon Anodes for Lithium-ion Batteries from Recycled Scrap Tires

The technical objective of this technical collaboration small business voucher (SBV) proposal was to develop methods at Oak Ridge National Laboratory (ORNL) to reduce the surface area and impurity contents present in the recovered carbon from scrap tires. Recycled tires have been used to make low-cost carbon anodes for lithium-ion batteries (LIB) with a cost-reduction of over 11-12%. Graphite is being used as the anode in LIBs. Oak Ridge National Laboratory (ORNL) has successfully recovered carbon composites from recycled tires with a yield of over 50% and demonstrated the electrochemical performance in a coin lithium ion cell configuration as an active anode material better than commercial graphite anode batteries [1]. ORNL has tailored the morphology of carbon powders from shredded recycled tires using a sulfonation process followed by pyrolysis to produce a highly value-added product and demonstrated its feasibility in LIBs. ORNL developed the methods to reduce impurities and surface area and provided carbon to Lawrence Berkley National Laboratory (LBNL) for detailed characterizations including lithium-ion battery testing. This SBV pilot project will also provide R&D infrastructure to FWD:Energy, Inc. (FWD) to establish a pre-pilot process to scale-up the synthesis of carbon composites from recycled tires and illustrate a high value commodity for anodes in large format LIBs.

25 ENERGY STORAGE↗