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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 NTRSDate not supplied

Sensitivity of Hybrid NEP-Chemical Vehicle Mass to Assumptions for Crewed Opposition-Class Mars Missions

This research illustrates the impact of different technology choices and their associated performance on overall sizing for a hybrid Nuclear Electric Propulsion (NEP) and chemical crewed Mars transportation vehicle. A set of models for the trajectory and vehicle mass, power system specific mass(α), and power conversion performance enable the analysis. Vehicle mass required to close the mission is calculated as a function of α and specific impulse (Isp) for multiple choices of high-level assumptions including system alpha vs. power scaling and electric thruster type. System alpha is built up and compared for multiple cases of technology assumptions. A Brayton cycle model is used to illustrate the alpha sensitivities to assumptions in cycle design such as peak operating temperature and component performance. The analysis illustrates how technology performance sensitivities affect the alpha and thus vehicle sizing for a range of mission and technology assumptions.

Matthew Duchek↗
DOE OSTI2021

Rapid Charging Made Practical in Graphite-Based Lithium Batteries: Surface-Acoustic Wave Turbulent Electrolyte Mixing to Overcome Diffusion Limited Charging Rates

One of the key limits in rapidly recharging a lithium-ion battery is the depletion of lithium ions within the electrolyte adjacent the anode during charging and long diffusion time to overcome this depletion. It also causes dendrite formation, inefficient use of the lithium, and battery degradation over many charge-discharge cycles. Because the liquid electrolyte remains quiescent and unmixed, this depletion layer's depth rapidly grows to match the anode-cathode separation distance at even modest charge rates. The solution proposed by PI Prof. James Friend and Co-PI Prof. Ping Liu, both from the University of California, San Diego, is to mix the electrolyte and minimize the Li ion concentration gradient during charging. Even in the presence of the separator, the charging rate could then be significantly increased. They propose to accomplish this using surface acoustic wave (SAW)-driven acoustic streaming, a technique employing 10-mW fingernail-sized solid-state devices from the telecommunications industry to drive turbulent mixing to submicron length scales in a manner completely compatible with the typical 20700 and 18650 cells used in electric vehicles.

25 ENERGY STORAGE↗
DOE OSTI2025

EVs@Scale Next-Gen Profiles - EV Profile Capture 2024

As part of the U.S. DOE EVs@Scale consortium Next-Gen Profiles (NGP) project, the profile capture and analysis of production electric vehicles undergoing high power charging (HPC) is conducted over a wide range of conditions to explore variance and performance. Charge session parameters are collected from both the electric vehicle (EV) and electric vehicle supply equipment (EVSE) at a rate of 10Hz and entered into a time-series database for analysis. These charge profiles are captured under nominal and off-nominal conditions, exploring the impact of battery state of charge (SOC), battery temperature, vehicle condition, smart charge management (SCM), and EVSE limitations. Nominal conditions are defined to be ideal conditions that should transfer the maximum allowable energy in the minimum possible amount of time. Nominal condition profiles are compared across EVs to characterize state-of-the-art EV charging performance against one another. Off-nominal condition profiles are compared against its nominal condition profile counterpart to highlight the variance across less desirable starting conditions within a single EV. This EV Profile Capture 2024 report stands as an update from the EV Profile Capture 2023 report to include the additional EV & EVSE assets tested and analyzed in 2024. The major updates within this report include the addition of three next-generation electric vehicles, added test cases, and further analysis. This expansion of analysis includes power profiles, power distribution, quantifying SOC, energy and range performance, EVSE limitation impacts, boost converter performance, etc. Additionally, NGP time-series data has been used as input towards three national laboratory-led grid modelling efforts: ANL’s IEEE-37 HIL model, INL’s Caldera model, and NREL’s EVI-X model. A summary of these platforms and how NGP has worked to improve their effectiveness has also been added to this years’ report.

Thurston, Sam↗
DOE OSTI2025

eMosaic: Electrification Mosaic Platform for Grid Informed Smart Charging Management (Final Scientific/Technical Report)

ABB (Prime Contractor), in collaboration with its partners at the Utah State University (USU), Idaho National Laboratory, Rocky Mountain Power (RMP), and Electric Power Engineers (EPE), have performed research, development, and wide scale demonstration of a scalable and resilient Electrification Mosaic (eMosaic) platform for Smart Charge Management (SCM) for Electric Vehicle Infrastructure. Work was completed under DE EE0009194, titled “eMosaic Electrification Mosaic Platform for Grid Informed Smart Charging Management”, funded by the US Department of Energy. The project members developed algorithms that provide localized and bulk grid services and that reduce and stabilize costs all the way down the supply chain to the PEV owner through SCM. This platform aggregates telemetry from multiple data sources as pieces of the larger picture including personal, private fleet or transportation EVs, fast chargers and other supply equipment, weather service information, and geographically distributed charging sites such as public lots, garage and retail, and private or shared usage depots. ABB and the project team designed, tested, and improved a charging management system at local/edge and cloud levels. The ultimate objective of the project was to convincingly demonstrate that the developed secure eMosaic plat-form can be readily and favorably adopted by diverse utilities and site owners at scale. This was achieved through a demonstration plan with field deployment at several physical sites across 4 states and additional scalable simulation from high fidelity charging models.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Real time operation of high-capacity electric vehicle ridesharing fleets

We study the feasibility of using electric vehicles in online, high-capacity ridepooling systems. Prior work has shown that online algorithms perform well for centrally-controlled, high-capacity ridepool systems. First, we propose a mixed integer linear program to expand past algorithms on ridepooling to electric vehicle fleets with the objective of scheduling vehicle charging to maintain sufficient fleet sizes at various times of day. Then we show a faster, scalable algorithm with similar performance that is practical for full-scale systems. Furthermore, our contributions reinforce the importance of having knowledge and estimates of future demand even when operating in the online setting.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Caldera_Grid

Caldera Grid is part of Caldera software platform, a suite of collective, open-source tools that was developed to improve the state of the art in modeling the impacts of Electric Vehicle (EV) charging on the grid. Caldera Grid is a co-simulation framework implemented using Hierarchical Engine for Large scale Infrastructure Co-Simulation (HELICS). The framework facilitates the co-simulation of EV charging and Smart Charge Management (SCM) strategies in Caldera Infrastructure Charge Model (ICM) with distribution level grid models in OpenDSS. Vehicle energy needs and charge session requirements generated using Caldera Charge Decision Module (CDM) are fed in as input to Caldera Grid. The EV charging models in Caldera ICM simulates both the uncontrolled charging loads as well as loads modified by the SCM strategies to develop distributed load profiles for each grid node hosting an Electric Vehicle Supply Equipment (EVSE) – also known as chargers. These loads were simulated in OpenDSS alongside existing distribution feeder loads. Each of these models are co-simulated in a HELICS federate. The HELICS co-simulation framework facilitates communication and synchronization between the federates. By co-simulating EV loads and distribution feeder loads, Caldera Grid can assess the potential grid impacts of EV charging on distribution feeders under various grid conditions. A control strategy federate is implemented with an interface where control strategies based on feedback from EV charging status and grid conditions can be developed and implemented. The platform can also support multiple control strategies in a single co-simulation.

Sundarrajan, ManojKumar Cebol↗
DOE OSTI2022

Important powertrain dynamics for developing models for control of connected and automated electrified vehicles

Connected and Automated Vehicles (CAV) technology presents significant opportunities for energy saving in the transportation sector. CAV technology forecasts vehicle and powertrain power needs under various terrain, ambient, and traffic conditions. Integration of the CAV technology in Hybrid Electric Vehicles (HEVs) provides the opportunity for optimal vehicle operation. Indeed, Hybrid Electric Vehicle powertrains present high degrees of flexibility and possibility for choosing optimum powertrain modes based on the predicted traction power needs. In modeling complex CAV powertrain dynamics, the modeler needs to consider short-time scale powertrain dynamics, such as engine transients, and hysteresis of mode-switching for a multi-mode HEV. Therefore, the powertrain dynamics essential for developing powertrain controllers for a class of connected HEVs is presented. To this end, control-oriented powertrain dynamic models for a test vehicle consisting of full electric, hybrid, and conventional engine operating modes are developed. The resulting powertrain model can forecast vehicle traction torque and energy consumption for the specified prediction horizon of the test vehicle. The model considers different operating modes and associated energy penalty terms for mode switching. Thus, the vehicle controller can determine the optimum powertrain mode, torque, and speed for forecasted vehicle operation via utilizing connectivity data. The powertrain model is validated against the experimental data and shows prediction error of less than 5% for predicting vehicle energy consumption. The model is used to create energy penalty maps that can be used for CAV control, for example fuel penalty map for engine torque changes (10–40 Nm) at each engine speed. The results of model-based optimization show optimum switching delays ranging from 0.4 to 1.4 s to avoid hysteresis in mode switching.

Engineering↗
DOE OSTI2022

Scalable Direct Recycling of Cathode Black Mass from Spent Lithium‐Ion Batteries

Abstract End of life (EoL) lithium‐ion batteries (LIBs) are piling up at an intimidating rate, which is alarming for environmental health. With further expected rapid growth of LIB use, the magnitude of spent battery accumulation is also expected to grow. LiNi x Co y Mn z O 2 (NCM) cathode materials are a dominant chemistry in high energy LIBs, and make up a huge portion of this waste accumulation. Direct recycling is one of the most promising ways to turn this waste to wealth, but has been limited to lab‐scale, due to lack of robustness, namely the tedious pretreatment required that involves toxic organic solvents. Herein, a process that integrates the pretreatment and relithiation of the cathode black mass is demonstrated. Cathode material from EoL electric vehicle (EV) batteries is treated in a 100 g per batch operation and the regenerated cathode active material demonstrates 100% electrochemical performance recovery, with 91% yield rate, and shows promise for further scale up. This process has the advantages of integration, scalability, and universality, which clears the barricade for direct recycling to move from lab to industry scale with considerable profitability.

Chemistry↗
NASA NTRS2022

Preliminary Airfoil Design for Low Reynolds Numbers

Advances in the fields of electronics, batteries, and electric motors have enabled broad adoption of small-scale aircraft for various terrestrial applications. Numerous Micro Aerial Vehicles (MAVs) and small Unmanned Aerial Vehicles (UAVs), both civil and military, are in use today. Operation at their design flight condition often requires rotors, propellers, or wings to perform at Reynolds numbers significantly below 500,000 [1]. Airfoil performance at low Reynolds numbers is generally characterized by low aerodynamic performance (i.e. the attainable lift-to-drag ratio) compared to performance of airfoils at higher Reynolds numbers. The critical chord-based Reynolds number for conventional airfoils lies around Rec = 100,000 to Rec = 500,000 [2]. Below this critical Reynolds number, laminar separation of the boundary layer is usually the cause for poor performance. Researchers have found that below the critical Reynolds number, flat and cambered plates can outperform smooth airfoils. Circular-arc cambered plates especially have remarkable performance advantages compared to conventional airfoil shapes [3].

airfoil↗
DOE OSTI2022

Multi-modular capacitive wireless power transfer circuit and related techniques

A high performance kilowatt-scale large air-gap multi-modular capacitive wireless power transfer (WPT) system is provided for electric vehicle (EV) charging. In one particular implementation, the multi-modular system achieves high power transfer while maintaining fringing electric fields within prescribed safety limits. The fringing fields are reduced using near-field phased-array field-focusing techniques, wherein the adjacent modules of the multi-modular system are out-phased with respect to one another. The inter-module interactions in this multi-modular system can be modeled, and an approach to eliminate these interactions in a practical EV charging environment is provided. To illustrate one example implementation, a prototype 1.2-kW 6.78-MHz 12-cm air-gap multi-modular capacitive WPT system comprising two 600-W modules is provided. This prototype system achieves 21.2 kW/m2 power transfer density and a peak efficiency of 89.8%. This multi-modular system also achieves a fringing field reduction of 50% compared to its individual modules.

Afridi, Khurram K.↗
DOE OSTI2025

EVs@Scale Next-Gen Profiles - Fleet Utilization 2024

As part of the U.S. Department of Energy’s EVs@Scale initiative, the Next-Gen Profiles (NGP) project provides a comprehensive, data-driven analysis of electric vehicle (EV) and electric vehicle supply equipment (EVSE) operations across real-world fleet deployments. This paper presents findings from the NGP’s Fleet Utilization study, which investigates operational behavior and asset usage across seventeen EV fleets and two EVSE fleets, encompassing a wide range of vehicle types and use cases. Data collected from diverse sources—varying in format and temporal resolution—are first reformatted into a unified structure. From this harmonized dataset, a suite of rigorously defined performance metrics is calculated at an hourly cadence, enabling consistent cross-comparison of charging, routing, and other key operational behaviors. Amid rapidly increasing EV adoption and growing demands for energy-efficient fleet operations, the analysis reveals clear utilization trends—including diurnal and weekly activity cycles, differences in short versus long charging session dependencies, and route-specific energy usage patterns. These findings highlight the need for tailored infrastructure strategies and the deployment of advanced energy management systems, such as Distributed Energy Resource Management Systems (DERMS) and Site Energy Management Systems (SEMS), which can optimize charging schedules and mitigate peak loads. By leveraging anonymized, harmonized datasets and standardized metrics, this study offers critical insights into fleet behavior and performance, providing a foundation to improve operational efficiency, reduce costs, and enable the scalable deployment of electrified transportation.

Wells, Landon↗
DOE OSTI2023

Emulation and Adversarial Analysis of EV Charging Networks

In the effort of decarbonization and evolution of the modern electrical grid, electric vehicles (EVs) play a key part to transform the grid. However, due to the rapid adoption of EVs and the demand of the charging infrastructure required to power said EVs, risk of a cyber-attack may impose serious consequences. There is a need to analyze and protect the charging ecosystem infrastructure from cyber threats before it reaches wide-scale deployment. In an effort to secure vehicle to grid (V2G) communications, standardization is necessary for continued reliable system operation. The protocol ISO 15118 outlines controls and practices that should be implemented for secure vehicle to grid (V2G) communications. The standard is gaining momentum for American markets as the demand for EV infrastructure grows. The adoption of ISO 15118 in American markets poses several challenges: the deployment of a public key infrastructure (PKI) as outlined within the standard, interoperability of charging different EVs with chargers from different manufactures using the PKI, and scaling the ecosystem to meet the demand while managing risks. This project was created to understand potential cyber and scaling challenges of PKI for EV infrastructure through utilizing a series of emulated components mapping to what exists in the EV ecosystem today, and the components of the PKI that are under development. The key nodes within the emulation that are under development are: electric vehicle (EV), electric vehicle supply equipment (EVSE), charge network operator (CNO), certificate authority (CA), and online certificate status protocol (OCSP) that must all interact using secure and trusted communications. With these emulated components and utilizing orchestration methods to rapidly deploy and scale the components, the ability to analyze risks of the ecosystem and address gaps before the PKI ecosystem is fully deployed to production should yield a more robust and mature production charging infrastructure. Our approach will use a modular architecture of virtual machines within an orchestration platform and will target scales of 100s, 1000s, and 10,000s of entities interacting. The core research questions trying to be answered with this scope of work are: what are the impacts of a rogue CA, what are the risks of certificate revocation list (CRL) management, what is the value of OCSP stapling, what components are vulnerable to DOS attacks, and what test effective payloads may impact the components.

charging ecosystem↗
NASA NTRS2015

Characterization of Hybrid CNT Polymer Matrix Composites

Carbon nanotubes (CNTs) have been studied extensively since their discovery and demonstrated at the nanoscale superior mechanical, electrical and thermal properties in comparison to micro and macro scale properties of conventional engineering materials. This combination of properties suggests their potential to enhance multi-functionality of composites in regions of primary structures on aerospace vehicles where lightweight materials with improved thermal and electrical conductivity are desirable. In this study, hybrid multifunctional polymer matrix composites were fabricated by interleaving layers of CNT sheets into Hexcel® IM7/8552 prepreg, a well-characterized toughened epoxy carbon fiber reinforced polymer (CFRP) composite. The resin content of these interleaved CNT sheets, as well as ply stacking location were varied to determine the effects on the electrical, thermal, and mechanical performance of the composites. The direct-current electrical conductivity of the hybrid CNT composites was characterized by in-line and Montgomery four-probe methods. For [0](sub 20) laminates containing a single layer of CNT sheet between each ply of IM7/8552, in-plane electrical conductivity of the hybrid laminate increased significantly, while in-plane thermal conductivity increased only slightly in comparison to the control IM7/8552 laminates. Photo-microscopy and short beam shear (SBS) strength tests were used to characterize the consolidation quality of the fabricated laminates. Hybrid panels fabricated without any pretreatment of the CNT sheets resulted in a SBS strength reduction of 70 percent. Aligning the tubes and pre-infusing the CNT sheets with resin significantly improved the SBS strength of the hybrid composite To determine the cause of this performance reduction, Mode I and Mode II fracture toughness of the CNT sheet to CFRP interface was characterized by double cantilever beam (DCB) and end notch flexure (ENF) testing, respectively. Results are compared to the control IM7/8552 laminate.

Grimsley, Brian W.↗
DOE OSTI2022

SCALED-PRODUCTION OF RARE EARTH OXIDES AND CRITICAL MATERIALS FROM COAL-BASED SOURCES

A projected exponential increase in the production of electric vehicles and high-end advanced technologies including those used in the defense industrial is expected to require nearly double the amount of rare earth elements (REEs) and critical elements currently available worldwide. As such, recovery from secondary sources such as coal and coal byproducts may be needed to meet the increased demand. A project has been initiated to evaluate methods and technologies integrated in an existing rare earth pilot plant that have the potential to improve the economics of extracting rare earths and critical materials from coal-based materials. This presentation will provide details about the technologies and results from pilot plant testing.

Honaker, Rick Q↗
DOE OSTI2022

U.S. Federal Policy Considerations for the Management of Retired Large-Format Batteries

The global demand for large-format batteries used in electric vehicles (EV) and battery energy storage is expected to continue as governments call for zero emission policies. Total installed large-scale stationary battery energy storage is expected to increase almost 20-fold in the coming years - from 17 GW installed globally in 2020 to 358 GW projected in 2030. Similarly, light duty EVs sales globally are expected to increase more than 8-fold from 2020 to 2030 - from 3 million units to 25 million units. The expected demand for large-format batteries brings supply chain concerns, and economic opportunities. Domestic reuse and recycling is one potential circular economy solution for large-format batteries. This presentation discusses current U.S. law and regulatory landscape for the reuse and recycling of large-format batteries, and how certain policy frameworks impact reuse and end-of-life management decisions for large-format battery materials.

battery↗
NASA NTRS2014

Misconceptions of Electric Propulsion Aircraft and Their Emergent Aviation Markets

Over the past several years there have been aircraft conceptual design and system studies that have reached conflicting conclusions relating to the feasibility of full and hybrid electric aircraft. Some studies and propulsion discipline experts have claimed that battery technologies will need to improve by 10 to 20 times before electric aircraft can effectively compete with reciprocating or turbine engines. However, such studies have approached comparative assessments without understanding the compelling differences that electric propulsion offers, how these technologies will fundamentally alter the way propulsion integration is approached, or how these new technologies can not only compete but far exceed existing propulsion solutions in many ways at battery specific energy densities of only 400 watt hours per kilogram. Electric propulsion characteristics offer the opportunity to achieve 4 to 8 time improvements in energy costs with dramatically lower total operating costs, while dramatically improving efficiency, community noise, propulsion system reliability and safety through redundancy, as well as life cycle Green House Gas emissions. Integration of electric propulsion will involve far greater degrees of distribution than existing propulsion solutions due to their compact and scale-free nature to achieve multi-disciplinary coupling and synergistic integration with the aerodynamics, highlift system, acoustics, vehicle control, balance, and aeroelasticity. Appropriate metrics of comparison and differences in analysis/design tools are discussed while comparing electric propulsion to other disruptive technologies. For several initial applications, battery energy density is already sufficient for competitive products, and for many additional markets energy densities will likely be adequate within the next 7 years for vibrant introduction. Market evolution and early adopter markets are discussed, along with the investment areas that will fill technology gaps and create opportunities for the effective, near-term electric aircraft products. Without understanding both the context of how electric propulsion will integrate into the vehicle system, and evolve into the market place it is likely that electric propulsion will continue to be misunderstood.

Moore, Mark D.↗
DOE OSTI2024

Viability of Additively Manufactured Electrodes for Lithium-Ion Batteries

As the global economy becomes increasingly electrified, the demand for batteries and energy storage is expected to rise significantly, particularly in the transportation and electricity sectors. Lithium-ion batteries (LIBs) are currently the most advanced and widely used technology in this field. Traditionally, LIBs are manufactured using simple 2D planar geometries to maximize production efficiency and minimize costs. However, this approach limits energy density due to the restricted design flexibility of the electrodes. Additive manufacturing (AM) offers a promising solution to enhance the energy density and efficiency of LIBs by enabling the design of architectures that reduce diffusive losses and allow for a greater amount of active material to be incorporated within the same device footprint, thereby minimizing the use of inactive materials. Different AM techniques come with their own set of limitations, including printing speed, material compatibility, and scale, which must be considered when designing electrodes. Scalable and cost-effective methods are particularly important for electric vehicle batteries, while achieving higher energy densities in microbatteries is crucial for the miniaturization of wearable electronics and medical devices. Here, in this study, we simulate various 3D porous electrode designs for LIBs using graphite and nickel manganese cobalt oxide (NMC) electrodes. These designs are selected to represent structures that could be produced using different AM techniques, such as direct ink writing, fused deposition modeling, and stereolithography. Our results indicate that at higher charging rates and increased areal mass loading, 3D structures can outperform traditional 2D electrodes, although the benefits may diminish with more complex designs that are harder to manufacture. The observed gains in energy density are attributed to improved electrode utilization and reduced diffusive energy losses. This comprehensive analysis of structure–performance relationships will provide valuable insights to guide future research on 3D designs, material selection, and AM techniques for additively manufactured battery electrodes.

25 ENERGY STORAGE↗
NASA NTRS1984

Hybrid vehicle assessment. Phase 1: Petroleum savings analysis

The results of a comprehensive analysis of near term electric hybrid vehicles are presented, with emphasis on their potential to save significant amounts of petroleum on a national scale in the 1990s. Performance requirements and expected annual usage patterns of these vehicles are first modeled. The projected U.S. fleet composition is estimated, and conceptual hybrid vehicle designs are conceived and analyzed for petroleum use when driven in the expected annual patterns. These petroleum consumption estimates are then compared to similar estimates for projected 1990 conventional vehicles having the same performance and driven in the same patterns. Results are presented in the form of three utility functions and comparisons of sevral conceptual designs are made. The Hybrid Vehicle (HV) design and assessment techniques are discussed and a general method is explained for selecting the optimum energy management strategy for any vehicle mission battery combination. Conclusions and recommendations are presented, and development recommendations are identified.

Levin, R.↗