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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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Cold-Starting All-Solid-State Batteries from Room Temperature by Thermally Modulated Current Collector in Sub-Minute
All-solid-state batteries (ASSBs) show great potential as high-energy and high-power energy storage devices but their attainable energy/power density at room temperature is severely reduced because of the sluggish kinetics of lithium-ion transport. Here we first reported a thermally modulated current collector (TMCC), which can rapidly cold-start ASSBs from room temperature to operating temperatures (70–90 °C) in less than one minute, and simultaneously enhance the transient peak power density by 15-fold compared to one without heating. This TMCC is prepared by integrating a uniform, ultrathin (~200 nm) nickel layer as a thermal modulator within an ultralight polymer-based current collector. By isolating the thermal modulator from the ion/electron pathway of ASSBs, it can provide fast, stable heat control yet does not interfere with regular battery operation. Moreover, this ultrathin (13.2 μm) TMCC effectively shortens the heat transfer pathway, minimizes heat losses, and mitigates the formation of local hot spots. The simulated heating energy consumption can be as low as ~3.94% of total battery energy. This TMCC design with good tunability opens new frontiers towards smart energy storage devices in the future from the current collector perspective.
Mitigation of Failure Propagation in Li-Ion Batteries
Propagation of thermal events from one damaged cell in a battery module to adjacent cells is a safety concern. A team of researchers from Sandia National Laboratories (SNL) and the National Renewable Energy Laboratory (NREL) have developed a “safety-map” to evaluate propensity for failure propagation. The model results were used to evaluate passive thermal management designs for Li-ion battery modules.
A Comparative Analysis of Lithium-Ion Battery Chemistries for Cold-Climate Maritime Applications
Energy storage, primarily in the form of electrochemical batteries, is critical for enabling integration of marine energy (e.g., power from waves and currents) with end-use applications at sea due to the periodicity of the resources and requirement of consistent, smooth power delivery. Powering high-latitude coastal or ocean-based observing systems has been identified as a high value-proposition use case, exemplifying the concept of Powering the Blue Economy. An existing power system implementation for such a platform uses solar panels coupled to rechargeable lithium-ion batteries, augmented by a non-rechargeable backup bank used to power heaters in winter months. As wave energy is a potential resource for powering this and similar use cases and is strongest when solar power is most limited, it was hypothesized that integration of wave power would alleviate some of the challenges in cold climates related to energy storage. In this work, we investigate the use case scenario in simulation and perform a comparative test of commercially-available lithium-ion battery chemistry formulations to determine the most appropriate choice for the application. The experiment compared the most commonly-used lithium-based battery types (NCM, NCA, and LFP) in laboratory conditions emulating a battery enclosure thermally coupled to freezing seawater using an industrial battery performance tester in PNNL's arctic simulation lab. Battery strings were repeatedly cycled (i.e., charged, discharged, rested) and their usable capacity was measured. Both NCM and NCA strings exhibited degradation upon cycling, while the LFP string maintained stable operation through over 700 complete cycles. Though lower in baseline capacity, LFP are recommended for this and similar low-temperature applications with access to high levels of bulk charging current (e.g., from high-energy wave events) and their use may reduce the cost and complexity of battery conditioning and protection apparatus.
Review—Thermal Safety Management in Li-Ion Batteries: Current Issues and Perspectives
Approaches for thermal management of lithium-ion (Li-ion) batteries do not always keep pace with advances in energy storage and power delivering capabilities. Root-cause analysis and empirical evidence indicate that thermal runaway (TR) in cells and cell-to-cell thermal propagation are due to adverse changes in physical and chemical characteristics internal to the cell. However, industry widely uses battery management systems (BMS) originally designed for aqueous-based batteries to manage Li-ion batteries. Even the "best" BMS that monitor both voltage and outside-surface temperature of each cell are not capable of preventing TR or TR propagation, because voltage and surface-mounted temperature sensors do not track fast-emerging adverse events inside a cell. Most BMS typically include a few thermistors mounted on select cells to monitor their surface temperature. Technology to track intra-cell changes that are TR precursors is becoming available. Simultaneously, the complex pathways resulting in cell-to-cell TR propagation are being successfully modelled and mapped. Innovative solutions to prevent TR and thermal propagation are being advanced. These include modern BMS for rapid monitoring the internal health of each individual cell and physical as well as chemical methods to reduce the deleterious effects of rapid cell-to-cell heat and material transport in case of TR.
Effect of the grain arrangements on the thermal stability of polycrystalline nickel-rich lithium-based battery cathodes
One of the most challenging aspects of developing high-energy lithium-based batteries is the structural and (electro)chemical stability of Ni-rich active cathode materials at thermally-abused and prolonged cell cycling conditions. Here, we report in situ physicochemical characterizations to improve the fundamental understanding of the degradation mechanism of charged polycrystalline Ni-rich cathodes at elevated temperatures (e.g., ≥ 40 °C). Using multiple microscopy, scattering, thermal, and electrochemical probes, we decouple the major contributors for the thermal instability from intertwined factors. Our research work demonstrates that the grain microstructures play an essential role in the thermal stability of polycrystalline lithium-based positive battery electrodes. We also show that the oxygen release, a crucial process during battery thermal runaway, can be regulated by engineering grain arrangements. Furthermore, the grain arrangements can also modulate the macroscopic crystallographic transformation pattern and oxygen diffusion length in layered oxide cathode materials.
Limited Accessibility to Surface Area Generated by Thermal Pretreatment of Electrodes Reduces Its Impact on Redox Flow Battery Performance
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Thermal Runaway Prevention Technologies for Lithium-Ion Batteries
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Tailoring Interfaces in Solid-State Batteries Using Interfacial Thermochemistry and Band Alignment
Solid-state lithium ion batteries have enhanced thermal stability compared to batteries using liquid electrolytes. Although their practical implementation is limited by undesired side reactions between the electrode and electrolyte, different modification strategies have been proposed to stabilize these reactive interfaces. These approaches have been primarily based upon bulk materials properties, however, which may not necessarily be representative of the chemistry at the solid/solid interface. In this work, first principles calculations and X-ray scattering experiments are used to elucidate molecular-level reactivity and develop design principles for tailored interfaces based on surface and interfacial properties. Because of its well-known instability, the interface between the Li metal anode and the lithium lanthanum titanate (LLTO) solid electrolyte is applied as a model system. Density functional theory calculations are used to describe bulk, surface, and interfacial thermochemistry of the Li/LLTO system, and interfacial reconstruction is probed using ab initio molecular dynamics. These simulations of the Li/LLTO interface demonstrate facile decomposition concomitant with reduction of Ti 4+ ions. Based on further insights from computational analysis of the surface band edge positions, La 2 O 3 is proposed as an interlayer coating and is shown to provide an energetic barrier for interfacial charge transfer and decomposition reactions from X-ray reflectivity measurements and theoretical calculations. The findings in this work suggest that design strategies based on surface and interfacial properties can be used to kinetically stabilize electrode/electrolyte interfaces in solid-state batteries.
Rational Electrolyte Design for Elevated-Temperature and Thermally Stable Lithium-Ion Batteries with Nickel-Rich Cathodes
As the energy density of lithium-ion batteries (LIBs) increases, the shortened cycle life and the increased safety hazard of LIBs are drawing increasing concerns. To address such challenges, a series of localized high-concentration electrolytes (LHCEs) based on a solvating-solvent mixture of tetramethylene sulfone and trimethyl phosphate and a high flash-point diluent 1H,1H,5H-octafluoropentyl 1,1,2,2-tetrafluoroethyl ether were designed. The LHCEs exhibited non-flammability and greatly suppressed heat release at high temperatures, which would potentially improve the safety performance of the LIBs. Moreover, the optimal LHCE achieved capacity retentions of 87.1% and 81.7% in graphite||LiNi 0.8 Mn 0.1 Co 0.1 O 2 cells after 500 cycles at 25 °C and 45 °C, respectively, which were significantly better than the conventional electrolyte, whose capacity retentions were only 75.2% and 38.5% under the same condition. Mechanistic studies revealed that the LHCE not only formed a more robust solid electrolyte interphase, but also exhibited improved anodic stability, compared with the conventional electrolyte. Further, this work sheds light in rational electrolyte design for high energy density LIBs with high battery performance and low safety concerns.
Thermodynamic assessment of lithium halide reciprocal salt systems for energy applications
Lithium halides are of interest because of their unique applications as fuel or coolants in molten salt reactors (MSRs) and electrolytes in thermally activated batteries. Because iodine is an important fission product for MSRs, the Molten Salt Thermal Properties Database-Thermochemical (MSTDB-TC) is being expanded to include relevant iodide reciprocal salt systems. In this work, we assess the thermochemical properties of lithium halide pseudobinary systems based on reported experimental phase diagrams, eutectic temperatures, and enthalpies of mixing. Within the framework of the modified quasi-chemical model in the quadruplet approximation (MQMQA), extrapolations to the related pseudoternary and pseudoquaternary systems have been performed. The pseudoquaternary representations of phase equilibria, enthalpy, entropy, and heat capacity are represented in the resultant models. Of interest for generating source terms for accident analysis is the ability to compute the vapor pressures of the dominant iodide species for the systems at any composition. Here, an example of such calculations is provided for the LiF-LiI system at x LiI = 0.01 and x LiI = 0.70, in this case indicating that the LiI vapor species are predominant.
Thermal design analysis for SuperTruck II lithium-titanate battery pack
Here, this paper presents a systematic thermal management analysis for a new lithium-titanate-oxide battery pack to be installed in a SuperTruck II, Class 8 hybrid truck. The authors investigate the feasibility of mounting the battery pack inside the vehicle and air-cooling it with fans supplying conditioned air from the cabin. Moreover, the cells within each module are to be immersed in a heat-transfer fluid to improve temperature homogeneity. A multi-stage thermal analysis is performed to ensure adequate thermal regulation of the battery under the proposed design, considering installation and operational constraints. The authors perform thermal and electrical characterization tests on a single cell. Results inform the development of computational fluid dynamics models of the cells, modules, and pack. Module-level analysis shows that the cell temperatures can be maintained below their upper operational limit of 55 °C with module wall-to-air heat transfer coefficients between 10 and 20 Wm -2 K -1 . Pack-level analysis of distinct configurations determines effective airflow paths for adequate heat transfer and delivers a final battery pack design that achieves sufficient cooling and temperature uniformity. A reduced-order electrothermal model is developed to rapidly predict the transient battery performance and to develop a temperature control strategy.
How to Model Batteries (with PV, Stand-Alone, or Hybrids) in SAM and PySAM
This tutorial will be a deep dive into considerations for battery modeling and demonstrating how to model them in SAM, including battery chemistry, thermal modeling, degradation/lifetime, dispatch, interconnection limits and curtailment, and their associated impacts on project profits and battery lifetime. By the end of the tutorial attendees will know how to size and model both behind-the-meter and front-of-meter battery systems, including financial analysis and pairing with other PV models (including pvlib) via PySAM.
Gas Generation Models for Thermal Runaway in Lithium Ion Batteries
A numerical model is implemented to study cell venting, internal pressure, and gas-phase dynamics behavior of Li-ion cells undergoing thermal runaway. A k-ɛ Reynolds-Averaged Navier-Stokes (RANS) model is adopted to describe the turbulent flow out of the cells, while the fluid dynamics inside the cells is described by Darcy-Forchheimer’s equation. Thermal abuse reactions and gas generation kinetics are described by a single-step lumped reaction model. A series of computational fluid dynamics (CFD) simulations are conducted on a single cell at various states-of-charge (100%, 50%, 25%) to demonstrate detailed flow and thermal behavior as a function of quantity of gas generated during cell venting. Venting events are categorized into two stages: i) breaching of the cell container and ii) thermal runaway reactions. It is shown that the cell response is dominated by the second stage since most of the gases are generated during thermal runaway. Also, the propensity for propagation is highly affected by state-of-charge (SOC). Cells at higher SOCs produce more heat and gas during the venting event, owing to higher mass and concentrations of reacting gases, and consequently reach higher internal cell pressures which increase the risk of side-wall breaching.
Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules
Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.
Effects of Trigger Method on Fire Propagation during the Thermal Runaway Process in Li-ion Batteries
Lithium-ion batteries are prone to fire hazards due to the possibility of thermal runaway propagation. During battery product development and subsequent safety tests for design validation and safety certification, the thermal runaway onset is triggered by various test methods such as nail penetration, thermal ramp, or external short circuit. This failure initiation method affects the amount of heat contributions and the composition of gas generations. This study compares two such trigger methods, external heating and using a thermally-activated internal short circuit device (ISCD). The effects of the trigger method on total heat generation are experimentally investigated within 18650 cylindrical cells at single cell level as well as at multiple cell configuration level. The severity of failure was observed to be worse for cells with ISCDs at single cell level, whereas quite the opposite results were observed at multiple cell configuration level. A preliminary numerical analysis was performed to better understand the battery safety performance with respect to thermal runaway trigger methods and heat transfer conditions.
Understanding Electric Vehicle Range and Charging Needs: Interactions Between Ambient Temperature, Commute Patterns, and State-of-Charge Usage
Electric vehicle (EV) performance can vary substantially under real-world operating conditions, particularly due to ambient temperature effects on energy consumption, battery behavior, and thermal management requirements. This study quantifies how weather conditions, daily driving patterns, and State-of-Charge (SOC) usage strategies jointly influence EV driving range, charging frequency, and overall energy efficiency. A detailed and experimentally validated Autonomie vehicle model is developed, integrating a powertrain, a mono-zonal cabin model, and a battery electro-thermal model. Three battery sizes (200-, 300-, and 400-mile homologated ranges) are assessed across five commute profiles (20–200 miles) and six ambient temperatures (−18 °C to 50 °C), including scenarios with and without preconditioning. Results show that extreme temperatures could significantly decrease the maximum achievable range by up to 55% in cold conditions (−18 °C) and 40% in hot conditions (50 °C), relative to moderate conditions. Larger battery packs retain a greater fraction of their nominal range under thermal stress, while smaller packs experience sharper relative penalties due to the higher contribution of thermal loads to total energy demand. The analysis further demonstrates that limiting operation to partial SOC windows (e.g., 80–20%), a common real-world practice, significantly reduces achievable range and increases charging frequency, particularly in cold weather. Thermal preconditioning while plugged in is shown to mitigate these effects for short trips, reducing energy consumption by up to 31% in hot conditions and 7% in cold conditions. The findings demonstrate how climate, SOC usage behavior, and thermal management jointly shape the practical driving capability of EVs, highlighting the importance of efficient thermal management and realistic user charging strategies for ensuring reliable EV operation across diverse climatic scenarios.
Techno-Economic Optimization of Advanced Energy Plants with Integrated Thermal, Mechanical, and Electro-Chemical Storage (Final Report)
The increasing use of renewable energy sources is leading to increased cycling of fossil-fueled power plants (FFPP) that are designed to operate at base-loaded conditions. Integrating energy storage facilities with the FFPPs can be helpful in reducing load-following operation of FFPPs. Decentralized deployment of energy storage facilities at the FFPP level has considerable advantages due to possibilities of smaller storage capacities, immediate benefits realized by the host power plant due to the increase in the efficiency, cleaner emission and higher plant life to name a few. Most importantly, deployment at the FFPP level can exploit the existing equipment items and facilities at the host power plant, thus reducing the CAPEX and reducing the storage capacity. However, realization of these benefits will critically depend on novel configuration/integration strategies with the least impact on the power plant operation and its configuration. Furthermore, dynamics of the entire integrated system including both the FFPP and the storage technologies must be taken into account to obtain the cost-optimal solution. With these motivations, the objective of this project was to complete a focused evaluation of decentralized deployments of energy storage facilities at the FFPP level. Promising thermal, chemical, mechanical, and electro-chemical storage technologies were evaluated with due consideration of their transient response to obtain various optimal system concepts that can minimize the levelized cost of storage. For thermal storage, cryogenic energy storage along with high temperature heat storage in molten salt as well as phase change material were evaluated. For mechanical storage, cryogenic air storage and pumped hydro storages were evaluated. For chemical storage, hydrogen storage was evaluated. For electrochemical storage, the team evaluated sodium sulfur, vanadium redox flow battery as well as Li-ion batteries. Integration of these storage technologies with the natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants was considered. Six technologies, namely molten salt, cryogenics, compressed air, pumped hydro, H2 storage and Li-ion battery storage, were downselected based on their levelized cost of storage. It was observed that the ranking of the optimal storage technology can differ based on the host power plant technology even when same demand/supply/price profile for electricity are considered. It was also observed that as the variability in power demand varies, the ranking of the optimal storage technologies vary. However, for the same demand and LMP profile, top six optimal storage technologies for NGCC vs SCPC plants did not differ much even though LCOS for the same technology and optimal size of a given storage technology did differ. Detailed techno-economic assessment of these six technologies was undertaken.