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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Reverse Logistics Ev Battery Recycling Agent Base Model

This represents the initial regional tier of the electric vehicle (EV) battery recycling agent base model. Through this model, we can ascertain the number of EV purchases at both the state and regional levels. We employ census data to develop a diverse household profile to inform decisions regarding the acquisition of new or used EVs. The number of EV purchases at the state level will affect the future demand for recycling, reuse, and repurposing of end-of-life EV batteries. Additionally, tax credits, EV rebate programs, and the financial capacity of households will influence the number of EV purchases, thereby further impacting the demand for EV battery recycling.

Alam, Lamia [Idaho National Laboratory (INL), Idah↗
DOE OSTI2026

A Reverse Logistics Tool For Ev Battery Recycling And Repurposing,

The demand for electric vehicles (EVs) in the United States is projected to rise significantly, with sales expected to reach approximately 4.1 million units by 2030. However, the U.S. remains heavily reliant on imports for the batteries and critical raw materials—such as lithium, cobalt, and nickel—that power these vehicles. As of 2024, around 70% of these imports originate from China. This dependency has become even more precarious following China’s imposition of export restrictions in April 2025, a retaliatory move against U.S. tariffs. These developments highlight the strategic vulnerabilities posed by China’s dominant position in the critical materials market. Compounding the issue, decades of intensive extraction have severely depleted global reserves of critical materials, widening the gap between supply and growing demand. This situation underscores the urgent need for the U.S. and other nations to diversify their sources of critical materials and enhance domestic capabilities to secure these resources—an essential step toward ensuring long-term energy security. At the end of their lifecycle—whether due to the battery’s degradation or the retirement of the vehicle—EV batteries are often improperly disposed of or sent to landfills. However, many of these batteries still retain usable capacity and can follow one of three alternative pathways: (a) Re-used: deployed in another vehicle with a shorter driving range, (b) Re-purposed: utilized act as a backup storage/power for data centers, solar panels, and e-scotters or (c) Recycled: broken down to recover the critical materials. To that end, the proposed tool (REBORN) is designed to optimize the reverse logistics network for battery repurposing and recycling. Its goal is to minimize associated costs while identifying optimal locations for battery collection and processing. Ultimately, REBORN ensures that each battery is used to its fullest potential.

Srinivas, SrikarV. [Idaho National Laboratory (INL↗
DOE OSTI2025

Coordinated Thermal Safety Attack and Defense on EV Battery Management Systems

Battery temperature sensor and battery current sensor data which are key sensing inputs to the Battery Management Controllers in electric vehicles, are vulnerable to possible cyber/ physical manipulation due to known vulnerabilities inherited from CAN bus technology that is used for in-vehicle communications between electronic control units that transfer sensing and control data. In this paper, we first create a simulation that enables us to evaluate impact of cyber physical attacks on electric vehicle battery management system in a controlled environment that violates thermal safety. Specifically, we emulate a Level 3 - DC fast charging system with SAE J1772/CCS, integrated with standard charging controls and thermal safety controls on EVs, and various sensing data flows. Second, we propose a coordinated current and battery temperature attack that has crippling economic, and safety impacts. Third, we quantify the usability, economic and safety impacts of such attacks as a function of the extent of data manipulation. Finally, we propose a physics model driven detection technique to detect presence of such attacks.

25 ENERGY STORAGE↗
DOE OSTI2024

An experimentally validated electro-thermal EV battery pack model incorporating cycle-life aging and cell-to-cell variations

Lithium-ion batteries are used in a wide variety of applications. To meet the power and energy demands of these applications battery packs are composed of hundreds to thousands of cells. The electrical and thermal interactions between cells introduce additional complexity in the pack dynamics. To capture these effects, a battery pack model composed of 192 cells based on a first-generation (2012) Nissan Leaf battery pack is developed in MATLAB/Simulink/Simscape. Here, with this model, we simulate the electrical dynamics (using a first-order equivalent-circuit model), the thermal dynamics (using a first-order lumped-parameter thermal model), and the aging dynamics (using a semi-empirical severity factor-based model) of every cell in the pack and we also create a pack thermal model that explicitly captures the heat exchange between the modules, and the cells contained within, during operation. The models are calibrated and validated, both at the cell and pack level, with experimental data. Two different case studies of this pack model are investigated. In the first case study, an initial, normally-distributed, cell-to-cell capacity variation is introduced and its effect on the pack voltage and module temperatures is studied. In the second case study, we deliberately insert cells with lower than nominal capacity into the pack and we investigate how this type of initial cell-to-cell capacity variation affects the pack’s ability to deliver energy over time. Finally, we also study how parallel-connected cells can reduce the effects of cell-to-cell variations at the expense of increased aging of the pack overall.

25 ENERGY STORAGE↗
DOE OSTI2022

Machine Learning Software for Cylindrical Battery Design and Performance Prediction

A software that delivers optimal design parameters and performance predictions for cylindrical cells, which can range in size from micro batteries to EV batteries, is developed. The Cylindrical battery design V1.0 is comprised of three types of cylindrical batteries, Micro battery (Primary), Micro battery (Secondary) and 18650/21700/xxxxx cylindrical battery. The software was developed in MATLAB. The software has the capability to output the cell design with the capacity ranges from several mAh to several million Ah. The software utilizes machine learning and includes a graphical user interface to enable rapid prototyping to accelerate energy storage research, development, and manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2023

Electric vehicle batteries alone could satisfy short-term grid storage demand by as early as 2030

The energy transition will require a rapid deployment of renewable energy (RE) and electric vehicles (EVs) where other transit modes are unavailable. EV batteries could complement RE generation by providing short-term grid services. However, estimating the market opportunity requires an understanding of many socio-technical parameters and constraints. We quantify the global EV battery capacity available for grid storage using an integrated model incorporating future EV battery deployment, battery degradation, and market participation. We include both in-use and end-of-vehicle-life use phases and find a technical capacity of 32–62 terawatt-hours by 2050. Low participation rates of 12%–43% are needed to provide short-term grid storage demand globally. Participation rates fall below 10% if half of EV batteries at end-of-vehicle-life are used as stationary storage. Short-term grid storage demand could be met as early as 2030 across most regions. Our estimates are generally conservative and offer a lower bound of future opportunities.

25 ENERGY STORAGE↗
DOE OSTI2025

Defining the State of Safety (SOS) for Lithium-Ion Batteries in EVs: A Discussion

The demand for lithium-ion batteries (LIBs) is skyrocketing, driven by the rapid growth of electric vehicles (EVs) and grid energy storage. However, current LIBs rely on flammable electrolytes, making them susceptible to thermal runaway and fires. Despite ongoing research and development efforts to enhance safety, fire incidents in EVs and energy storage systems persist. As LIB deployment increases, so too does the risk of fires. Therefore, it's crucial to define a "State of Safety" for LIBs - encompassing both operational safety and post-incident safety, such as after a car accident. This concept can help stakeholder and first responders to effectively manage LIB fire risks.

25 ENERGY STORAGE↗
DOE OSTI2024

Analytic Neural Network Gaussian Process Enabled Chance-Constrained Voltage Regulation for Active Distribution Systems with PVs, Batteries and EVs

This paper proposes an analytic neural network Gaussian process (NNGP)-based chance-constrained real-time voltage regulation method for active distribution systems with photovoltaics (PVs), batteries, and electric vehicles (EVs). NNGP can utilize historical measurement data to achieve real-time probabilistic node voltage estimation through Bayesian inference. Then, NNGP is fully analytically embedded into the optimal power flow model to perform voltage regulation and adapt to various topological changes. The uncertainties of voltage estimations are easily considered via the chance constraint, and it has been shown that the adoption of this chance constraint can significantly improve the reliability of voltage regulation under various scenarios. The comparison results with other methods, carried out on a real 759-node distribution system located in western Colorado, U.S., show that the proposed method can achieve accurate voltage estimation across different topologies and reliably perform voltage regulation considering PVs, batteries, and EVs.

active distribution systems↗
DOE OSTI2025

Clean Energy for the Battery-to-EV Supply Chain: A Roadmap for Indonesia - Summary Brief

Indonesia has a unique opportunity to support the clean energy transition, enhance energy security, and spur economic growth with local battery manufacturing, bridging from the material supply all the way to pack designs and, ultimately, the manufacturing of electric cars. Following the elevation of United States and Indonesia relations to a Comprehensive Strategic Partnership, leaders of both countries highlighted the importance of Net Zero World support for Indonesia's energy transition, including collaboration on low-carbon battery supply chains. In support of this agreement, Net Zero World has partnered with Indonesia's Ministry of Energy and Mineral Resources and other Indonesian partners to chart actionable steps for establishing a clean, resilient battery supply chain and circular economy. This partnership aims to position Indonesia as a regional leader in clean energy and can help attract investment in the domestic battery and electric vehicle (EV) sectors.

batteries↗
DOE OSTI2024

North America’s Potential for an Environmentally Sustainable Nickel, Manganese, and Cobalt Battery Value Chain

The Detroit Big Three General Motors (GMs), Ford, and Stellantis predict that electric vehicle (EV) sales will comprise 40–50% of the annual vehicle sales by 2030. Among the key components of LIBs, the LiNixMnyCo1−x−yO2 cathode, which comprises nickel, manganese, and cobalt (NMC) in various stoichiometric ratios, is widely used in EV batteries. This review reveals NMC cathodes from laboratory research. Furthermore, this study examines the environmental effect of NMC cathode production for EV batteries (including coating technologies), encompassing aspects such as energy consumption, water usage, and air emissions. Although gaps persist in NMC cathode environmental assessments (NMC111, NMC532, NMC622, and NMC811), limited life cycle assessments “(LCA)” have been conducted. Most available data originate from Asia (primarily China), accounting for 85% of the production of EV LIB cathode materials. The concept of battery passports for data collection on LIB components has been proposed to facilitate material traceability as a system for ensuring a sustainable supply chain for critical minerals. The automotive industry’s shift to electrification necessitates a sustainable supply chain from mine to vehicle end-of-life. As the critical mineral supply moves from Asia to North America, environmentally friendly industrial methods must be studied to provide this supply chain direction.

25 ENERGY STORAGE↗
DOE OSTI2026

Thermal Damage Potential of Electric Vehicles

The main objective is to assess the risk that electric vehicle (EV) battery fires pose regarding thermal damage to other vehicles involved in a crash and to compare EV and internal combustion engine vehicle (ICEV) fires. A literature review of experimental data and statistics are used to perform the assessment. The findings indicate: (1) the heat flux emitted from an EV and ICEV fire are similar due to cabin materials being the main contributor to heat flux, (2) for ICEVs involved in a crash with fuel tank leakage, the thermal damage is significantly more than from an EV fire for equivalent fire durations, (3) the thermal damage potential from ICEV pool fires is at least 5 times higher than EV fires, and (4) EV and ICEV crashes resulting in a fire is about 0.002% and 0.2%, respectively. Thus, EV battery fires have a lower risk than ICEV fires.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

20-kW Bi-directional Wireless Power Transfer System with Energy Storage System Connectivity

The severity of the economic impact caused by grid outages has been the driving factor for creating innovative solutions that increases interest for the deployment of distributed energy resources to reduce the impact of grid outages. This study presents a novel way of providing export power using bi-directional wireless power transfer (WPT) systems for ac grid side power and mobile energy storage systems (ESSs) connectivity. The proposed concept here interfaces the EV batteries to the AC grid and also can redirect the power from the stationary ESS to grid, to EV batteries, or both simultaneously; providing the capabilities of an uninterrupted power supply (UPS). Results demonstrate the performance and the functionality of the system with overall efficiencies 93% to 97%, depending on the operating mode.

Onar, Omer↗
DOE OSTI2026

White Paper on Case Study of Safe Installation of Second-Life Energy Storage System

This technical report provides for a case study for the safe installation of a second-life, or repurposed, battery, that has been reconfigured for use as a stationary energy storage systems (ESS). Driven by legislative requirements such as California Senate Bill 615 and projections that retired EV batteries could meet a substantial portion of U.S. grid ESS needs beginning in 2035, the repurposing of EV batteries is anticipated to grow significantly. However, safety concerns arise from the effects of aging, unknown prior usage history, and changes in thermal runaway behavior, which may increase failure risks compared to new batteries. NFPA 855, the predominant U.S. standard for ESS installation, mandates that second-life batteries meet all requirements for new batteries, with repurposers complying with UL 1974 in addition to obtaining UL 9540 and UL 1973 listings. These are certifications that few repurposers have achieved and represent a regulatory barrier to entry for the market as a whole.

47 OTHER INSTRUMENTATION↗