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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

Opportunities and challenges for the expansion of LFP battery supply chains

Global markets for energy storage are growing rapidly, with some applications transitioning from traditional LiNi x Mn y Co 1−x−y O 2 (NMC) toward LiFePO 4 (LFP) due to cost, safety, and performance advantages. Battery growth has seeded interest in critical material supplies such as high-purity lithium precursors. In contrast, challenges in securing high-purity iron and phosphorus, historically not considered critical materials, are often overlooked. Precursors must remain inexpensive to maintain LFP's current cost advantage, which leverages the low-cost (∼$\$100$ per t) FeSO 4 byproduct from titanium dioxide manufacturing and will not be available as LFP manufacturing expands. As an alternative, iron is mined primarily for steel manufacturing, for which the existing supply chain and beneficiation process is optimized. LFP batteries require small iron volumes compared to steel (0.11%), but profit margins associated with existing low-cost iron ores and high costs (∼$27 000 per t) associated with low volume high-purity iron oxides may limit interest in manufacturing small volumes of high-purity, specialized iron battery precursors. The complementary LFP precursor, phosphoric acid (H 3 PO 4 ), is primarily utilized in fertilizers. Of the current phosphate ore demand for fertilizers, 4–22.8% would be required to meet projected 2045 LFP H 3 PO 4 demand, suggesting significant supply chain planning is needed to achieve projected demand. If only higher-grade material is considered, demand jumps to 15–77% of current world production. While lithium precursor purity requirements have been evaluated (Li 2 CO 3 is commonly defined as ≥99.5%), “battery grade” iron and phosphorus precursors remain poorly defined, with no internationally accessible and widely adopted standard, further challenging expanding industry by creating manufacturing uncertainty and increasing potential costs.

25 ENERGY STORAGE↗
DOE OSTI2026

An Accelerated Testing and Analysis Framework for Qualification of Battery Materials Part I: A Case Study with LFP Cathodes

The growing demand for batteries used within automotive, aviation, and grid applications has exacerbated the need to supplement critical battery material feedstocks, such as those for anode and cathode active materials. New or supplementary material sources, however, universally comprise unique properties that can affect the lifetime and performance of resultant batteries. Even minor differences between new sources and established supplies can delay qualification, making it difficult for new suppliers to commercialize and resulting in a less resilient supply chain. Accordingly, the influence of composition, microstructure, and morphology on electrochemical performance should be characterized quickly and accurately to accelerate commercialization of new sources. This work introduces a tiered framework to assess new material viability and understand the influence of physicochemical properties on battery performance. The Tier 1 testing described here is rapid and low-effort to recognize materials with fundamental flaws and potentially disqualify them. Later testing would require more effort but provide higher-fidelity information with a goal of application-based validation. A case study examining commercial sources of LiFePO4 (LFP) is presented, using Tier 1 of the protocol to identify rapid electrochemical and physicochemical signals that correlate with performance and provide early go/no-go decisions for LFP materials without requiring long-term cycling.

25 ENERGY STORAGE↗
DOE OSTI2022

Synthesis of high-density olivine LiFePO 4 from paleozoic siderite FeCO 3 and its electrochemical performance in lithium batteries

The lithium-ion cathode material olivine LiFePO 4 (LFP) has been synthesized for the first time from natural paleozoic iron carbonate (FeCO 3 ). The ferrous carbonate starting material consists of the mineral siderite at about 92 wt. % purity. Because FeCO 3 has divalent iron, the reaction with lithium dihydrogen phosphate (LiH 2 PO 4 ) provides a unique method to develop iron-(II) containing LFP in an inert atmosphere. Since siderite FeCO 3 is a common mineral that can be directly mined, it may, therefore, provide an inexpensive route for the production of LFP. After carbon-coating, the LFP yields a capacity in the range of 80–110 mAh g -1 LFP (in one chosen specimen sample), which is lower than commercially available LiFePO 4 (150–160 mAh g -1 LFP ). However, the tap density of LFP derived from siderite is noticeably high at 1.65 g cm -3 . The material is likely to be improved with powder purification, nanosized processing, and more complete carbon-coating coverage with increased optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Redox‐Mediated Electrochemical Regeneration of Spent LiFePO 4 Battery Cathodes

Direct recycling of lithium-ion battery cathodes offers considerable appeal over metallurgical approaches. Here, we demonstrate a mediated electrochemical method for direct regeneration of degraded LiFePO 4 (LFP). The approach uses a redox mediator, iron propylenediamine tetraacetate, that undergoes electrochemical reduction and is circulated through an external reservoir, where it supplies the electrons needed to regenerate LFP in the presence of Li + ions derived from LiOH oxidation. Rapid outer-sphere electron transfer is observed from the mediator to the degraded LFP material. This feature, together with good aqueous solubility of the mediator (0.3 M), supports current densities up to 100 mA/cm 2 , and this electrochemical recycling process is demonstrated on 100 g scale. 57 Fe Mössbauer spectroscopy is used to monitor the correction of structural defects in the degraded LFP, providing the basis for regeneration of LFP that matches the electrochemical performance of pristine LFP.

Electrochemical Relithiation↗
DOE OSTI2023

Degradation of Lithium Iron Phosphate Sulfide Solid-State Batteries by Conductive Interfaces

The superionic solid-state argyrodite electrolyte Li 6 PS 5 Br can improve lithium and lithium-ion batteries' safety and energy density. Despite many reports validating the conductivity of this electrolyte, it still suffers from passivating electrode degradation mechanisms. At first analysis, lithium iron phosphate (LFP) should be more thermodynamically stable in contact with sulfide electrolytes. However, without substantial improvements to interfacial engineering, we find that LFP is not inherently stable against Li 6 PS 5 Br. We hypothesize argyrodite oxidation favorably competes with LFPAs delithiation, insulating the electrolyte-electrode interface and causing large overpotential losses. We show that compared to LiNi x Mn y Co z O 2 , LFP has no actual electrochemical stability advantage despite operating at a lower voltage. We utilize tender energy XAS and XPS to show that chemical reactions occur between LFP and the Li 6 PS 5 Br solid electrolyte and these reactions are exacerbated by cycling. We also show that electrochemical degradation occurs at the interface between the solid electrolyte ion conductor and any electron conductor, namely the active material and carbon additives. We further demonstrate that LiNbO 3 cathode coatings on LFP can delay electrochemical degradation by electronically insulating the LFP-sulfide electrolyte interface but not prevent its occurrence at the carbon-electrolyte interface.

25 ENERGY STORAGE↗
DOE OSTI2025

Gas-solid reaction-based selective lithium leaching strategy for efficient LiFePO 4 recycling

As the electric-vehicle market continues to expand, LiFePO 4 (LFP) batteries, valued for their intrinsic safety and cost-effectiveness, are being increasingly utilized. However, this widespread adoption highlights the urgent need for innovative and environmentally friendly recycling methods for spent LFP batteries due to their relatively low material value and the environmental challenges associated with traditional recycling processes. Here, in this study, we present a novel selective lithium leaching technique that involves a gas–solid reaction with chlorine gas. This method achieves a remarkable leaching efficiency of 99.8 % and a selectivity of 98.8 % at 200 °C within just 10 min, without generating acidic wastewater. The resulting LiCl solution was successfully converted into Li 2 CO 3 with an excellent purity of 99.5 %, while producing NaCl solution as the only byproduct. Notably, the olivine structure of the LFP was preserved as FePO 4 after lithium leaching. The regenerated LFP demonstrated excellent performance, retaining 94.1 % of its capacity after 150 cycles, while the lithium-leached FePO 4 delivered a reversible capacity exceeding 150 mAh/g. This approach not only enhances the efficiency of LFP recycling but also paves the way for more sustainable battery technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Overcharge-to-thermal-runaway behavior and safety assessment of commercial lithium-ion cells with different cathode materials: A comparison study

In this paper, overcharge behaviors and thermal runaway (TR) features of large format lithium-ion (Li-ion) cells with different cathode materials (LiFePO 4 (LFP), Li[Ni 1/3 Co 1/3 Mn 1/3 ]O 2 (NCM111), Li[Ni 0.6 Co 0.2 Mn 0.2 ]O 2 (NCM622) and Li[Ni 0.8 Co 0.1 Mn 0.1 ]O 2 (NCM811)) were investigated. The results showed that, under the same overcharge condition, the TR of LFP Li-ion cell occurred earlier compared with the NCM Li-ion cells, indicating its poor overcharge tolerance and high TR risk. However, when TR occurred, LFP Li-ion cell exhibited lower maximum temperature and mild TR response. All NCM Li-ion cells caught fire or exploded during TR, while the LFP Li-ion cell only released a large amount of smoke without fire. According to the overcharge behaviors and TR features, a safety assessment score system was proposed to evaluate the safety of the cells. In short, NCM Li-ion cells have better performance in energy density and overcharge tolerance (or low TR risk), while LFP Li-ion cell showed less severe response to overcharging (or less TR hazards). For NCM Li-ion cells, as the ratio of nickel in cathode material increases, the thermal stability of the cathode materials becomes poorer, and the TR hazards increase. Such a comparison study on large format Li-ion cells with different cathode materials can provide deeper insights into the overcharge behaviors and TR features, and provide guidance for engineers to reasonably choose battery materials in automotive applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Liquid Fed Pyrolysis of Polyethylene Films: Environmental and Economic Assessments of Co-located and Remotely-Located U.S. Facilities

Polyethylene (PE) films are one of the highest production volume plastic products, but they have very low recycling rates. A novel liquid fed pyrolysis process (LFP) is an advanced recycling technology that can be applied to waste PE films. In this work, two environmental and six economic metrics were evaluated for the LFP process under different scenarios with a baseline production capacity of 8,400 Metric Tons (MT) of pyrolysis products/year. The studied scenarios considered process improvement such as heat integration, changing the final product yields, and location of the LFP process facility (i.e., co-located at a petrochemical facility or located remotely). Results show that producing refined pyrolysis wax in remote areas is the most environmentally favorable and profitable scenario. The LFP process co-located at a petrochemical facility and selling only liquid and gaseous pyrolysis products to the facility would require a capacity of >18,000 MT/year to be economically feasible. Heat integration led to greenhouse gas emission savings of at least 14%, 19%, and 32% for the pyrolysis oil, gas, and wax products, respectively. Fianlly, the LFP process in remote and less populated locations producing a high yield of refined wax may be a feasible solution for increasing recycling rates of PE films.

Advanced recycling↗
DOE OSTI2024

Beyond conventional batteries: a review on semi-solid and redox targeting flow batteries-LiFePO{sub 4} as a case study.

Clean and sustainable energy is becoming increasingly crucial to tackle the current energy crisis. However, the intermittent nature of renewable energy sources presents a challenge for their effective implementation. Redox flow batteries (RFBs) have emerged as a promising solution to this problem, as they can help enhance the stability of grid networks and promote the use of renewable energy sources. RFBs are highly modular and scalable systems that can be customized to meet the power and energy requirements of different renewable energy plants. Moreover, they offer several advantages over conventional battery technologies, including cost and safety concerns. However, conventional RFBs have limited energy densities due to the low solubility of their active species in electrolyte. To overcome this limitation, semi-solid (SSRFBs) and redox targeting (RTFBs) flow batteries have been proposed. These systems feature high concentrations of active species and impressive energy densities, making them highly attractive for renewable energy applications. LiFePO4 (LFP) is a highly promising active material for semi-solid and targeting flow batteries. One of the key advantages of LFP is its low raw materials cost, as it is composed of Earth-abundant elements such as iron and phosphorus. This makes it an attractive option for large-scale battery production. The recent developments in SSRFBs and RTFBs using LFP as catholyte hold great promise for the future of sustainable energy storage. The combination of LFP's low cost, safety, durability, and high energy density with the modularity and scalability of flow battery systems make for a compelling solution to the challenges of intermittent renewable energy sources. Ongoing research and development in this area will likely yield even further improvements in the performance and efficiency of LFP-based flow batteries, opening exciting new possibilities for sustainable energy storage.

El Halya, Nabil↗
DOE OSTI2026

ICL Commercial Production of Lithium Iron Phosphate Cathode Powder for the Global Lithium Battery Industry Final Technical Report

ICL was investing in producing cathode active material, Lithium Iron Phosphate (LFP), used in the production of batteries for both electric vehicles and stationary storage. The demand for LFP was increasing with the global focus on sustainable energy, and there was no current manufacturer of this material in the United States. As such, imported LFP is subject to the uncertainties around supply chain and control of a foreign supplier. This investment would have allowed ICL to be a United States leader in LFP production. To gain a position in this market, ICL licensed the technology from a firm that has the process technology and has reliably supplied LFP into the battery market and currently has customers purchasing their product.

25 ENERGY STORAGE↗
DOE OSTI2025

Probing the Effect of Electrode Thermodynamics on Reaction Heterogeneity in Thick Battery Electrodes

Thick electrodes present a viable strategy for enhancing energy density and reducing manufacturing costs of lithium-ion batteries. However, reaction heterogeneity during cycling compromises their rate capability and cycle life. While this nonuniformity is commonly attributed to sluggish charge transport, it is demonstrated here that the thermodynamic properties of the electrode material play an equally critical role. Through combined X-ray fluorescence microscopy and absorption near-edge structure spectroscopy, reaction distributions in LiFePO 4 (LFP) and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC) thick electrodes with matched porosity and tortuosity are compared. LFP electrodes develop pronounced depth-oriented state-of-charge (SOC) gradients that worsen with increasing discharge rates, whereas NMC maintains much more uniform SOC distributions under such conditions. This difference originates from their distinct SOC dependence of equilibrium potentials and is quantifiable through a dimensionless “reaction uniformity” number. Intriguingly, LFP thick electrodes also exhibit lateral SOC variations that strengthen during slow discharge. In conclusion, the enhanced reaction uniformity in NMC correlates with better active material utilization and slower capacity fade than LFP, highlighting electrode thermodynamics as a key design consideration for thick electrodes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Unveiling the Role of Critical Impurities in Spent LiFePO 4 Cathodes for Scalable Direct Regeneration

Direct regeneration offers a promising alternative to recycling End-of-Life (EoL) batteries by restoring metal elements and preserving the material structure, yet scaling these technologies to handle practical cathode black mass (CBM) with impurities remains challenging. Here, this study investigates the evolution of impurities, including aluminum (Al), polyvinylidene difluoride (PVDF) binder, and residual carbon (C), during direct recycling of spent LiFePO 4 (LFP) cathodes and their impact on electrochemical performance. Using various ex situ and in situ analyses, it is shown that the formation of lithium fluoride (LiF) during the traditional direct recycling process hinders lithium diffusion and deteriorates the reversible capacity. To address this major challenge, the combination of pH-controlled hydrothermal purification and the two-step sintering process is proposed effectively to regenerate spent LFP cathodes, eliminating the negative effect of Al and fluorine (F) impurities while mitigating any potential impacts of carbon residuals. The regenerated LFP from spent CBM achieves superior performance, retaining 152.5 mAh g −1 at 0.1 C and 133 mAh g −1 at 1 C with 98.7% capacity retention after 200 cycles. This approach is further validated using three distinct waste feedstocks from battery modules, enhancing impurity management and scalability in direct recycling. These findings present a sustainable and economically viable solution for large-scale LFP regeneration.

25 ENERGY STORAGE↗
DOE OSTI2024

Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

Here, this paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

Engineering↗
DOE OSTI2024

Status and prospects of lithium iron phosphate manufacturing in the lithium battery industry

Abstract Lithium iron phosphate (LiFePO 4 , LFP) has long been a key player in the lithium battery industry for its exceptional stability, safety, and cost-effectiveness as a cathode material. Major car makers (e.g., Tesla, Volkswagen, Ford, Toyota) have either incorporated or are considering the use of LFP-based batteries in their latest electric vehicle (EV) models. Despite LFP’s well-researched status as a cathode material, it is expected to fulfill additional demands in electric vehicle applications, such as fast-charging capabilities, wide temperature range adaptability, and higher energy density. This perspective examines the LFP supply chain, synthetic approaches, manufacturing processes, market trends, recent advancements, and evolving demands to better understand its future role in the EV market. Graphical abstract

Lu, Yanying↗
DOE OSTI2022

Ultra-Stretchable, Ionic Conducting, Pressure-Sensitive Adhesive with Dual Role for Stable Li-Metal Batteries

The practical application of lithium (Li) metal battery is impeded by the Li dendrite growth and unstable solid electrolyte interphase (SEI) layer. Herein, an ultra-stretchable and ionic conducting chemically crosslinked pressure-sensitive adhesive (cPSA) synthesized via the copolymerization of 2-ethylhexyl acrylate and acrylic acid with poly(ethyleneglycol)dimethacrylate as crosslinker (short for 70cPSA), is developed as both artificial SEI layer and solid polymer electrolyte (SPE) for stable Li-metal electrode, enabling all-solid-state Li metal batteries with excellent cycling performance. As an artificial SEI layer, the 70cPSA-modified electrodes exhibit excellent electrochemical performance in Li|70cPSA@Cu half cells and 70cPSA@Li|70cPSA@Li symmetric cells. In full cells with LiFePO 4 (LFP) as cathode, the 70cPSA@Li|LFP cell exhibits stable cycling performance over 250 cycles. Utilized as SPE, the all-solid-state Li|SPE|LFP cell delivers excellent cycling stability with a capacity retention of 86% over 500 cycles. With high-voltage LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) as cathode, the Li|SPE|NMC811 cell exhibits a discharge capacity of 124.3 mAh g -1 with a capacity retention of 71% after 200 cycles. Furthermore, the rational design of PSAs and investigation of their dual role for stable and safe Li-metal batteries may shed a light on adhesive polymers for battery applications.

25 ENERGY STORAGE↗