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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 OSTI2025

Dynamic Capacitive Wireless Power Transfer System for Electric Vehicles (CRADA Final Report)

Road transportation accounts for 23% of our nation's total energy consumption, 59% of our petroleum consumption and 22% of our total emissions. Electric vehicles (EVs) have much higher well-to-wheel efficiency compared to gasoline vehicles and can reduce our dependence on oil, minimize emissions, improve local air quality and provide a platform for technological innovation and economic growth. While major progress has been made in the development of electric vehicles, their penetration remains under 1 The main hurdles in their widespread adoption are high cost, limited range and long charging times, due to limitations in battery technology. An approach to overcome these hurdles is to substantially reduce the on-board energy storage and instead deliver power wirelessly to the vehicle while it is in motion dynamic wireless power transfer (WPT). For EV charging applications, researchers have traditionally focused on inductive WPT. An issue with inductive WPT systems is that for magnetic flux guidance and shielding, they require ferrite cores, making them expensive, bulky and difficult to embed in the roadway. Under an ARPA-E IDEAS grant, the CU Boulder team has recently developed an alternative approach to WPT based on capacitive coupling that is much smaller, lighter, less expensive, and easier to embed in the roadway than inductive WPT; and have demonstrated a 1.2-kW 6.78-MHz version of this capacitive WPT system on a stationary platform. Under this seed grant program, preliminary work will be carried out on a dynamic capacitive WPT system to prepare a strong proposal for the ARPA-E OPEN 2018 FOA.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Integrated Magnetics for Multiport Inductive and Conductive Power Transfer Architecture for Electric Vehicles

This paper proposes a shared magnetic arrangement for an electric-vehicle charger that supports both conductive and inductive charging while preserving independent power control at the two ports. In the proposed implementation, the high-frequency transformer used for the conductive path and the resonant inductor required by the inductive path are realized in an integrated form. By combining the magnetic structure and primary-side converter hardware, the charger can deliver improved hardware utilization and higher power density without a corresponding increase in cost or implementation complexity. The paper describes the magnetic realization and presents finite-element and circuit-level simulation results to confirm minimal interaction between the two charging paths. The study demonstrates that the proposed charger is a viable option for flexible, high-power EV charging systems.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
DOE OSTI2023

Smart Droplets Stabilized by Designer Surfactants: From Biomimicry to Active Motion to Materials Healing

The science and technologies of emulsion droplets have been a long‐term focus of extensive research endeavors for their practical utility across a breadth of industries, including pharmaceutical products, oil recovery processes, and the food sciences. However, with advances in materials chemistry and characterization tools, new emerging areas are arising with a focus on “smart droplets”. The versatility of emulsion droplets across is based on their ability to partition and create isolated systems with properties defined by the liquid–liquid interface, while preparative routes allow manipulation of droplet size, stability, and encapsulated contents. As described in this article, significant efforts are being devoted to creating new types of droplets by “activating” this interface through the incorporation of reactive structures that trigger droplet response to applied or environmental stimuli (e.g., pH, temperature, salt, or external fields). Moreover, parallels between droplets and live cells inspire efforts to conceive systems that resemble biological motifs or that can produce cellular behaviors that imitate biology (e.g., swarming, communication, or motion). Here, the authors highlight recent advances in smart droplets, with emphasis on organic, polymer, and/or particle surfactants that give rise to inter‐droplet communication (via aggregation, fusion, division, or mass transfer), droplet vehicles for controlled delivery, autonomous droplet motion, and tunable emulsion inversion. Especially emphasized is the macromolecular design to produce reactive and functional surfactants, which are crucial to responsive droplet behavior and their underlying mechanisms. More generally, the exquisite interplay between materials science and biology inspires the review of this research area that provides unique opportunities for insight and inspiration into the capabilities of new droplet designs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Performance Characterization of InCharge™ ICE-66 V2X Bidirectional DC Fast Charger

Vehicle-to-grid (V2G) technology extends the role of Plug-in Hybrid Vehicle’s (PHEV) and Battery Electric Vehicle’s (BEV) batteries beyond transportation by enabling bidirectional power transfer between the vehicle's onboard energy storage and the utility grid. Modern battery-powered vehicles are equipped with high-capacity battery packs that remain stationary and underutilized for the majority of their operational life. A vehicle used for daily commuting may be parked and connected to charging infrastructure for 18–20 hours per day, representing a significant untapped energy resource. When considered at scale, the aggregated storage capacity of a modest fleet of 10–15 vehicles within a single parking facility can reach the MWh range, sufficient to partially offset peak demand for a mid-size commercial building or contribute meaningful ancillary services to the local grid. The ability to charge during off-peak periods when electricity prices are low and discharge during peak demand when prices are high positions EV batteries as distributed energy arbitrage assets, with the potential to offset vehicle ownership and charging costs. Beyond energy arbitrage, V2G-capable assets can provide ancillary grid services through active and reactive power injections. Active power supports grid frequency regulation, while reactive power supports local voltage regulation. Together, these capabilities establish V2G as a technically promising and economically relevant pathway toward greater integration of battery-powered vehicles into the broader energy system.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Thermal Analysis of a 100 kW Polyphase Wireless Power Transfer System

Charging Electric Vehicles (EVs) fast and safely has a crucial role in the future of the EV technology. High-power Wireless Power Transfer (WPT) helps to significantly decrease the charging time. However, when the power transfer levels increase, thermal management becomes a significant challenge. The thermal design of the WPT systems needs more consideration in the design and implementation steps. This paper presents a thermal analysis of a 100 kW high-power WPT system. The thermal performance of the proposed design was evaluated at different power levels by considering the magnetic design and loss analysis. Finite Element Analysis (FEA) of the proposed design was performed and the thermal images of the implemented system were taken to prove the simulation results. The results show that, a liquid cooling design is needed for a high-power WPT systems for the long-time continuous operations of the charging pads.

Aydin, Emrullah↗
DOE OSTI2025

A Misalignment Tolerant Magnetic Coupler Design and Implementation for Wireless Charging of Unmanned Aerial Vehicles (UAVs)

Wireless power transfer technology is getting more attention these days as a part of expanded battery charging infrastructure and network at a wide range of power levels. Charging Unmanned aerial vehicles (UAVs) is one wireless charging application, and charging their batteries can be challenging because they have short flight times and are frequently charged. For wireless charging of UAVs, the misalignment performance of the magnetic coupler pads is critical because landing on a charging pad at a perfectly aligned position is difficult and can be time-consuming. Different coil shapes and system structures have been proposed in the literature to overcome this challenge. A new design with a high misalignment tolerance is needed; therefore, to fill this gap, a wireless power transfer system has been designed for a 250 W UAV battery charging system with a new magnetic coupler design. A 3D model of the proposed design was created, and finite element simulations were performed. To prove the proposed design, the magnetic coupler prototypes were developed, and experimental results are presented herein. The misalignment tolerance of the proposed system was observed for various rotational positions of the secondary coil, from 0° to 360°. The results demonstrate that DC–DC efficiency varies between 80% and 85% within full 360° rotation of the receiver coil. This result enables the proposed system to address the misalignment problem for wireless charging of UAVs.

UAVs↗
DOE OSTI2026

Design and Performance Assessment of Intermediary Coils for Misalignment Tolerance Improvement in Wireless Power Transfer Systems

This paper investigates the use of intermediate coils positioned between the primary and secondary coils in Wireless Power Transfer (WPT) systems for electric vehicle (EV) charging, with the objective of improving power transfer efficiency and robustness under misalignment conditions. An optimized 1 kW power system that operates at 85 kHz is developed and the misalignment performance was analyzed and compared with and without intermediate coils. A preliminary increase in efficiency of 2.3% at a misalignment of 52% of the coil radius is shown to be possible for a passive intermediate coil. An experimental prototype is built for design verification.

Sivka, Gozde [ORNL]↗
DOE OSTI2025

Improving Dynamic Wireless Charging System Performance For Electric Vehicles Through Variable Speed Limit Control Integration

Electric Vehicle (EV) charging has been a significant barrier to the widespread use of EVs. Traditional EV charging methods depend on cables, and there are concerns about safety, accessibility, convenience, and weather. A recent development, dynamic (or in-motion) wireless charging, enables EVs to charge wirelessly by incorporating charging infrastructure into roadways, allowing EVs to charge while moving. However, the energy transferred relies heavily on vehicle speed and time spent in the charging lane. This paper proposes an innovative solution that combines dynamic wire-less charging with Variable Speed Limit (VSL) control. This dynamic traffic control strategy adjusts speed limits based on real-time traffic, weather, and incidents. This integration of dynamic wireless charging and VSL has two potential benefits. First, it can motivate driver compliance with VSL through the incentive of charging. Second, it can promote smoother traffic flow and improve traffic safety by implementing lower speed limits at certain times. To verify these benefits, microscopic traffic simulations in SUMO were conducted under different EV penetration rates and VSL compliance rates. Simulation results reveal that the proposed approach can enhance dynamic wireless charging system performance while improving traffic flow and safety.

Xu, Guanhao [ORNL] (ORCID:0000000214326357)↗
DOE OSTI2024

Medium-Duty Delivery Truck Integrated Bidirectional Wireless Power Transfer System With Grid and Stationary Energy Storage System Connectivity

Electric vehicles (EVs) can provide power to the grid or buildings similar to distributed energy resources (DER) for energy balancing applications or optimizing the operation of the microgrids in harmony with the other DER assets. This article presents the operating modes of a bidirectional wireless power transfer (WPT) system designed for a medium-duty package delivery vehicle. The WPT system designed for this study can transfer 20 kW of power across 11 in of air gap using custom-designed double-D (DD) couplers with LCC–LCC tuning networks. The proposed system utilizes a 480-V three-phase grid connection, a plug-in hybrid delivery truck with bidirectional WPT, and a stationary energy storage system (SESS) that can be connected to the primary-side dc link. Due to the differences in primary and secondary dc bus voltages, and considering the voltage of the SESS, asymmetric voltage gains were used in the system. Sensitivity analyses of this system with respect to these voltage levels are presented. Five different operating modes of the grid, SESS, and the EV battery are investigated with experimental results. Control algorithms are described for grid-to-vehicle (G2V) and vehicle-to-grid (V2G) operating modes. A bidirectional WPT system is operated with a power factor of 0.99 on the grid side in every operating mode. The EV battery was charged with 20.3 kW with an overall efficiency of 93.02% in the G2V operating mode. Finally, in the V2G operating mode, the WPT system provided 12.82 kW of power back to the grid with an overall efficiency of 89.08%.

25 ENERGY STORAGE↗
DOE OSTI2024

Promoting electrochemical rates by concurrent ionic-electronic conductivity enhancement in high mass loading cathode electrode

Enhancing the fast charging capacity of thick electrodes with high mass loading is imperative in expediting the widespread adoption of electric vehicles. Nonetheless, the insufficient charge transfer kinetics of thick electrodes hinder the movement of effective electrons and ions, hence diminishing capacity at high current rates. In this work, we applied sustainable and biodegradable cellulose nanocrystals (CNCs) as electrode additives. It is the first time to simultaneously improve the electronic conductivity by optimizing the carbon dispersion and establishing electron transfer networks, as well as boosting the ionic conductivity of electrodes by shortening the ion transfer pathway. Specifically, the LiNi 0.6 Mn 0.2 Co 0.2 O 2 electrodes incorporating 1% dual functional CNCs additive exhibit improved effective electrical conductivity from 0.11 to 0.16 S/m and risen effective ionic conductivity from 0.36 to 0.62 S/m, in comparison to counterpart electrodes without CNCs. Therefore, the 1% CNC electrode with a high mass loading of 27.0 mg/cm 2 delivers a discharge capacity of 128 mAh/g at 1 C, which is superior to that of the CNC-free electrodes (95 mAh/g). In short, this study presents a novel environmentally friendly, economically viable, and dual-functional electrode additive that enhances both electronic and ionic conductivities with the aim of facilitating the widespread adoption of fast-charging high mass loading electrodes.

25 ENERGY STORAGE↗
DOE OSTI2025

Stability Analysis of Parallel Connected Bidirectional WPT System

This paper presents a stability analysis of parallel-connected bi-directional series-series resonant network wireless power transfer (WPT), optimized for Electric Vehicle (EV) charging and vehicle-to-grid (V2G) applications. The study addresses critical stability challenges in systems integrated with diverse distributed energy resources (DERs), including photovoltaics, fuel cells, wind turbines, energy storage systems, and the AC grid. The stability of such integrated DC grid systems is paramount for ensuring reliable operation, particularly under varying power flow conditions and dynamic interactions between parallel WPT systems. The analysis included system impedance characterization, state-space modeling, and open and closed-loop stability evaluations. The results demonstrated that the integration of a robust control architecture effectively mitigates instability risks and supports scalable, efficient operation. This work underscores the converter's adaptability and its potential for large-scale deployment in wireless EV charging infrastructures and integrated DC grid systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
DOE OSTI2026

Supervised Learning-Based Spatial Position Estimation with Vertical Displacement for Hovering UAV Wireless Power Transfer

This study presents a supervised learning-based spatial position estimation approach for wireless power transfer (WPT) systems supporting hovering unmanned aerial vehicle (UAV) charging. Unlike stationary charging scenarios, hovering UAVs introduce continuous lateral misalignment and vertical displacement, leading to variations in magnetic coupling and reduced power transfer efficiency. To address this challenge, the proposed method estimates the relative spatial position of the receiver coil using only electrical measurements obtained at the secondary side. A supervised learning model is trained to map output voltage and current features to spatial coordinates, enabling position awareness without requiring external sensors, vision systems, or communication links. The sensing functionality is inherently integrated into the WPT system, allowing simultaneous power transfer and localization through the same magnetic interface. Experimental validation is conducted on a laboratory-scale prototype under varying lateral offsets and air-gap conditions. In addition, spline-based interpolation is employed to increase spatial data density for training. The results demonstrate that the proposed framework can capture spatial variations associated with both lateral and vertical displacement, providing reliable position estimation under hovering conditions. This work establishes a hardware-efficient, sensorless solution for UAV wireless charging and serves as a baseline for advanced data-driven position estimation methods in dynamic WPT systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
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

TCO Analysis Approach and Regional Analysis of dWPT for Class 8 Tractors

Dynamic Wireless Power Transfer (dWPT) is a method by which battery electric vehicles (BEVs) can charge their battery while traveling on the road without the need for a physical conductive connection to the power source. dWPT has been proposed as a strategy to enable a reduction in vehicle battery capacity and associated mass and cost. In this slide deck presented at the EVs@Scale Consortium - Wireless Power Transfer Pillar Deep-Dive Meeting on November 11th, 2023, NREL provides results from an evaluation of dWPT using data from Class 8 tractors driving in the Atlanta Metro Area. NREL selected data for archetypal days representing local, regional, and long-haul trips, defined according to trip length, that included travel on primary roadways. EVI-InMotion (Electric Vehicle Infrastructure - InMotion), a systems planning and optimization tool developed at NREL, was used to evaluate dWPT performance assuming dWPT charging on 120 road segments for a total roadway lane distance of 2,365 miles. The EVI-InMotion results and representative day drive cycles were analyzed with NREL's T3CO (Transportation Technology Total Cost of Ownership) tool to estimate the total cost of ownership (TCO) for scenarios comprising two model years - 2030 and 2040 - and two technology progress cases. TCO was calculated for diesel, fuel cell electric, BEVs with batteries sized assuming no dWPT capabilities, and 200kWh BEVs with dWPT installed. This analysis finds that en-route stationary charging frequency and downtime when not on electrified roadways are the main contributors to TCO for the dWPT vehicles and that these vehicles can achieve cost parity with FCEVs at low electricity costs. Based on the scenario assumptions used here, low electricity costs would further help the cost parity with diesel vehicles in regional and long-haul cases due to stationary fueling downtime. This presentation also concludes that key factors affecting the parity potential of dWPT-capable vehicles include more extensive dWPT road coverage, higher en-route charging power, less expensive power batteries, and higher hydrogen or diesel fuel costs.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2025

Speed Variation Based Power Regulation Concept for Dynamic Wireless Charging

On-road wireless charging of electric vehicles (EVs) in-motion could potentially reduce range anxiety or battery size with wide-spread deployment. The planning and implementation of such systems are greatly complicated due to their susceptibility to load variation inherent to traffic flow. Here, this paper proposes a method for derisking the potential for traffic slowdowns by compensating for reduced vehicle speed and investigates how implementation may affect system performance. A load modeling case study is presented at 200kW for a mile of high-speed roadway employing speed-based power regulation with results indicating average power usage and maximum car hosting capability can be reduced by 20% and increased by 30% respectively. An 85kHz power electronics model is developed based on designs and prototypes for an 11kW, 190m airgap static system and a 200kW dynamic wireless track. The simulation is validated in the 11kW experimental prototype and modified for 200kW operation to compare with simulated performance. Sensitivity studies are performed in MATLAB/Simulink to evaluate how parameters influence system performance and confirm the capability to reduce output power and maintain efficiency at 11 and 200kW. The static 11kW experimental system operates at 93.6% efficiency and multiple options exist to reduce power while maintaining efficiency greater than 90%. The capability to dynamically modify power output from WPT coils, in an experimentally validated simulation, enables techniques to significantly mitigate load variability due to reductions in vehicle speed.

42 ENGINEERING↗
DOE OSTI2026

A System Level Comparative Study of SecondarySide Rectifiers for UAV Wireless Power Transfer in High-Altitude Airborne Energy Platforms

Wireless power transfer (WPT) systems for unmanned aerial vehicles (UAVs) must satisfy stringent design requirements to ensure reliable operation under constraints related to efficiency, thermal performance, altitude, weight, and reliability, particularly in airborne and high-altitude environments. Thermal management becomes increasingly challenging at higher altitudes due to reduced air density, while reliability is strongly affected by the number and complexity of active components. The weight and compactness of secondary-side rectifiers directly impact UAV flight endurance and system integration, influencing energy consumption and payload allocation. These factors collectively define the practical feasibility of UAV WPT systems and guide rectifier topology selection. This paper presents a comparative and experimentally validated evaluation framework for secondary-side rectifiers under UAV-specific constraints. Three representative rectifier architectures are analyzed using component-based assessment of weight, thermal behavior, and reliability, together with experimental efficiency measurements obtained from a 1 kW WPT prototype. The results show that the single-switch active rectifier achieves the highest peak efficiency of approximately 93.2% and an overall efficiency of 91%, while also offering advantages in weight and reliability. The findings demonstrate how constraint-oriented analysis, combined with experimental validation, enables informed selection of secondary-side rectifiers for UAV wireless power transfer applications, including emerging airborne and high-altitude platforms.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗
DOE OSTI2026

A Reflection on the Evolution of Sodium/Metal Chloride (ZEBRA) Batteries and Lithium-Ion Cathode Materials (1975–2025): A Tribute to Johan Coetzer

This narrative summarizes, in retrospect, the enormous and quietly-conducted contribution of Dr Johan Coetzer, a South African scientist and entrepreneur, to the discovery, development and implementation of the high temperature sodium—metal chloride “ZEBRA” battery (Na/β-Al 2 O 3 , NaAlCl 4 /MCl 2 (M = Ni, Fe)). Here, this research activity was initiated in the mid 1970’s at the Council for Scientific and Industrial Research (CSIR) in South Africa and subsequently developed primarily in partnership with the Atomic Energy Research Establishment (AERE, Harwell, UK), Beta R&D (Derby, UK) and Daimler Benz (Germany), before being transferred to industry worldwide for electric vehicle and energy storage applications, albeit at a relatively low production rate. Coetzer’s wide-ranging, innovative and, at times, unconventional scientific approach also laid the foundation for the discovery and implementation of manganese-based spinel and layered metal oxide cathode materials for the Li-ion battery industry.

ZEBRA Battery↗
DOE OSTI2025

Additively manufactured and cast high-temperature aluminum alloys for electric vehicle brake rotor application

Electric vehicle brake rotors demand lightweight, high thermal conductivity materials with good resistance to wear, creep, salt corrosion, and thermal fade, all of which present challenges to the traditionally used cast iron. In this work, we investigated the braking performance of recently developed high-temperature aluminum alloys in both cast and 3D printed forms, that possess excellent microstructural and mechanical stability at elevated temperatures. Three aluminum alloys, Al-6Cu-Mn-Zr, Al-9Cu-Mn-Zr, and Al-Ce-Ni-Mn-Zr and a reference cast iron were tested on a sub-scale brake tester against a commercial brake pad material over a range of sliding speeds between 2 and 15 m/s. The performance of these alloys was evaluated for wear resistance, friction behavior, temperature elevation, and surface morphological change. Although all three candidate alloys had lower wear-resistance than cast iron, Al-Ce-Ni-Mn-Zr showed a significantly reduced wear rate in comparison to the Al-Cu-Mn-Zr alloys. Moreover, Al-Ce-Ni-Mn-Zr alloy had the most consistent friction behavior at all sliding speeds and good fade resistance, as the coefficient of friction did not dramatically decrease with temperature rise but stayed within a desirable range of 0.35–0.50 instead. The superior wear resistance and braking performance of the Al-Ce-Ni-Mn-Zr alloy were attributed to its higher hardness, and high temperature yield strength and creep resistance compared with the Al-Cu-Mn-Zr alloys. In conclusion, the results suggest that the braking performance of these aluminum alloys could be further enhanced by increasing the hardness and forming a more stable transfer layer on the sliding surface.

36 MATERIALS SCIENCE↗