NREL Capabilities for Notice of Funding Opportunity Announcements

NREL has extensive experience in battery safety research, including with gas analysis, thermal analysis, particulate analysis, high speed radiography imaging, and advanced compositional and microstructural characterization. NREL also has extensive experience with multi-physics modelling of the thermal and gaseous behavior of cells during thermal runaway. NREL hosts the open-access Battery Failure Databank which is the largest open-access database on the thermal and mass ejection behaviors of commercial cells, presenting a unique opportunity to benchmark new cell designs against the failure behaviors of commercial cells.

Contact Donal Finegan to partner with NREL on AOI 1.

NREL has developed novel methods to coat lithium metal anodes with solution-processed, ionically conductive, polymeric materials to help improve electrochemical stability in solid state battery systems. NREL is also well versed in evaluating the stability of lithium metal in contact with polymer/solid-state electrolytes in symmetric cells using various electrochemical techniques as well as X-ray photoelectron spectroscopy. Passivated lithium metal anode films can be combined with NREL's robust sulfide-based solid-state, thin-film separators and dry processed solid-state catholytes to form high-performance, high-energy density all solid-state batteries. Additionally, NREL's unique characterization capabilities can map intact coin cell cross-sections using cryoEM within a fs-laser focused ion beam (laser PFIB), which allows for imaging and x-ray mapping of lithium metal without cell disassembly. This paired with a lift-out specimen from the cross-section for cryo electron energy loss spectroscopy will determine how the passivation coating affects lithium morphology/composition during cycling. Lastly, the team has atomistic modeling tools (DFT and MD) to make suggestions for coating compositions that are ideal for passivating metallic lithium and mechanically resilient to withstand large volume changes of cycling metallic lithium.

Contact Andrew Colclasure to partner with NREL on AOI 2b.

NREL has nearly two decades of experience developing multi-scale models of battery physics and diagnostics that precisely quantify how battery performance, safety, and degradation vary with chemistry, design and use. In battery-electrode design, cycle life and fast charging typically come at the expense of energy density and cost. NREL's computer-aided engineering (CAE) models readily optimize such tradeoffs and accelerate battery design by improving understanding and reducing the need for experiments. Under DOE's Extreme Fast Charge (XFC) Program NREL's models co-optimized multiple length-scale technologies to achieve a >1000-cycle life, <15-min. fast-charge from 290-Wh/kg graphite/NMC811 battery. Examples of these XFC technologies include advanced active materials, electrodes, large-cell/systems designs, as well as adaptive electrochemical fast-charge protocols, AI-based health diagnostics, and life prognostics. NREL's thermal runaway/mechanical abuse 3D CAE models similarly accelerate the design cycle by guiding safety-engineering decisions and reducing testing cost.

Contact Kandler Smith to partner with NREL on AOI 3a.

Designing high-performance, cost-effective and affordable energy-storage systems for heavy-duty electric trucks can present challenges, especially in the critical area of battery thermal control, packaging, and safety. As manufacturers strive to make batteries more compact and powerful, knowing how and where heat is generated becomes even more essential to the design of effective thermal-management systems. NREL's world-class facilities provide developers, manufacturers, and vehicle manufacturers with the knowledge and assurance necessary that batteries are designed to perform well, last a long time, operate at maximum efficiency, and are enabled with fast charging capabilities. Researchers at NREL also use electro-thermal finite element models to analyze the performance of battery systems in order to aid battery developers with improved packaging and safety designs. Our experts also use validation and modeling tools in collaborating with battery manufacturers and vehicle manufacturers to meet stringent electric-vehicle life, performance, cost, and safety goals.

Contact Matt Keyser to partner with NREL on AOI 3b.

Thermal management and effective control for electric vehicles (EVs) are critical to optimal vehicle operations. Efficient thermal systems that optimize the use of air conditioning, waste heat, and thermal management for vehicle components, can reduce energy and fuel use to positively impact vehicle range, performance, and reliability. NREL is a globally recognized leader in vehicle and component thermal management, with a strong focus on medium- and heavy-duty EVs. The laboratory conducts cutting-edge modeling of advanced heat pump systems, integrated thermal systems, heat exchangers, and cabin thermal management across a range of weather conditions. NREL accelerates the design and implementation of novel thermal systems; high-efficiency components such as power electronics, vehicle batteries, and HVAC systems; and load reduction technologies.

Contact Jason Lustbader to partner with NREL on AOI 4.

As electrification of transportation rapidly expands, the U.S. grid will be required to support the growing electric vehicle (EV) charging demand. These EVs will represent some of the largest electrical loads at both homes and businesses but also may be the most flexible. Smart charge management (SCM) and vehicle grid integration (VGI) is the key to unlocking the temporal and spatial flexibility that is possible throughout many charging needs. Through a multitude of successful projects, NREL has demonstrated the capability to forecast EV adoption and resultant charging loads, assess possible grid impacts across diverse scenarios, and establish SCM and VGI solutions to accelerate the future of electric transportation. NREL has world-class capabilities to design, develop, and validate the integration of charging load through advanced metering infrastructure with building control systems leveraging our commercial and residential building research infrastructure, the distribution system leveraging our ADMS test bed, and electric vehicle research infrastructure.

Contact Andrew Meintz to partner with NREL on Area of Interest 5.

U.S. Farms are a vital part of the economy, employing millions of people, conserving natural resources, and supplying food, fuel, and clothing for U.S. and global consumption. In order to play this important role, they also consume large amounts of fuel. Looking at producing local fuel from local resources for farm consumption will ensure that farms continue to operate in an economical way, while decreasing pollution to continue conserving the environment. Throughout its history, NREL has demonstrated experience in assessing local feedstock resources, evaluating potential supply chains, performing techno-economic biofuels analysis, and exploring integration of alternative fuels into existing farm infrastructure. NREL also specializes in advanced off‐road vehicle powertrain analysis, including electrification, machine learning based hydraulic controls, and new-technology simulations for potential fuel savings. By drawing on real‐world testing and advanced simulation capabilities, NREL helps reduce emissions and operating costs without compromising the performance needed for essential farming operations.

Contact Laura Vimmerstedt to partner with NREL on AOI 6.

Workforce development programs and resources are critical to support all aspects of the electric vehicle/infrastructure lifecycle, ranging from vehicle/battery manufacturing, vehicle repair, infrastructure installation and maintenance, emergency response, and recycling used vehicle batteries. NREL draws on decades of electric vehicle research and customized technical assistance to identify and address workforce development gaps and opportunities, bridging the divide between real-world experience and applied research. Lab experts specialize in all facets of electric vehicle, battery, and infrastructure technology, and uniquely provides "boots on the ground" real-world technical assistance by partnering with Clean Cities coalitions, the Joint Office of Energy and Transportation, fleets, states, communities, manufacturers and emergency responders on EV-related challenges and workforce needs for all vehicle classes.

Contact Sarah Cardinali to partner with NREL on AOI 9.