Mechanistic Determination of the Electrochemical and Thermomechanical Effects of Freeze-Thaw Cycles on Li-ion Batteries

Electrochemical and thermomechanical phenomena in lithium-ion batteries are of critical importance to NASA and others because of their influence on operational characteristics and safety, especially in extreme thermal conditions (e.g., extreme cold). Specifically, the role of time-varying thermal conditions—some so severe they subject the electrolyte to freeze-thaw cycles—on Li-ion characteristics is of interest to NASA because they are often encountered in lunar/Martian platforms. However, the underlying electrochemical and thermomechanical mechanisms of battery degradation and failure during such freeze-thaw cycles remain unknown. The goal of this project is to identify and quantify the electrochemical and thermomechanical effects and underlying mechanisms for Li-ion cells subjected to freeze-thaw cycles encountered by lunar/Martian spacecraft, and establish the first shared research-scale pilot battery fabrication and testing facility within the Iowa NASA EPSCoR (INE) jurisdiction. We will attain this goal by quantifying the cell-level effects of thermal/freeze-thaw cycles on Li-ion batteries (Objective 1), determining the corresponding subcell-level mechanisms (Objective 2), and establishing a state-of-the-art battery fabrication and testing facility that is available to scientists and engineers within the INE jurisdiction. To accomplish Objective 1, we will diagnose the failure and degradation of Li-ion batteries exposed to different (constant) temperatures (Task 1.1), during and after thermal and/or freeze-thaw cycling (Tasks 1.2 and 1.3), under ultra-high vacuum conditions (Task 1.4), and using accelerating rate calorimetry (Task 1.5). Objective 2 will be focused on understanding the mechanistic origins of degradation and failure on electrodes, electrolytes, and interfaces within the battery using in-operando analysis (Task 2.1), in-situ studies (Task 2.2), accelerating rate calorimetry (Task 2.3), and ex-situ characterization techniques (Task 2.4). This will provide a comprehensive understanding of battery performance and safety and its mechanistic origins under thermal conditions related to those in lunar/Martian platforms. Finally, Objective 3 will be realized by procuring new and consolidating existing battery fabrication and testing equipment into a state-of-the-art shared battery facility at Iowa State University (Task 3.1) and providing scientists and engineers across the INE jurisdiction with shared access to the battery facility (Task 3.2). Upon completion of the proposed work, we will have, for the first time, a first-principles understanding and quantitative link between the electrochemical and thermomechanical effects of subjecting Li-ion batteries to thermal/freeze-thaw cycles and the mechanistic underpinnings. Moreover, we will have established the first shared research-scale pilot battery fabrication and testing facility within the INE jurisdiction that is open to all INE scientists and engineers. These contributions will be significant for several reasons. First, they will have a significant impact and dramatic improvements on current and future NASA missions—specifically spacecraft and power hibernation technologies—and several of NASA’s Mission Directorates (e.g., STMD, SMD, and ESDMD). Moreover, they will significantly impact the state of Iowa by providing INE battery researchers with the critical infrastructure needed for Li-ion battery fabrication and subsequent testing and a platform for interdisciplinary collaborations.

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