Standards Pave the Road for Electric Vehicle Resilience
In the iconic Rocky film series, the titular underdog faces a succession of formidable opponents—Apollo Creed, Clubber Lang, Ivan Drago—each representing a new challenge on the path to victory. What defines Rocky Balboa is not invincibility, but perseverance: the ability to endure, adapt, and ultimately prevail against mounting odds. Today, the electric vehicle (EV) industry finds itself in a similar arena, battling consumer skepticism, technological limitations, and infrastructure gaps. Yet, much like the fictional boxer, the EV sector is proving resilient, driven forward by innovation and, increasingly, by the quiet but critical force of standardization.
The parallels between Rocky’s journey and the evolution of electric mobility are more than metaphorical. Both require endurance, strategic preparation, and the right support system to succeed. For EVs, one of the most crucial elements in that support system is the development of rigorous technical standards—particularly in areas that directly impact performance, safety, and consumer confidence. Among the most impactful efforts in this domain are the recent advancements led by ASTM International’s Engine Coolants Committee (D15), whose work is helping to address two of the most persistent barriers to EV adoption: range anxiety and inadequate charging infrastructure.
According to data from the International Council on Clean Transportation, over 1.4 million electric vehicles were sold in the United States in 2023. Projections from the National Renewable Energy Laboratory suggest that by 2030, that number could swell to 33 million EVs on American roads. These figures reflect a clear upward trajectory, signaling strong market momentum and growing consumer interest. However, beneath the surface of this growth lies a persistent hesitation. A 2023 survey by the American Automobile Association revealed that 53% of respondents cited range anxiety as a primary concern when considering an EV purchase, while 56% pointed to the lack of accessible charging stations as a major deterrent.
These concerns are not unfounded. While the average EV range reached approximately 270 miles on a single charge in 2023, real-world performance often falls short of laboratory estimates, particularly under extreme environmental conditions. As Tom White, former senior policy analyst at the U.S. Department of Energy, explains, “The performance of lithium-ion batteries—the heart of most electric vehicles—is highly sensitive to temperature. When ambient conditions deviate from the optimal range, efficiency drops, and so does driving range.”
This is where thermal management becomes a decisive factor. Unlike internal combustion engines, which generate heat as a byproduct of fuel combustion, electric vehicles rely on complex battery systems that must be kept within a narrow thermal window to operate efficiently. According to Dynamic Manufacturing, a leading supplier of automotive components, lithium-ion batteries perform best when ambient temperatures range between 68°F and 86°F (20°C to 30°C). Beyond this range, performance degrades significantly. At temperatures exceeding 90°F (32°C), range can decrease by 2% to 5%. When temperatures climb to 95°F (35°C) or higher, the reduction can reach 20% to 30%, effectively cutting a 300-mile range vehicle down to just over 200 miles.
The implications are profound. In regions with hot climates—such as the American Southwest or the Gulf Coast—this thermal degradation can severely limit the practicality of EV ownership, especially for long-distance travel. Similarly, in colder climates, battery efficiency drops due to increased internal resistance, further compounding range concerns. The result is a consumer experience that feels unpredictable and unreliable, undermining trust in the technology.
To combat this, automakers have invested heavily in thermal management systems, including liquid cooling circuits that regulate battery temperature. However, the effectiveness of these systems depends not only on design but also on the quality and compatibility of the coolant used. Until recently, there were no universally accepted standards governing the formulation, performance, or safety of coolants specifically designed for electric vehicles. This lack of standardization created inconsistencies across manufacturers, potential compatibility issues, and uncertainty for both consumers and service providers.
Recognizing this gap, ASTM International’s D15 Committee has taken a leading role in establishing a new framework for EV coolant specifications. In a significant step forward, the committee has published two new standards—D8565 and D8566—and is currently developing two additional ones, designated WK80854 and WK87295. These standards are not merely technical documents; they represent a foundational shift in how the industry approaches thermal management in electric mobility.
Standard D8565, titled Standard Specification for Glycol-Based Engine Coolant for Fuel Cell Electric Vehicles (FCEVs), sets performance and safety benchmarks for coolants used in fuel cell systems. It specifically addresses the unique requirements of fuel cell stacks, which are highly sensitive to contaminants and require coolants with low electrical conductivity to prevent short circuits and corrosion. By defining acceptable levels of conductivity, pH stability, and material compatibility, D8565 ensures that coolants used in FCEVs do not compromise the integrity of the fuel cell stack, thereby enhancing both durability and efficiency.
Complementing this is D8566, the Standard Specification for Low Electrical Conductivity Glycol-Based Engine Coolant for Electric Vehicles. This standard targets battery electric vehicles (BEVs) and focuses on minimizing the risk of electrical leakage when coolant comes into contact with high-voltage battery components. In many EV designs, the cooling system runs in close proximity to, or even directly through, the battery pack. If the coolant has high electrical conductivity, it can create a conductive path, leading to short circuits, thermal runaway, or even catastrophic failure. D8566 establishes strict limits on conductivity—typically below 10 microsiemens per centimeter—ensuring that the coolant acts as an insulator rather than a conductor.
“These standards are not just about performance—they’re about safety and reliability,” says Allan Morrison, a voting member of the D15.26 subcommittee on engine coolant performance. “When you’re dealing with high-voltage systems, even a small oversight in coolant selection can have serious consequences. These specifications give manufacturers, service technicians, and consumers a clear benchmark for what constitutes a safe and effective coolant.”
Beyond immediate safety, these standards also contribute to long-term vehicle performance. Coolants that meet D8565 and D8566 are engineered to resist thermal degradation, maintain chemical stability over time, and prevent the formation of deposits that can clog cooling channels. This means more consistent heat transfer, reduced thermal stress on batteries, and ultimately, better range retention over the vehicle’s lifespan.
But the committee’s work does not stop there. The two draft standards currently under development—WK80854 (Standard Specification for Anhydrous, Non-Electrolytic Engine Coolant for Electric Vehicles) and WK87295 (Standard Specification for Anhydrous Engine Coolant for Electric Vehicles)—point to the next frontier in EV thermal management: waterless cooling systems.
Traditional coolants are glycol-water mixtures, typically in a 50/50 ratio. While effective, water introduces several challenges. It has a relatively narrow liquid range (freezing at 32°F and boiling at 212°F), requires additives to prevent corrosion, and, critically, conducts electricity. In contrast, anhydrous (water-free) coolants eliminate these drawbacks. They operate over a wider temperature range, do not require anti-corrosion inhibitors, and, when formulated correctly, exhibit negligible electrical conductivity.
WK80854 and WK87295 aim to define the performance criteria for these next-generation fluids, including thermal stability, viscosity, material compatibility, and electrical insulation properties. If successfully implemented, these standards could enable the development of more compact, efficient, and safer cooling systems—particularly for high-performance EVs and heavy-duty applications where thermal loads are extreme.
The broader impact of these standards extends beyond individual vehicles. By creating a common technical language, they facilitate interoperability across the automotive supply chain. Manufacturers can design cooling systems with confidence, knowing that compliant coolants will be available. Service centers can stock standardized fluids, reducing the risk of misapplication. Consumers can make informed choices, trusting that the coolant used in their vehicle meets rigorous, independently verified criteria.
Moreover, standardization plays a critical role in scaling the EV ecosystem. As the number of electric vehicles grows, so too does the demand for maintenance, repair, and recycling infrastructure. Standardized coolants simplify training for technicians, streamline diagnostic procedures, and support the development of automated service equipment. They also aid in end-of-life processing, where proper handling of coolant is essential to prevent environmental contamination.
From an environmental perspective, these advancements align with broader sustainability goals. Improved thermal management leads to more efficient battery operation, which in turn reduces energy consumption and extends battery life. Longer-lasting batteries mean fewer replacements, less mining of raw materials, and lower overall carbon emissions. Additionally, by enabling vehicles to maintain optimal performance across a wider range of climates, standardized coolants reduce the need for excessive charging or range-reducing behaviors, further enhancing energy efficiency.
Tom White emphasizes that the development of such standards is not a one-time achievement but an ongoing process. “Many of our goals have been met, but not all,” he notes. “The importance of research and standards—like those from ASTM—cannot be overstated. They are the bridge between innovation and real-world impact, ensuring that new technologies deliver on their economic and environmental promises.”
The role of ASTM International in this process underscores the value of collaborative, consensus-driven standardization. The D15 Committee brings together stakeholders from across the automotive industry—manufacturers, fluid suppliers, testing laboratories, regulatory agencies, and independent experts—to develop specifications that reflect both current needs and future trends. This inclusive approach ensures that standards are technically sound, commercially viable, and adaptable to emerging technologies.
Looking ahead, the committee plans to continue its work in several key areas, including the evaluation of coolant performance in hybrid systems, the impact of coolant aging on long-term vehicle reliability, and the development of test methods for emerging cooling technologies such as phase-change materials and direct battery immersion cooling. These efforts will be critical as the industry moves toward more integrated and efficient thermal management architectures.
In many ways, the story of EV coolant standardization mirrors the larger narrative of electric mobility itself: a journey marked by challenges, innovation, and gradual but steady progress. Just as Rocky Balboa did not win every fight but earned respect through perseverance, the EV industry is building credibility not through perfection, but through continuous improvement. Standards like D8565, D8566, and the upcoming anhydrous coolant specifications are not flashy headlines—they are the behind-the-scenes enablers that make the technology more reliable, safer, and ultimately, more accessible.
For consumers, the benefits are tangible. A vehicle with a well-regulated battery temperature will deliver more consistent range, require fewer unscheduled repairs, and provide a more predictable ownership experience. For automakers, standardized coolants reduce engineering complexity, lower warranty risks, and enhance brand reputation. For society, the ripple effects include reduced greenhouse gas emissions, decreased dependence on fossil fuels, and a more resilient transportation system.
As the EV market matures, the importance of such foundational work will only grow. The race is no longer just about who can build the fastest or longest-range vehicle; it is about who can deliver the most dependable, sustainable, and user-friendly experience. In this race, standards are not a finish line—they are the track itself.
The road to widespread EV adoption remains challenging, but with each new standard, the path becomes clearer. Like Rocky, the electric vehicle industry is learning to take the hits, adapt, and keep moving forward. And just as the fictional champion found victory not in a single knockout, but in enduring to the final bell, the real triumph of electric mobility will be measured not by a moment of glory, but by the sustained success of millions of vehicles on the road—powered by innovation, guided by standards, and trusted by drivers everywhere.
John Peterson
Senior Automotive Analyst
Journal of Sustainable Mobility
DOI: 10.1016/j.jsm.2025.04.003