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NASA NTRS2008

Electrocatalytic Reduction of Carbon Dioxide to Methane

A room-temperature electrocatalytic process that effects the overall chemical reaction CO2 + 2H2O yields CH4 + 2O2 has been investigated as a means of removing carbon dioxide from air and restoring oxygen to the air. The process was originally intended for use in a spacecraft life-support system, in which the methane would be vented to outer space. The process may also have potential utility in terrestrial applications in which either or both of the methane and oxygen produced might be utilized or vented to the atmosphere. A typical cell used to implement the process includes a polymer solid-electrolyte membrane, onto which are deposited cathode and anode films. The cathode film is catalytic for electrolytic reduction of CO2 at low overpotential. The anode film is typically made of platinum. When CO2 is circulated past the cathode, water is circulated past the anode, and a suitable potential is applied, the anode half-cell reaction is 4H2O yields 2O2 + 8H(+) + 8e(-). The H(+) ions travel through the membrane to the cathode, where they participate in the half-cell reaction CO2 + 8H(+) + 8e(-) yields CH4 + 2H2O.

Sammells, Anthony F.↗

NASA NTRS2005

History of the Development of Liquid-Applied Coatings for Protection of Reinforced Concrete

Corrosion of reinforcing steel in concrete is an insidious problem for structures at Kennedy Space Center (KSC). KSC is located on the coast of Florida in a highly corrosive atmosphere. Launch pads, highway bridge infrastructure, and buildings are strongly affected. To mitigate these problems, NASA initiated a development program for a Galvanic Liquid-Applied Coating System (GLACS). A breakthrough in this area would have great commercial value in transportation, marine and construction industry infrastructures. The patented NASA GLACS system has undergone considerable testing to meet the needs of commercialization. A moisture-cure coating gives excellent adhesion with ease of application compared to existing galvanic products on the market. The latest development, GalvaCori; can be sprayed or hand applied to almost any structure shape. A self-adhesive conductive tape system has been devised to simplify current collection within the coating areas. In testing programs, millivolt potential and milliamp output per square foot of anode have been closely studied at actual test sites. These two parameters are probably the most challenging items of a resin-based, room-temperature-applied, galvanic coating. Extensive re-formulation has resulted in a system that provides the needed polarization for catholic protection of reinforcing steel in concrete in a variety of structure environments. The rate of corrosion of rebar in concrete is greatly affected by the environment of the structure. In addition to this, for any given concrete structure; moisture level, carbonization, and chloride contamination influences the rate of rebar corrosion. Similarly, the cathodic protection level of galvanic systems is also dependent on the moisture level of the concrete. GalvaCorr is formulated to maintain galvanic activity as the moisture level of the structure declines. GalvaCorr is available as a three-part kit. The mixing step requires about ten minutes. The viscosity can be easily adjusted to meet the application needs. The pot or working life is four to six hours, depending on the temperature. GalvaCorr can be thought of as a spray-on coating, battery ready to provide up to -1.4 volts (relative to CSE) of cathodic protection (CP) potential.

Curran, Joseph J.↗

NASA NTRS2009

Electrolytes for Low-Temperature Operation of Li-CFx Cells

A report describes a study of electrolyte compositions selected as candidates for improving the low-temperature performances of primary electrochemical cells that contain lithium anodes and fluorinated carbonaceous (CFx) cathodes. This study complements the developments reported in Additive for Low-Temperature Operation of Li-(CF)n Cells (NPO- 43579) and Li/CFx Cells Optimized for Low-Temperature Operation (NPO- 43585), which appear elsewhere in this issue of NASA Tech Briefs. Similar to lithium-based electrolytes described in several previous NASA Tech Briefs articles, each of these electrolytes consisted of a lithium salt dissolved in a nonaqueous solvent mixture. Each such mixture consisted of two or more of the following ingredients: propylene carbonate (PC); 1,2-dimethoxyethane (DME); trifluoropropylene carbonate; bis(2,2,2-trifluoroethyl) ether; diethyl carbonate; dimethyl carbonate; and ethyl methyl carbonate. The report describes the physical and chemical principles underlying the selection of the compositions (which were not optimized) and presents results of preliminary tests made to determine effects of the compositions upon the low-temperature capabilities of Li-CFx cells, relative to a baseline composition of LiBF4 at a concentration of 1.0 M in a solvent comprising equal volume parts of PC and DME.

Smart, Marshall C.↗

NASA NTRS1993

Surface characterization of selected LDEF tray clamps

The surface characterization of chromic acid anodized 6061-T6 aluminum alloy tray clamps has shown differences in surface chemistry depending upon the position on the Long Duration Exposure Facility (LDEF). Water contact angle results showed no changes in wettability of the tray clamps. The overall surface topography of the control, trailing edge(E3) and leading edge(D9) samples was similar. The thickness of the aluminum oxide layer for all samples determined by Auger depth profiling was less than one micron. X-ray photoelectron spectroscopy (XPS) analysis of the tray clamps showed significant differences in the surface composition. Carbon and silicon containing compounds were the primary contaminants detected.

Cromer, T. F.↗

NASA NTRS1980

The kinetics of the O2/CO2 reaction in molten carbonate - Reaction orders for O2 and CO2 on NiO

The kinetics of the O2/CO2 reaction in molten carbonate is investigated using paste electrolytes and nickel sinter electrodes. A two-step approach to the determination of reaction orders is employed. First, exchange currents at various P(CO2) and P(O2) were measured using the low polarization method. Second, alpha(+) and alpha(-) values were obtained from the slope of the Allen-Hickling plot for current densities low enough so that concentration polarization within the electrode can be neglected. The reaction orders are + 1/4 in CO2 and + 5/8 in O2 in the cathodic direction, and - 3/4 in CO2 and + 1/8 in O2 in the anodic direction.

Winnick, J.↗

NASA NTRS2024

Reliable and Efficient Electrochemical Recovery of O 2 from Metabolic CO 2 at the International Space Station (ISS)

Maximum O 2 recovery from metabolic carbon dioxide (CO 2 ) is desired for future long-duration missions beyond Low Earth Orbit (LEO). The O 2 recovery for the Environmental Control and Life Support System (ECLSS) at the International Space Station (ISS), presently limited to 50% (Sabatier), must be highly reliable and efficient and recover a minimum of 75% oxygen (O 2 ) from metabolic CO 2 . An alternative technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) via a Microfluidic Electrochemical Reactor (MFECR) approach has the potential to increase O 2 recovery significantly and reduce the complexity of the ECLSS O 2 recovery at the ISS as it would replace three pieces, the CO 2 Reduction Assembly (CRA) (Sabatier reactor), the Oxygen Generation Assembly (OGA), and the Plasma Pyrolysis Assembly (PPA). The MFECR's electrochemical process generates ethylene (C 2 H 4 ) and carbon moxide (CO) instead of methane (CH 4 ) (Sabatier) as a byproduct, eliminating the need for further dehydrogenation through the PPA. As in the OGA, the MFECR's electrochemical process generates O 2 and hydrogen (H 2 ) from the water electrolysis process. MSFC and the University of Texas in Arlington (UTA) have jointly designed and fabricated an MFECR's single cell that operates at ambient conditions and utilizes a proprietary catalysis highly selective on reducing CO 2 to C 2 H 4 and CO at the cathode. This MFECR's single cell consists of gas diffusion layers at the cathode and anode for respective intake of CO 2 and output of O 2 from the catalytic layer. This approach is expected to substantially improve the ISS ECLSS sustainability and reduce power and weight requirements as the MFECR would replace three units currently installed in the ISS. In this paper, the authors discuss the outcome of preliminary tests, the current development, and the evaluation efforts on different alternatives for the cathode and the anode configurations, the setup of the MFECR at an engineering development unit (EDU) scale, and the O 2 recovery performance, and evaluation efforts on different alternatives on not only the configuration and setup of the MFECR at an Engineering Design Unit (EDU) scale but also the selection of component materials.

Jesus A Dominguez↗

NASA NTRS2005

NSTAR Extended Life Test Discharge Chamber Flake Analysis

The Extended Life Test (ELT) of the NASA Solar Electric Propulsion Technology Readiness (NSTAR) ion thruster was concluded after 30,352 hours of operation. The ELT was conducted using the Deep Space 1 (DS1) back-up flight engine, a 30 cm diameter xenon ion thruster. Post-test inspection of the ELT engine revealed numerous contaminant flakes distributed over the bottom of the cylindrical section of the anode within the discharge chamber (DC). Extensive analyses were conducted to determine the source of the particles, which is critical to the understanding of degradation mechanisms of long life ion thruster operation. Analyses included: optical microscopy (OM) and particle length histograms, field emission scanning electron microscopy (FESEM) combined with energy dispersive spectroscopy (EDS), and atomic oxygen plasma exposure tests. Analyses of the particles indicate that the majority of the DC flakes consist of a layered structure, typically with either two or three layers. The flakes comprising two layers were typically found to have a molybdenum-rich (Mo-rich) layer on one side and a carbon-rich (C-rich) layer on the other side. The flakes comprising three layers were found to be sandwich-like structures with Mo-rich exterior layers and a C-rich interior layer. The presence of the C-rich layers indicates that these particles were produced by sputter deposition build-up on a surface external to the discharge chamber from ion sputter erosion of the graphite target in the test chamber. This contaminant layer became thick enough that particles spalled off, and then were electro-statically attracted into the ion thruster interior, where they were coated with Mo from internal sputter erosion of the screen grid and cathode components. Atomic oxygen tests provided evidence that the DC chamber flakes are composed of a significant fraction of carbon. Particle size histograms further indicated that the source of the particles was spalling of carbon flakes from downstream surfaces. Analyses of flakes taken from the downstream surface of the accelerator grid provided additional supportive information. The production of the downstream carbon flakes, and hence the potential problems associated with the flake particles in the ELT ion thruster engine is a facility induced effect and would not occur in the space environment.

deGroh, Kim K.↗

NASA NTRS1985

Concentration of carbon dioxide by a high-temperature electrochemical membrane cell

The performance of a molten carbonate carbon dioxide concentrator (MCCDC) cell, as a device for removal of CO2 from manned spacecraft cabins without fuel expenditure, is investigated. The test system consists of an electrochemical cell (with an Li2CO3-38 mol pct K2CO3 membrane contained in a LiAlO2 matrix), a furnace, and a flow IR analyzer for monitoring CO2. Operation of the MCCDC-driven cell was found to be suitable for the task of CO2 removal: the cell performed at extremely low CO2 partial pressures (at or above 0.1 mm Hg); cathode CO2 efficiencies of 97 percent were achieved with 0.25 CO2 inlet concentration at 19 mA sq cm, at temperatures near 873 K. Anode concentrations of up to 5.8 percent were obtained. Simple cathode and anode performance equations applied to correlate cell performance agreed well with those measured experimentally. A flow diagram for the process is included.

Kang, M. P.↗

NASA NTRS2012

Radiation Shielding System Using a Composite of Carbon Nanotubes Loaded with Electropolymers

Single-wall carbon nanotubes (SWCNTs) coated with a hydrogen-rich, electrically conducting polymer such as polyethylene, receive and dissipate a portion of incoming radiation pulse energy to electrical signals that are transmitted along the CNT axes, and are received at energy-dissipating terminals. In this innovation, an array of highly aligned nanowires is grown using a strong electric field or another suitable orientation procedure. Polyethylene (PE), polymethymlethacrylate (PMMA), or other electrically conducting polymer is spin-coated onto the SWCNTs with an average thickness of a few hundred nanometers to a few tenths of micrometers to form a PE/SWCNT composite. Alternatively, the polymer is spin-coated onto the nanowire array or an anodized alumina membrane (AAM) to form a PE/metal core shell structure, or PE can be electropolymerized using the SWCNTs or the metal nanowires as an electrode to form a PE/SWCNT core shell structure. The core shell structures can be extruded as anisotropic fibers. A monomer can be polymerized in the presence of SWCNTs to form highly cross-linked PE/SWCNT films. Alternatively, Pb colloid solution can be impregnated into a three-dimensional PE/SWCNT nanostructure to form a PW/SWCNT/Pb composite structure. A face-centered cubic (FCC) arrangement provides up to 12 interconnection channels connected to each core, with transverse channel dimensions up to 20 nm, with adequate mechanical compressive strength, and with an associated electrical conductivity of around 3 Seimens/cm for currents ranging from 0.01 to 10 mA. This threedimensional nanostructure is used as a host material to house appropriate radiation shielding material such as hydrogen- rich polymer/CNT structures, metal nanoparticles, and nanowires. Thicknesses of this material required to attenuate 10 percent, 50 percent, and 90 percent of an incident beam (gamma, X-ray, ultraviolet, neutron, proton, and electron) at energies in the range of 0 440 MeV are being determined, for example, by measuring fluence rate reduction. For example, a radiation field arrives first at an exposed surface of the innovation and produces an associated first electric field within the metal-like fingers of the three-dimensional nanostructure. This field is intensified near the exposed tips of the fingers, and this intensified field generates an intensified second electric field near the adjacent exposed tips of the coated CNSs. This generates an associated electrical current in the CNSs, and the associated electropolymer coating. The current is received by the second substrate transport component and is transported to the dissipation mechanism located contiguously to the second substrate.

McKay, Chris↗

NASA NTRS2013

Advanced Materials and Fabrication Techniques for the Orion Attitude Control Motor

Rhenium, with its high melting temperature, excellent elevated temperature properties, and lack of a ductile-to-brittle transition temperature (DBTT), is ideally suited for the hot gas components of the ACM (Attitude Control Motor), and other high-temperature applications. However, the high cost of rhenium makes fabricating these components using conventional fabrication techniques prohibitive. Therefore, near-net-shape forming techniques were investigated for producing cost-effective rhenium and rhenium alloy components for the ACM and other propulsion applications. During this investigation, electrochemical forming (EL-Form ) techniques were evaluated for producing the hot gas components. The investigation focused on demonstrating that EL-Form processing techniques could be used to produce the ACM flow distributor. Once the EL-Form processing techniques were established, a representative rhenium flow distributor was fabricated, and samples were harvested for material properties testing at both room and elevated temperatures. As a lower cost and lighter weight alternative to an all-rhenium component, rhenium- coated graphite and carbon-carbon were also evaluated. The rhenium-coated components were thermal-cycle tested to verify that they could withstand the expected thermal loads during service. High-temperature electroforming is based on electrochemical deposition of compact layers of metals onto a mandrel of the desired shape. Mandrels used for electro-deposition of near-net shaped parts are generally fabricated from high-density graphite. The graphite mandrel is easily machined and does not react with the molten electrolyte. For near-net shape components, the inner surface of the electroformed part replicates the polished graphite mandrel. During processing, the mandrel itself becomes the cathode, and scrap or refined refractory metal is the anode. Refractory metal atoms from the anode material are ionized in the molten electrolytic solution, and are deposited onto the cathodic mandrel by electrochemical reduction. Rotation of the mandrel ensures uniform distribution of refractory material. The EL-Form process allows for manufacturing in an inert atmosphere with deposition rates from 0.0004 to 0.002 in./h (10.2 to 50.8 m/h). Thicknesses typically range from microns to greater than 0.5 in. (13 mm). The refractory component produced is fabricated, dependably, to within one micron of the desired tolerances with no shrinkage or distortion as in other refractory metal manufacture techniques. The electroforming process has been used to produce solid, nonporous deposits of rhenium, iridium, niobium, tungsten, and their alloys.

Gorti, Sridhar↗

NASA NTRS1974

Analysis for Mar Vel Black and acetylene soot low reflectivity surfaces for star tracker sunshade applications

Mar Vel Black is a revolutionary new extremely low reflectivity anodized coating developed by Martin Marietta of Denver. It is of great interest in optics in general, and in star trackers specifically because it can reduce extraneous light reflections. A sample of Mar Vel Black was evaluated. Mar Vel Black looks much like a super black surface with many small peaks and very steep sides so that any light incident upon the surface will tend to reflect many times before exiting that surface. Even a high reflectivity surface would thus appear to have a very low reflectivity under such conditions. Conversely, acetylene soot does not have the magnified surface appearance of a super black surface. Its performance is, however, predictable from the surface structure, considering the known configuration of virtually pure carbon.

Yung, E.↗

NASA NTRS2023

Development of an Efficient Alternative to Recovery O2 From Metabolic CO2 Via Electrolysis Operated at Ambient Temperature and Driven By A Highly Selective Catalysis

The current State of Art (SOA) on oxygen recovery onboard the Environmental Control and Life Support System (ECLSS) at the International Space Station (ISS) is complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O 2 ) from metabolic carbon dioxide (CO 2 ). For future long duration beyond low earth orbit missions (LEO), O 2 recovery systems will need to be highly reliable, efficient, and recover a minimum of 75% O 2 from metabolic CO 2 . An alternative technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) has the potential to significantly increase O 2 recovery currently limited to 50% (Sabatier) and reduce the complexity of ECLSS O 2 recovery. MSFC and University of Texas in Arlington (UTA) have jointly designed and fabricated a microfluid electrochemical reactor (MFECR) that operates at ambient conditions and utilizes a proprietary catalysis highly selective on reducing CO 2 to ethylene (C 2 H 4 ) at the cathode while O 2 is generated at the anode. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current CO 2 Reduction Assembly (CRA) (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly (OGA). It is designed to interface directly with the CO 2 Removal Assembly (CDRA) and the Water Processing Assembly (WPA) to supply CO 2 reactant and water replenish respectively. This is expected to substantially improve sustainability of the ISS ECLSS and reduce requirement on power and weight. Here, we discuss the current development and evaluation efforts on different alternatives on not only the configuration and setup of the MFECR at an Engineering Design Unit (EDU) scale but also the selection of component materials.

Jesus A Dominguez↗

NASA NTRS2012

Development of a Robust, High Current, Low Power Field Emission Electron Gun for a Spaceflight Reflectron Time-of-Flight Mass Spectrometer

Carbon materials, including carbon nanotubes (CNTs) and nitrogen-incorporated ultrananocrystalline diamond (N-UNCD), have been of considerable interest for field emission applications for over a decade. In particular, robust field emission materials are compelling for space applications due to the low power consumption and potential for miniaturization. A reflectron time-of-flight mass spectrometer (TOF-MS) under development for in situ measurements on the Moon and other Solar System bodies uses a field emitter to generate ions from gaseous samples, using electron ionization. For these unusual environments, robustness, reliability, and long life are of paramount importance, and to this end, we have explored the field emission properties and lifetime of carbon nanotubes and nitrogen-incorporated ultrananocrystalline diamond (N-UNCD) thin films, the latter developed and patented by Argonne National Laboratory. We will present recent investigations of N-UNCD as a robust field emitter, revealing that this material offers stable performance in high vacuum for up to 1000 hours with threshold voltage for emission of about 3-4 V/lJm and current densities in the range of tens of microA. Optimizing the mass resolution and sensitivity of such a mass spectrometer has also been enabled by a parallel effort to scale up a CNT emitter to an array measuring 2 mm x 40 mm. Through simulation and experiment of the new extended format emitter, we have determined that focusing the electron beam is limited due to the angular spread of the emitted electrons. This dispersion effect can be reduced through modification of the electron gun geometry, but this reduces the current reaching the ionization region. By increasing the transmission efficiency of the electron beam to the anode, we have increased the anode current by two orders of magnitude to realize a corresponding enhancement in instrument sensitivity, at a moderate cost to mass resolution. We will report recent experimental and modeling results to describe the performance of a field emission electron gun as employed in the Volatile Analysis by Pyrolysis of Regolith (VAPoR) TOF-MS prototype.

Southard, Adrian E.↗

NASA NTRS1993

Low-gravity electrodeposition and growth of polymer thin films with large third-order optical nonlinearities by electrochemical processes for devices: Thiophene-based polymers

It has been proposed that NLO thin film properties may be improved by low-gravity processing. Strong candidates for NLO thin film applications are the polythiophenes. Polymeric thiophenes are attractive materials due to their ease of preparation, stability, and high X(exp 3). A simple and convenient method for preparation of polythiophenes is electrochemical oxidation. We will apply some of our experience and lessons learned in low-gravity metal, metal/cermet electrode position to improve the quality of polythiophene(s) thin films. In low gravity electrode position of Ni at a high rate on an Au substrate often results in the production of an x-ray non diffracting surface. Cobalt metal deposition does not give this result nor does Ni when deposited similarly on a glassy carbon substrate. Co/Ni alloy composition produced during electrode position is strongly dependent upon the amount of convection. Code position of neutral inert cermets with metals is influenced significantly by the presence of gravity and the size of the cermets. Tracks left in the 1-g surfaces by unsuccessful particle occlusion indicate suspension of the large particles is not the only reason for poor volume percentages of the larger particles in the deposits. All size particles are more homogeneously distributed in the deposits in low-gravity electrocodeposition than in 1-g. Low gravity gives larger volume percentages for the larger particles in the deposits, while 1-g gives larger volume percentages for the smaller particles. Intermediate size particles give mixed results. The experimental cells were constructed with flat electrode end plates such that 1-g bench reference electrode positions could be carried out at various orientations with respect to gravity. A series of bench studies using similar designed cells are suggested so that convection modification can be applied to electrochemical thin film preparation. Convection effects can then be coupled with other parameter variations in current, temperature, concentration, solvent, electrolyte, and anode substrates to optimize the properties of NLO thin films before resorting to low-gravity processing.

Penn, Benjamin G.↗

NASA NTRS1992

Scanning electron microscope/energy dispersive x ray analysis of impact residues on LDEF tray clamps

To better understand the nature of particulates in low-Earth orbit (LEO), and their effects on spacecraft hardware, we are analyzing residues found in impacts on the Long Duration Exposure Facility (LDEF) tray clamps. LDEF experiment trays were held in place by 6 to 8 chromic-anodized aluminum (6061-T6) clamps that were fastened to the spacecraft frame using three stainless steel hex bolts. Each clamp exposed an area of approximately 58 sq cm (4.8 cm x 12.7 cm x .45 cm, minus the bolt coverage). Some 337 out of 774 LDEF tray clamps were archived at JSC and are available through the Meteoroid & Debris Special Investigation Group (M&D SIG). Optical scanning of clamps, starting with Bay/Row A01 and working toward H25, is being conducted at JSC to locate and document impacts as small as 40 microns. These impacts are then inspected by Scanning Electron Microscopy/Energy Dispersive X-ray Analysis (SEM/EDXA) to select those features which contain appreciable impact residue material. Based upon the composition of projectile remnants, and using criteria developed at JSC, we have made a preliminary discrimination between micrometeoroid and space debris residue-containing impact features. Presently, 13 impacts containing significant amounts of unmelted and semi-melted micrometeoritic residues were forwarded to Centre National d'Etudes Spatiales (CNES) in France. At the CNES facilities, the upgraded impacts were analyzed using a JEOL T330A SEM equipped with a NORAN Instruments, Voyager X-ray Analyzer. All residues were quantitatively characterized by composition (including oxygen and carbon) to help understand interplanetary dust as possibly being derived from comets and asteroids.

Bernhard, Ronald P.↗

NASA NTRS2001

A Survey of Alternative Oxygen Production Technologies

Utilization of the Martian atmosphere for the production of fuel and oxygen has been extensively studied. The baseline fuel production process is a Sabatier reactor, which produces methane and water from carbon dioxide and hydrogen. The oxygen produced from the electrolysis of the water is only half of that needed for methane-based rocket propellant, and additional oxygen is needed for breathing air, fuel cells and other energy sources. Zirconia electrolysis cells for the direct reduction of CO2 arc being developed as an alternative means of producing oxygen, but present many challenges for a large-scale oxygen production system. The very high operating temperatures and fragile nature of the cells coupled with fairly high operating voltages leave room for improvement. This paper will survey alternative oxygen production technologies, present data on operating characteristics, materials of construction, and some preliminary laboratory results on attempts to implement each. Our goal is to significantly improve upon the characteristics of proposed zirconia cells for oxygen production. To achieve that goal we are looking at electrolytic systems that operate at significantly lower temperatures, preferably below 31C to allow the incorporation of liquid CO2 in the electrolyte. Our preliminary results indicate that such a system will have much higher current densities and have simpler cathode construction than a porous gas feed electrode system. Such a system could be achieved based on nonaqueous electrolytes or ionic liquids. We are focusing our research on the anode reaction that will produce oxygen from a product generated at the cathode using CO2 as the feed. Operation at low temperatures also will open up the full range of polymer and metal materials, allowing a more robust system design to withstand the rigors of flight, landing, and long term unattended operation on the surface of Mars.

Lueck, Dale E.↗

NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety for Electric Aircraft

All electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The most challenging of these technical barriers to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL craft are at least 2 times greater than those of electric automobiles. Furthermore, safety is essential for operation of commercial electric aerovehicles. Preliminary systems level analysis has indicated that there are five key properties which must be optimized for successful implementation of battery systems. Those five key criteria are: safety, energy density, power, packaging design and scalability. Current state-of-the-art (SOA) lithium-ion batteries meet or exceed the requirements for electric aviation in the areas of power and scalability, yet are insufficient in the key performance criteria of energy, safety and packaging design. The SABERS concept proposes a battery that meets all five key performance criteria through development of a solid-state architecture battery utilizing high energy density and power density sulfur-selenium cathode with a lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This cathode will be developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur-selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, reducing the amount of interfaced connections for the cell, and minimizing the cooling requirements for the cell. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures from 0 °C to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace performance criteria. This presentation will show initial results that demonstrate the SABERS Team has developed a composite carbon-sulfur cathode which exceeds 1100 Wh/kg at a discharge rate of 0.4C, and 804 Wh/kg at a discharge rate of 1C. Additionally, this presentation will show the SABERS Team multiscale computational modeling approach and has produced a novel particle dynamics method called Solid Electrolyte Sphere Approximation Model (SESAM). SESAM is on the 1-10 µm scale and provides electromechanical and grain interactions for predictive design guidelines for the experimental team to follow.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Computational Modeling Development of Solid-state Architecture Batteries for Enhanced Rechargeability and Safety for Electric Aircraft

Urban Air Mobility (UAM) Vehicles↗