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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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The design, performance and safety of a fully engineered, selfcontained Li/SOCl2 battery as the power source for underwater applications. In addition to meeting the performance standards of the end user this battery is successfully tested under the rigorous safety conditions of NAVSEA Instruction 9310.1A for use on land, aircraft and surface ships.
A high rate active Li/SOCl2 cell was designed for use in a 28 volt, 250 amp-hour space battery system. The lithium battery is being considered as a replacement of its heavier silver-zinc counterpart on board the Centaur-G booster rocket which is used to launch payloads from the Space Shuttle cargo bay into deep-space. Basically a feasibility study, this development effort is demonstrating the ability of the lithium cell to deliver up to 90 amps safely at power densities of approximately 25 watts per pound. Test data on 4 prototype units is showing an energy density of 85 watt-hours per pound and 9.0 watt-hours/cu in. The cells tested typically delivered 280 to 300 amp-hours under ambient temperature test conditions using alternating continuous loads of 90, 55, and 20 amperes throughout life. Data from four cells tested are presented to demonstrate the capability of Li/SOCl2 technology for a C/3 discharge rate in active and hermetic cell units.
New NASA requirements for the screening of lithium cells for space applications involve thermal soaks at elevated temperatures (149 C). The currently qualified Li/BCX cells and three design modifications have been evaluated showing that a design incorporating a shortened electrode stack met this test condition while continuing to satisfy the performance and safety requirements for cells used on NASA manned space vehicles. Information was also developed to show that measured heat capacities for the BCX D size cells correlated well with the heat generated from cells discharged in an insulated environment. Calculated heat capacities based on the amounts and types of materials in a cell were low compared to these values. This information provides the basis for the design of battery packs in the highly insulating environment of outer space.
New NASA requirements for the screening of lithium cells for space applications involve thermal soaks at elevated temperatures (149 C). The BCX DD and C size cells have been redesigned to pass this test with only marginal losses in capacity as was done previously for the D cells. In addition, the pressure increases in cells subjected to this high temperature environment have been characterized showing that the earlier designs failed this exposure due to lack of void volume. An improve BCX chemistry has been demonstrated which significantly improves voltage delay problems encountered after partial discharge and storage of the cells.
As part of the NASA contingency planning related to aborting a launch after liftoff, an emergency radio is required for use by the crew when they return to Earth at some unplanned location. The power source for the radio must be able to satisfy the performance requirements for the radio's mission as well as be compatible with in-cabin storage in the space shuttle. The radio needs a base load power of about 1 W with capability to handle power spikes greater then 6.5 W. A slightly enlarged battery pack using the Li/BCX chemistry in C-size cells was developed that meets these power levels and extends the operational life of the radio by over a factor of four compared to its operation using a Li/SO2 cell battery pack. In addition, the cells meet the requirements for the Li/BCX cells used for extra-vehicular activities by the crew of the shuttle. One of the major qualifying tests is the ability of the cells to withstand exposure to high temperature (149 C) without leaking. Electrical performance and thermal abuse test data will be presented for the cells.
A discussion of the power requirements for the Mars Pathfinder Mission is given. Topics include: battery requirements; cell design; battery design; test descriptions and results. A summary of the results is also included.
Most cells survived the 3 amp (A) over-discharge at room temperature for 2 hours. The cell that failed was the LTC-114 after high rate discharge of 500 mA similar to the results of the 1 A over-discharge test. Most cells opened during 0.05 Ohm short circuit test without incident but three LTC-111 cells exploded apparently due to a lack of a thermal cutoff switch. The LTC-114 cells exposed to a hard short of 0.05 Ohms recovered but the LTC-114 cells exposed to a soft short of 1 Ohm did not. This is probably due to the activation of a resetable fuse during a hard short. Fresh cells tend to survive exposure to higher temperatures than cells previously discharged at high rate (1 Amp). LTC-111 cells tend to vent at lower temperatures than the all LTC-114 cells and the LTC-115 cells that were previously discharged at rates exceeding 1 Amp.
This project is divided into four main tasks: cell manufacture, acceptance, and lot certification of cells, performance testing of cells, and abuse testing of cells. Lithium/bromine chloride in thionyl chloride (Li/BCX) 149 DD cells (PN 3B2085-XA) were built according to the provisions of Electrochem Industries Quality Plan 17096. Acceptance and lot certification testing was performed according to NASA JSC Document EP5-83-025, Revision B. Acceptance testing included open circuit and load voltage check, visual examination, size and weight measurements, and high temperature exposure. Lot certification tests were performed for capacity performance and for performance under conditions of thermal and electrical abuse. These tests included 149 C exposure, capacity discharge, fuse check, high temperature exposure, high rate discharge, short circuit, vibration, and overdischarge testing. A quantity of 200 cells was delivered to Johnson Space Center for life test evaluation. A parametric evaluation of the capacity discharge of Li/BCX DD cells was performed over a variety of temperatures and discharge rates. This testing served to map the performance capability of the cell. Tests were also performed over a variety of electrical and thermal abuse conditions. Abuse tests included short circuit, charging, overdischarge, high temperature exposure, shock, and vibration.
Li/BCX (bromine chloride in thionyl chloride) primary cells have been qualified for flight aboard the space shuttle for over fifteen years. These cells provide high energy density while maintaining an excellent safety record. Recently, changes to the electrolyte have resulted in an improved Li/BCX II system with a lower self-discharge rate. The use of low molarity electrolytes in programs unique to NASA have improved the safety hazards tolerance of these cells while maintaining or increasing their energy density.
An analysis was made of wiper samples used to wipe down lithium/chlorine fluorine battery components and production equipment. These components and equipment were potentially exposed to thionyl chloride vapors. In the presence of moisture, thionyl chloride decomposes to sulfur dioxide and hydrogen chloride. The wiper samples were analyzed for soluble chlorides and fluorides by anion exchange chromatography. During the examination of the test chromatographs, fluoride contamination was discovered in wiper samples from the test equipment. An analytical method to determine fluoride was developed. The first 3 extracts from the potentially exposed and clean wiper samples were tested, and the total fluoride from both groups determined. A comparison of the results from both groups was made to determine the extent of fluoride contamination.
A 250 Ah lithium thionyl chloride battery is being developed for a booster rocket engine. Extensive cell testing is running to evaluate functional and safety performances. Some results are presented. The lithium/thionyl chloride batteries were selected for their high energy density (low weight) as compared to other sources. The temperature of a lower weight item will be more sensitive to variations of internal and external heat fluxes than a heavier one. The use of high energy density L/TC batteries is subjected to stringent thermal environments to have benefit of energy density and to stay safe in any conditions. The battery thermal environment and discharge rate have to be adjusted to obtain the right temperature range at cell level, to have the maximum performances. Voltage and capacity are very sensitive to temperature. This temperature is the cell internal actual temperature during discharge. This temperature is directed by external thermal environment and by cell internal heat dissipation, i.e., cell actual voltage.
An active thionyl chloride high rate battery is under development for spacecraft operations. It is a 540kC (150 Ah) battery capable of pulses up to 75A. This paper describes the design and initial test data on a 'state-of-the-art' cell that has been selected to be the baseline for the prototype cell for that battery. Initial data indicate that the specification can be met with fresh cells. Data for stored cells and additional environmental test data are in the process of being developed.
An analysis was made of Lithium/carbon fluoride cell parts for possible chloride contamination induced by exposure to thionyl chloride (SOCl2); various samples were submitted for analysis. Only a portion of the analysis which has been conducted is covered, herein, namely analysis by scanning electron microscopy with energy dispersive x ray spectrometry (SEM/EDS). A strip of nickel was exposed to SOCl2 vapors to observe variations in surface concentrations of sulfur and chlorine with time. By detecting chlorine one can not infer contamination by SOCl2 only that contamination is present. Six samples of stainless steel foil were analyzed for chlorine using EDS. Chlorine was not detected on background samples but was detected on the samples which had been handled including those which had been cleaned. Cell covers suspected of being contaminated while in storage and covers which were not exposed to the same storage conditions were analyzed for chlorine. Although no chlorine was found on the covers from cells, it was found on all stored covers. Results are presented with techniques shown for analysis and identification. Relevant photomicrographs are presented.
Heat flow measurements of 25-Ah lithium thionyl chloride cells provided a method to calculate an effective thermal potential, E(TP) of 3.907 V. The calculation is useful to determine specific heat generation of this cell chemistry and design. The E(TP) value includes heat generation by electrochemical cell reactions, competitive chemical reactions, and resistance heating at the tabs, connectors, and leads. Heat flow was measured while applying electrical loads to the cell in an isothermal calorimeter set at 0, 20, and 60 C.
A 1-D math model for the lithium/thionyl chloride primary cell is used in conjunction with a parameter estimation technique in order to estimate the electro-kinetic parameters of this electrochemical system. The electro-kinetic parameters include the anodic transfer coefficient and exchange current density of the lithium oxidation, alpha sub a,1 and i sub o,i,ref, the cathodic transfer coefficient and the effective exchange current density of the thionyl chloride reduction, alpha sub c,2 and a sup o i sub o,2,ref, and a morphology parameter, Xi. The parameter estimation is performed on simulated data first in order to gain confidence in the method. Data, reported in the literature, for a high rate discharge of an experimental lithium/thionyl chloride cell is used for an analysis.
A lithium-chlorine rechargeable battery is considered along with an FeS electrode development for a secondary Li5Si-FeS battery, the sodium-sulfur battery, nickel battery systems for electric vehicles, reactions in lithium thionyl chloride cells, progress in the development of lithium inorganic batteries, a stable electrolyte for Li/SO2 reserve cells, and rechargeable lithium transition metal sulfide batteries. Attention is also given to thermal runaway tests on nickel-cadmium aircraft batteries, the development of nickel-zinc batteries for aircraft, an evaluation of sealed lead acid batteries for aircraft applications, the charging of sealed lead-acid batteries, hydrogen recombination in sealed nickel-cadmium cells, the characteristics of nickel-hydrogen flight cells, the lithium-iodine cell, low power methanol fuel cells, and a nuclear battery hybrid configuration study.
A series of abuse tests on large lithium thionyl chloride cells was initiated. Performance data obtained in testing rectangular 2,000 and 10,000 ampere-hour cells are discussed and graphically presented.
A general overview of activities involving lithium batteries, which shows the various applications and data that were performed for numerous industry and government sponsors is presented. Brief discussions on electrochemical criteria selection, and typical storage and performance data obtained from three systems being developed are presented. Current safety work being done on high-rate, D, SO2 cells is also discussed. Three chemistries were developed and are discussed: lithium vanadium pentoxide, lithium sulfur dioxide, and lithium thionyl chloride. Storage, performance and safety data are graphically presented.