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NASA NTRS2019

Hazardous Product Detection and Environmental Clean-up Removal in Spacecraft Vehicles from Fire Induced Li-Ion Fires

A fire on-board the International Space Station (ISS) resulting from a commercial Surface Pro tablet Lithium-Ion (Li-ion) battery can be detrimental to the spacercraft and the astronauts. The Spacecraft Fire Safety Demonstration (Saffire) program is focused on identifying and quantifying the risks that potentially arise inside a space vehicle by conducting large fire experiments inside the Cygnus cargo vehicle upon re-entry to Earth. The potential candidate that will be flown on the ISS is a 4- cell Li-ion battery pack Surface Pro tablet (42 Wh). The tablets were tested at the White Sands Test Facility (WSTF) using a localized heating method to emulate the failing mechanism that leads the unit into thermal runaway. Measurements inside the test chamber were performed on aerosol mass concentrations and for specific toxic products (i.e. from CO, HCN, HCl and CO2). These toxic products depend on the size of the fire and energy content of the tablet. Comparisons will be made with the Dell XPS (97 Wh). The concentrations are then used to extrapolate to laptop fires on a vehicle at the approximate volumetric size of the Orion spacecraft. The presentation provides an analysis on the detection capability and the response time to trigger fire alarms aboard a vehicle by using the mass concentration levels. These results will consider the rate at which the life support system is able to filter the atmosphere in order to provide a hazardous free environment.

Padilla, Rosa E.↗

NASA NTRS1972

Operation and maintenance, fire rescue air-pack. Volume 2: Communications

The operation and maintenance procedures are described for the development model of the fire rescue air pack (FRAP) voice amplifier assembly, including the battery charger. Operational instructions include a general description of the assembly, specifications, and installation and operation. Maintenance instructions include theory of operation, preventive maintenance, repair, adjustment, and a parts list. The FRAP is intended to permit fire rescue personnel to enter a smoke-filled, toxic or oxygen depleted environment carrying their own source of breathing air. The voice amplifier assembly permits the wearer to communicate by voice with other persons in the vicinity. The battery charger assembly provides a means of keeping the amplifier batteries fully charged.

Source record↗

NASA NTRS2016

Evaluation of Containment Boxes as a Fire Mitigation Method in Elevated Oxygen Conditions

NASA performed testing to evaluate the efficacy of fire containment boxes without forced ventilation. Configurational flammability testing was performed on a simulation avionics box replicating critical design features and filled with materials possessing representative flammability characteristics. This paper discusses the box's ability, under simulated end-use conditions, to inhibit the propagation of combustion to surrounding materials. Analysis was also performed to evaluate the potential for the fire containment box to serve as an overheat/ignition source to temperature sensitive equipment (such as items with lithium-ion batteries). Unrealistically severe combustion scenarios were used as a means to better understand the fire containment mechanism. These scenarios were achieved by utilizing materials/fuels not typically used in space vehicles due to flammability concerns. Oxygen depletion, during combustion within the fire containment boxes, drove self-extinguishment and proved an effective method of fire containment

Juarez, Alfredo↗

NASA NTRS1994

Arcjet system integration development

Compatibility between an arcjet propulsion system and a communications satellite was verified by testing a Government-furnished, 1.4 kW hydrazine arcjet system with the FLTSATCOM qualification model satellite in a 9.1-meter (30-foot) diameter thermal-vacuum test chamber. Background pressure was maintained at 10(exp -5) torr during arcjet operation by cryopumping the thruster exhaust with an array of 5 K liquid helium cooled panels. Power for the arcjet system was obtained from the FLTSATCOM battery simulator. Spacecraft telemetry was monitored during each thruster firing period. No changes in telemetry data attributable to arcjet operation were detected in any of the tests. Electromagnetic compatibility data obtained included radiated emission measurements, conducted emission measurements, and cable coupling measurements. Significant noise was observed at lower frequencies. Above 500 MHz, radiated emissions were generally within limits, indicating that communication links at S-band and higher frequencies will not be affected. Other test data taken with a diagnostic array of calorimeters, radiometers, witness plates, and a residual gas analyzer evidenced compatible operation, and added to the data base for arcjet system integration. Two test series were conducted. The first series only included the arcjet and diagnostic array operating at approximately 0.1 torr background pressure. The second series added the qualification model spacecraft, a solar panel, and the helium cryopanels. Tests were conducted at 0.1 torr and 10(exp-5) torr. The arcjet thruster was canted 20 degrees relative to the solar panel axis, typical of the configuration used for stationkeeping thrusters on geosynchronous communications satellites.

Zafran, Sidney↗

NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗

NASA NTRS2023

Fighting Wildfires Using UAVs Using Autonomous Biodegradable Self-sacrificing (ABS) Drones to Combat Large Wildfires with the Assistance of Satellite Imagery

As wildfires continue to increase in number and severity due to global warming, firefighters are having a harder time combating them safely. This paper examines the application of Autonomous Biodegradable Self-sacrificing (ABS) Drones as a method of fighting wildfires that decreases the number of lives put at risk and proposes a sustainable alternative to current aerial firefighting methods. When a fire is detected or predicted through satellite imagery, ABS Drones are dispatched from firefighting stations or aerial watchtowers to fly towards designated areas and release fire retardants, preventing the fire from further spreading. The most significant feature of this drone is its ability to complete its mission without having to worry about returning safely because ABS Drones are designed to crash and release fire retardants, while not further harming the environment with water-based lithium-ion batteries and a biodegradable body. ABS Drones make it safer for firefighters as it gives firefighters one less life-threatening task to do and allows them to focus on putting out the fire. This solution aims to tackle the unpredictable nature of wildfires that often threaten the safety of firefighters and civilian communities.

ABS Drones↗

NASA NTRS2001

Multifunctional Carbon Foams for Aerospace Applications

Carbon foams produced by the controlled thermal decomposition of inexpensive coal extracts exhibit a combination of structural and thermal properties that make them attractive for aerospace applications. Their thermal conductivity can be tailored between 0.5 and 100 W/mK through precursor selection/modification and heat treatment conditions; thus, they can serve in either thermal protection or heat transfer systems such as heat exchangers. Because their structure is essentially a 3D random network of graphite-like members, they also can be considered low-cost, easily fabricated replacements for multi-directional structural carbon fiber preforms. Strengths of over 4000 psi in compression are common. Their density can be designed between 0.1 and 0.8 g/cc, and they can be impregnated with a variety of matrices or used, unfilled, in sandwich structures. These foams also exhibit intriguing electrochemical properties that offer potential in high-efficiency fuel cell and battery applications, mandrels and tooling for composite manufacture, ablative performance, and fire resistance. This paper presents the results of research conducted under NASA SBIR Topic 99.04.01, General Aviation Technology, supported from Langley Research Center. The potential of foam design through precursor selection, cell size and density control, density grading, and heat treatment is demonstrated.

Rogers, D. K.↗

NASA NTRS2006

An Update of the Ground Testing of the Li-ion Batteries in Support of JPL's 2003 Mars Exploration Rover Mission

In early 2004, JPL successfully landed two Rovers, named Spirit and Opportunity, on the surface of Mars after traveling > 300 million miles over a 6-7 month period. In order to operate for extended duration (>9 months), both Rovers are equipped with rechargeable Lithium-ion batteries, which have enabled operation for over 854 and 834 Sols of operation, respectively, to date. Given that the batteries were required to support the mission for 90 Sols of operation by design, it is significant that the batteries have demonstrated over a nine fold increase in life over mission objectives. In addition to supporting the surface operations in conjunction with a triple-junction deployable solar arrays, the batteries were designed to aid in the launch and the EDL pyros, and allow for anomalies during cruise. In summary, the requirements of the Lithium-ion battery include the ability to provide power at least 90 sols on the surface of Mars, operate over a wide temperature range (-20 C to +30 C), withstand long storage periods (e.g., cruise period), operate in an inverted orientation, and support high current pulses (e.g., firing pyro events). In order to determine the viability of meeting these requirements, ground testing was performed on a Rover Battery Assembly Unit (RBAU), consisting of two 8-cell 10 Ah lithium-ion batteries connected in parallel. The RBAU upon which the performance testing was performed is nearly identical to the batteries incorporated into the two Rovers currently on Mars. The testing includes, (a) performing initial characterization tests (discharge capacity at different temperatures), (b) simulating the launch conditions, (c) simulating the cruise phase conditions (including trajectory correction maneuvers), (d) simulating the entry, decent, and landing (EDL) pulse load profile (required to support the pyros) (e) simulating the Mars surface operation mission simulation conditions, as well as, (f) assessing capacity loss and impedance characteristics as a function of temperature and life. This paper provides further detail to previously reported results1 of the RBAU testing program, especially with regard to the life characteristics. To date, the lithium-ion batteries (fabricated by Lithion/Yardney, Inc.) have been demonstrated to far exceed the requirements defined by the mission, both on Mars and on the ground, and are projected to support an extended mission (> 4 years).

Mars Exploration Rovers (MER) Mission↗

NASA NTRS2005

Ground testing of the Li-ion batteries in support of JPL's 2003 Mars Exploration Rover Mission

In early 2004, JPL successfully landed two Rovers, named Spirit and Opportunity, on the surface of Mars after traveling > 300 million miles over a 6-7 month period. In order to operate for extended duration on the surface of Mars, both Rovers are equipped with rechargeable Lithium-ion batteries, which were designed to aid in the launch, correct anomalies during cruise, and support surface operations in conjunction with a triple-junction deployable solar arrays. The requirements of the Lithium-ion battery include the ability to provide power at least 90 sols on the surface of Mars, operate over a wide temperature range (-20(deg)C to +4O(deg)C), withstand long storage periods (e.g., cruise period), operate in an inverted position, and support high currents (e.g., firing pyro events). In order to determine the viability of meeting these requirements, ground testing was performed on a Rover Battery Assembly Unit (RBAU), consisting of two 8-cell 8 Ah lithium-ion batteries connected in parallel. The RBAU upon which the performance testing was performed is nearly identical to the batteries incorporated into the two Rovers currently on Mars. The testing performed includes, (a) performing initial characterization tests (discharge capacity at different temperatures), (b) simulating the launch conditions, (c) simulating the cruise phase conditions (including trajectory corrections), (d) simulating the entry, decent, and landing pulse load profile (if required to support the pyros) (e) simulating the Mars surface operation mission simulation conditions, as well as, (f) assessing performance capacity loss and impedance characteristics as a function of temperature and life. As will be discussed, the lithium-ion batteries (fabricated by LithiodYardney, Inc.) were demonstrated to far exceed the requirements defined by the mission, and are projected to support an extended mission (> 2 years) with margin to spare.

Li-ion batteries↗

NASA NTRS1993

Two-Band Pyrometers Detect Hydrogen Fires

Two-band infrared pyrometers detect small hydrogen fires at greater distances in full daylight being developed. Detectors utilize part of infrared spectrum in which signals from hydrogen flames 10 to the 3rd power to 10 to the 4th power times as intense as ultraviolet region of current detectors. Utilize low-loss infrared lenses for focusing and for limiting fields of view to screen out spurious signals from nearby sources. Working distances of as much as 100 meters possible. Portable, battery-powered unit gives audible alarm, in form of increase in frequency of tone, when aimed at hydrogen fire.

Collins, J. David↗

NASA NTRS2007

Performance Testing of Lithium Li-ion Cells and Batteries in Support of JPL's 2003 Mars Exploration Rover Mission

In early 2004, JPL successfully landed two Rovers, named Spirit and Opportunity, on the surface of Mars after traveling > 300 million miles over a 6-7 month period. In order to operate for extended duration on the surface of Mars, both Rovers are equipped with rechargeable Lithium-ion batteries, which were designed to aid in the launch, correct anomalies during cruise, and support surface operations in conjunction with a triple-junction deployable solar arrays. The requirements of the Lithium-ion battery include the ability to provide power at least 90 sols on the surface of Mars, operate over a wide temperature range (-20(super 0)C to +40(super 0)C), withstand long storage periods (e.g., including pre-launch and cruise period), operate in an inverted position, and support high currents (e.g., firing pyro events). In order to determine the inability of meeting these requirements, ground testing was performed on a Rover Battery Assembly Unit RBAU), consisting of two 8-cell 8 Ah lithium-ion batteries connected in parallel. The RBAU upon which the performance testing was performed is nearly identical to the batteries incorporated into the two Rovers currently on Mars. The primary focus of this paper is to communicate the latest results regarding Mars surface operation mission simulation testing, as well as, the corresponding performance capacity loss and impedance characteristics as a function of temperature and life. As will be discussed, the lithium-ion batteries (fabricated by Yardney Technical Products, Inc.) have been demonstrated to far exceed the requirements defined by the mission, being able to support the operation of the rovers for over three years, and are projected to support an even further extended mission.

low temperature electrolytes↗

NASA NTRS2012

Spinoff 2011

Topics include: Bioreactors Drive Advances in Tissue Engineering; Tooling Techniques Enhance Medical Imaging; Ventilator Technologies Sustain Critically Injured Patients; Protein Innovations Advance Drug Treatments, Skin Care; Mass Analyzers Facilitate Research on Addiction; Frameworks Coordinate Scientific Data Management; Cameras Improve Navigation for Pilots, Drivers; Integrated Design Tools Reduce Risk, Cost; Advisory Systems Save Time, Fuel for Airlines; Modeling Programs Increase Aircraft Design Safety; Fly-by-Wire Systems Enable Safer, More Efficient Flight; Modified Fittings Enhance Industrial Safety; Simulation Tools Model Icing for Aircraft Design; Information Systems Coordinate Emergency Management; Imaging Systems Provide Maps for U.S. Soldiers; High-Pressure Systems Suppress Fires in Seconds; Alloy-Enhanced Fans Maintain Fresh Air in Tunnels; Control Algorithms Charge Batteries Faster; Software Programs Derive Measurements from Photographs; Retrofits Convert Gas Vehicles into Hybrids; NASA Missions Inspire Online Video Games; Monitors Track Vital Signs for Fitness and Safety; Thermal Components Boost Performance of HVAC Systems; World Wind Tools Reveal Environmental Change; Analyzers Measure Greenhouse Gasses, Airborne Pollutants; Remediation Technologies Eliminate Contaminants; Receivers Gather Data for Climate, Weather Prediction; Coating Processes Boost Performance of Solar Cells; Analyzers Provide Water Security in Space and on Earth; Catalyst Substrates Remove Contaminants, Produce Fuel; Rocket Engine Innovations Advance Clean Energy; Technologies Render Views of Earth for Virtual Navigation; Content Platforms Meet Data Storage, Retrieval Needs; Tools Ensure Reliability of Critical Software; Electronic Handbooks Simplify Process Management; Software Innovations Speed Scientific Computing; Controller Chips Preserve Microprocessor Function; Nanotube Production Devices Expand Research Capabilities; Custom Machines Advance Composite Manufacturing; Polyimide Foams Offer Superior Insulation; Beam Steering Devices Reduce Payload Weight; Models Support Energy-Saving Microwave Technologies; Materials Advance Chemical Propulsion Technology; and High-Temperature Coatings Offer Energy Savings.

Source record↗

NASA NTRS2000

STS-106 Crew Activities Report/Flight Day 07 Highlights

On this seventh day of the STS-106 Atlantis mission, the flight crew, Commander Commander Terrence W. Wilcutt, Pilot Scott D. Altman, and Mission Specialists Daniel C. Burbank, Edward T. Lu, Richard A. Mastracchio, Yuri Ivanovich Malenchenko, and Boris V. Morukov are seen participating in several outfitting activities. Burbank and Morukov remove and replace a fourth battery in Zarya. Lu and Malenchenko finish installing the third and final battery and other electrical equipment inside the Zvezda Service Module. While Altman and Wilcutt perform a series of jet firings, Altman is shown as he narrates a tour of the Zvezda Service Module. Scenes also include Lu and Malenchenko unpacking the Russian-made Orlan space suits, Burbank and Wilcutt participating in an interview, and a beautiful night shot of the International Space Station (ISS) and Atlantis complex above the Earth.

Source record↗

NASA NTRSDate not supplied

Molten Salt Electrolytes: Computational Analysis of Transport, Electrochemical Properties and Designing New Mixtures

Electric aircraft propulsion has gained a traction over the last decade due to possible high-energy density electrochemistries with reasonable cycle life and identification of non-flammable chemistries that can guarantee much better safety. Commercial Li-ion batteries cannot reach such high capacities because of weight limitations that arise from the widely used intercalation electrodes. Also, use of organic electrolytes make them highly susceptible to fire on exposure to air and humidity. Currently, use of Lithium metal anode along with conversion electrochemistries such as Li-O2 and Li-S are being pursued to achieve such high energy densities. Safer inorganic solid-state electrolytes, recently discovered Water-in-Salt electrolytes, molten salt electrolytes are some of the alternatives being pursued for a safer/non-flammable battery. Of these safer alternatives, molten-salt electrolytes offer some attractive properties: liquid at operating temperatures resulting in better electrode-wetting, stable interface with Li-metal anodes and good ionic conductivity; their only drawback being high operating temperatures. In this talk, we will discuss some of the computational studies, driven via atomistic simulations, of the properties of molten-salt electrolytes including transport mechanism and interface stability. We will also discuss predicting electrochemical properties of these high-temperature electrolytes. Further, we will discuss a thermodynamic approach to predicting new molten-salt eutectics with lower melting points.

Molten Salt Electrolytes↗

NASA NTRSDate not supplied

An Autonomous sUAS Operating in UTM TCL4+ and STEReO Fire Scenario

This study presents a sUAS payload point design that enables autonomous BVLOS flightin UTM TCL4+ urban environments and STEReO fire responses. The payload components include an onboard computer, 360 deg LIDAR, range finder altimeter, downward-facing monocular camera, forward-facing thermal and visible light dual camera, vehicle-to-vehicle radio modem, and Li-ion smart battery. The components are mounted on an enclosed structural frame that was designed in-house. Placing the autonomy components onboard leverages the advantages of sUAS over manned aircraft such as low-cost, quick response time, and increased scalability. Autonomous capabilities include object and fire detection, V2V communication, embedded processing, and SLAM. Data processing is conducted on-board the aircraft to eliminate the dependency on a ground station downlink. The payload is evaluated in both software simulation as well as flight tests.

Autonomous UAS↗

NASA NTRS2007

Hazards, Safety and Design Considerations for Commercial Lithium-ion Cells and Batteries

This viewgraph presentation reviews the features of the Lithium-ion batteries, particularly in reference to the hazards and safety of the battery. Some of the characteristics of the Lithium-ion cell are: Highest Energy Density of Rechargeable Battery Chemistries, No metallic lithium, Leading edge technology, Contains flammable electrolyte, Charge cut-off voltage is critical (overcharge can result in fire), Open circuit voltage higher than metallic lithium anode types with similar organic electrolytes. Intercalation is a process that places small ions in crystal lattice. Small ions (such as lithium, sodium, and the other alkali metals) can fit in the interstitial spaces in a graphite lattice. These metallic ions can go farther and force the graphitic planes apart to fit two, three, or more layers of metallic ions between the carbon sheets. Other features of the battery/cell are: The graphite is conductive, Very high energy density compared to NiMH or NiCd, Corrosion of aluminum occurs very quickly in the presence of air and electrolyte due to the formation of HF from LiPF6 and HF is highly corrosive. Slides showing the Intercalation/Deintercalation and the chemical reactions are shown along with the typical charge/discharge for a cylindrical cell. There are several graphs that review the hazards of the cells.

Jeevarajan, Judith↗

NASA NTRSDate not supplied

Towards An Autonomous sUAS Operating in UTM TCL4+ and STEReO Fire Scenario

This study presents two sUAS payload point designs for enabling autonomous BVLOS flight in UTM TCL4+ urban environments and STEReO fire responses. The payload components for the first payload include an onboard computer and a 360 LIDAR. The second payload, which is a continuation of the first, adds a range finder altimeter, downward-facing monocular camera, forward-facing thermal and visible light dual camera, vehicle-to-vehicle radio modem, and Li-ion smart battery. The components are mounted on enclosed structural frames that were designed in-house. Placing the autonomy components onboard leverages the advantages of sUAS over manned aircraft such as low-cost, quick response time, and increased scalability. Autonomous capabilities include embedded processing, SLAM, object and fire detection, and V2V communication. Data processing is conducted onboard the aircraft to eliminate the dependency on a groundstation downlink. The first iteration of the payload is tested in both simulation and flight tests while the continuing iteration is in development.

Autonomous UAS↗

NASA NTRS2011

Thermal Properties of Microstrain Gauges Used for Protection of Lithium-Ion Cells of Different Designs

The purpose of this innovation is to use microstrain gauges to monitor minute changes in temperature along with material properties of the metal cans and pouches used in the construction of lithium-ion cells. The sensitivity of the microstrain gauges to extremely small changes in temperatures internal to the cells makes them a valuable asset in controlling the hazards in lithium-ion cells. The test program on lithium-ion cells included various cell configurations, including the pouch type configurations. The thermal properties of microstrain gauges have been found to contribute significantly as safety monitors in lithium-ion cells that are designed even with hard metal cases. Although the metal cans do not undergo changes in material property, even under worst-case unsafe conditions, the small changes in thermal properties observed during charge and discharge of the cell provide an observable change in resistance of the strain gauge. Under abusive or unsafe conditions, the change in the resistance is large. This large change is observed as a significant change in slope, and this can be used to prevent cells from going into a thermal runaway condition. For flexible metal cans or pouch-type lithium-ion cells, combinations of changes in material properties along with thermal changes can be used as an indication for the initiation of an unsafe condition. Lithium-ion cells have a very high energy density, no memory effect, and almost 100-percent efficiency of charge and discharge. However, due to the presence of a flammable electrolyte, along with the very high energy density and the capability of releasing oxygen from the cathode, these cells can go into a hazardous condition of venting, fire, and thermal runaway. Commercial lithium-ion cells have current and voltage monitoring devices that are used to control the charge and discharge of the batteries. Some lithium-ion cells have internal protective devices, but when used in multi-cell configurations, these protective devices either do not protect or are themselves a hazard to the cell due to their limitations. These devices do not help in cases where the cells develop high impedance that suddenly causes them to go into a thermal runaway condition. Temperature monitoring typically helps with tracking the performance of a battery. But normal thermistors or thermal sensors do not provide the accuracy needed for this and cannot track a change in internal cell temperatures until it is too late to stop a thermal runaway.

Jeevarajan, Judith↗