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By using Bi-gram and Tri-gram tables, a pattern can be formed to determine failure modes and mechanisms. Computer programs provide accurate predictions of cell failure several thousand cycles before actual failure.
The Solar Array System for the Skylab Orbital Workshop is designed to supply average power to power-conditioning equipment of 10496 watts while oriented toward the sun during the sunlit portion of each orbit. This paper discusses the operating voltage of the arrays over the expected temperature range, temperature cycling effects on both cell interconnects and cells, and overall effects of hot spots induced by shadows cast on the arrays by elements of the spacecraft.
Empirical equation derived from cycles-to-failure, temperature cells, and prediction of normal packs are presented.
The energy use and costs of the on-site integrated energy system (OS/IES) which provides electric power from an on-site power plant and recovers heat that would normally be rejected to the environment is compared to a conventional system purchasing electricity from a utility and a phosphoric acid fuel cell powered system. The analysis showed that for a 500-unit apartment complex a fuel OS/IES would be about 10% more energy conservative in terms of total coal consumption than a diesel OS/IES system or a conventional system. The fuel cell OS/IES capital costs could be 30 to 55% greater than the diesel OS/IES capital costs for the same life cycle costs. The life cycle cost of a fuel cell OS/IES would be lower than that for a conventional system as long as the cost of electricity is greater than $0.05 to $0.065/kWh. An analysis of several parametric combinations of fuel cell power plant and state-of-art energy recovery systems and annual fuel requirement calculations for four locations were made. It was shown that OS/IES component choices are a major factor in fuel consumption, with the least efficient system using 25% more fuel than the most efficient. Central air conditioning and heat pumps result in minimum fuel consumption while individual air conditioning units increase it, and in general the fuel cell of highest electrical efficiency has the lowest fuel consumption.
A radiator for heat rejection in space is described which utilizes a stream of liquid droplets to radiate waste heat. The large surface area per mass makes the liquid droplet radiator at least an order of magnitude lighter than tube and fin radiators. Generation and collection of the droplets, as well as heat transfer to the liquid, can be achieved with modest extensions of conventional technology. Low vapor pressure liquids are available which cover a radiating temperature range 250-1000 K with negligible evaporation losses. The droplet radiator may be employed for a wide range of heat rejection applications in space. Three applications - heat rejection for a high temperature Rankine cycle, cooling of photovoltaic cells, and low temperature heat rejection for refrigeration in space illustrate the versatility of the radiator.
Technology readiness and development trends are discussed for three advanced power generation systems: combined cycle gas turbine, fuel cells, and magnetohydrodynamics. Power plants using these technologies are described and their performance either utilizing a medium-Btu coal derived fuel supplied by pipeline from a large central coal gasification facility or integrated with a gasification facility for supplying medium-Btu fuel gas is assessed.
All medially related activities of the Space Transportation System 2 flight are described, ranging from preflight to postflight. Several medical problems occured during the flight. Their was marginal operation on-board potable water system caused by a malfunctioning fuel cell. Work and rest cycles by the crew were altered to maximize the scientific data acquisition. Inadequate time was allocated for food preparation and consumption. There was low water intake by the crew because of the water shortage.
Corrosion tests were run with AISI 52100, AISI M-50 and AMS 5794 under conditions that simulate the crevice corrosion found in aircraft ball and roller bearings rejected at overhaul for corrosion. Test specimens were fabricated that simulated the contacts of balls or rollers and the raceways. Corrosion cells were assembled in the presence of a lubricant contaminated with water and chloride ions. The cell was then thermally cycled between 339 K (150 F) and 276 K (37 F). The corrosion observed after 14 cycles was that of crevice and pitting corrosion typically found in aircraft bearings. AMS 5749 showed a very slight amount of corrosion. No appreciable differences were noted between AISI 52100 and AISI M-50, but both showed much greater corrosion than AMS 5749. The corrosion pits observed in AISI M-50 appeared to be fewer in number but generally deeper and larger than in AISI 52100.
A number of 12 ampere-hour cells, nickel cadmium, were cycled under various conditions of temperature and depth of discharge. Using this data, it was confirmed that a five parameter fit equation could be used to model the data within a few millivolts. Both charge and discharge curves can be fit with accuracies in the range of one or two millivolts. The fit coefficients when plotted versus cycles show definite trends and patterns which can be used in an operational sense to predict battery voltage as a function of temperature and depth of discharge.
This paper is an overview of a wide range of recent aerospace technologies under development at the NASA Glenn Research Center, in collaboration with other NASA centers, government agencies, industry and academia. The focused areas are space solar power, advanced power management and distribution systems, Stirling cycle conversion systems, fuel cells, advanced thin film photovoltaics and batteries, and combustion technologies. The aerospace-related objectives of the technologies are generation of space power, development of cost-effective and reliable, high performance power systems, cryogenic applications, energy storage, and reduction in gas-turbine emissions, with attendant clean jet engines. The terrestrial energy applications of the technologies include augmentation of bulk power in ground power distribution systems, and generation of residential, commercial and remote power, as well as promotion of pollution-free environment via reduction in combustion emissions.
During the course of this grant, dye-sensitized solar cells were prepared and characterized. The solar cells were prepared using materials (dyes, electrolytes, transparent conductive oxide coated glass, nanocrystalline TiO2) entirely prepared in-house, as well as prepared using materials available commercially. Complete cells were characterized under simulated AM0 illumination. The best cell prepared at NASA had an AM0 efficiency of 1.22% for a 1.1 sq cm cell. Short circuit current (Isc), open circuit voltage (Voc) and fill factor (FF) for the cell were 6.95 mA, 618 mV and 42.8%, respectively. For comparison purposes, two commercially prepared dye-sensitized solar cells were obtained from Solaronix SA, Aubonne, Switzerland. The Solaronix cells were also characterized under simulated AM0 illumination. The best cell from Solaronix had an active area of 3.71 sq cm and measured an AM0 efficiency of 3.16%. with Isc, Voc and FF of 45.80 mA, 669.6 mV and 52.3%, respectively. Both cells from Solaronix were rapid thermal cycled between -80 C and 80 C. Thermal cycling led to a 4.6% loss of efficiency in one of the cells and led to nearly a complete failure in the second cell.
Measurement of Raman and native fluorescence emission using ultraviolet (UV) sources (<400 nm) on targeted materials is suitable for both sensitive detection and accurate identification of explosive materials. When the UV emission data are analyzed using a combination of Principal Component Analysis (PCA) and cluster analysis, chemicals and biological samples can be differentiated based on the geometric arrangement of molecules, the number of repeating aromatic rings, associated functional groups (nitrogen, sulfur, hydroxyl, and methyl), microbial life cycles (spores vs. vegetative cells), and the number of conjugated bonds. Explosive materials can be separated from one another as well as from a range of possible background materials, which includes microbes, car doors, motor oil, and fingerprints on car doors, etc. Many explosives are comprised of similar atomic constituents found in potential background samples such as fingerprint oils/skin, motor oil, and soil. This technique is sensitive to chemical bonds between the elements that lead to the discriminating separability between backgrounds and explosive materials.
Results of cyclic tests on seven 3-cell 100 A-H nickel cadmium batteries on 1.5 hr cycles are presented. The failure of the nylon and polypropylene separators was not analyzed.
Thirty-six (36) experimental 40AH sealed silver-zinc cells were constructed during phase I of this two (2) phase program. These cells were divided into six (6) groups of six (6) cells each. Each group of six (6) cells was evenly divided into two batches of three (3) cells each. Groups 1 through 4 each featured a different inorganic filler material in the slurry used to coat the separator substrate. Groups 5 and 6 featured an alternate method of separator bag construction. With the exception of the various separator materials, the parts and processes used to produce these thirty-six (36) cells were the same as those used to make the HR40-7 cell. The two (2) batches of cells in each cell group differed only in the lots of solutions and other separator slurry components used. Each cell was given two formation charge/discharge cycles prior to being shipped to NASA Lewis Research Center. Phase II of the program consisted of constructing another thirty-six (36) 40AH experimental cells in six (6) groups of six (6) cells each. Each group was distinguished by the type of precoated separator material used to fabricate separator bags. A new method of separator bag construction was used in this phase of the program. These cells were given two (2) formation cycles and shipped to NASA Lewis Research Center.
Testing on a variety of secondary silver-zinc (Ag-Zn) cells has been in progress at the Marshall Space Flight Center (MSFC) for over six years. The latest test involves a 350-Ah cell design that has been cycled at 10 C for 16 months. This design has achieved over 7200 low-earth-orbit (LEO) cycles as well as 17 deep discharges at an 85 percent depth of discharge. This test not only is a life test on these cells but also addresses different methods of storing these cells between the deep discharges. As the test is approaching completion, some interesting results are being seen. In particular, two of the four packs currently on test have failed to meet the 35-h (295-Ah) deep discharge requirement that was arbitrarily set at the beginning of the test. This capacity loss failure is likely a result of the storage method used on these two packs between deep discharges. The two packs are LEO cycled in such a way as to minimize overcharge in an attempt to prolong life.
Nineteen different designs of nickel electrodes were tested in Ni/H2 boiler plate cells in an accelerated low earth orbit cycle regime to the end of their life. The failure analyses of these cells showed that the major performance changes due to the cycling was a severe reduction of their high rate discharge capability rather than an absolute capacity reduction. Many physical changes of the nickel electrodes were observed after the cycling test. These changes include dimensional expansion, sinter rupture, loose black powdering of the active material, morphology changes, active material migration, increase of pore volume, change of pore distribution, and increase of surface area. All of these were caused by active material expansion with cycling. Among these changes, the morphology change which involves migration of active material away from the current collecting nickel sinter appears to be that most responsible for the reduction of the rate capability.
Cycle capability of optimal design spacecraft nickel cadmium cells with recombination and signal electrodes
Sealed nickel cadmium cells having large number of cycles on them are discharged using Hg/HgO reference electrode. The negative electrode exhibits the second plateau. A SEM of negative plates of such cells show a number of large crystals of cadmium hydroxide. The large crystals on the negative plates disappear after continuous overcharging in flooded cells.