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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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At least 109 records · Page 6

Safe, High Specific Energy & Power Lithium Ion Cell Designs

The higher energy content (265 Wh/kg, 725 Wh/L) of the newer cell designs from LG, Panasonic, and Samsung have made them susceptible to side wall ruptures (SWR) during thermal runaway, rather than venting through the intended vent path in the cell header. This is also due to higher reaction kinetics of the electrochemistry, thinner can walls, tight crimp enclosure of the cell header, and inadequate flow rate through the header vent. This effort determined that bottom vents and thicker cell can walls both are necessary for reducing the risk of SWR. Compelling evidence was obtained using novel test methods that included an on-demand internal short circuit device, high speed X-ray videography, and cell thermal runaway calorimetry.

side wall rupture↗

Evaluation of Ultrasonic Battery Inspection Techniques

Lithium metal batteries are prone to subtle defects such as internal dendrites, which can cause internal short circuits and lead to catastrophic ignition. These defects are often undetectable by battery management systems, prompting the need to advance nondestructive evaluation (NDE) techniques for battery applications. In this work, two ultrasonic approaches were compared to establish their relative merits for this application: local ultrasonic resonance spectroscopy, and guided wave ultrasound. Benchtop experiments on batteries seeded with lithium chips emulating plating were used to demonstrate the two techniques. The results show the ability to identify and map local changes in cell structure.

Ultrasound↗

Evaluation of Ultrasonic Battery Inspection Techniques

Lithium metal batteries are prone to subtle defects such as internal dendrites, which can cause internal short circuits and lead to catastrophic ignition. These defects are often undetectable by battery management systems, prompting the need to advance nondestructive evaluation (NDE) techniques for battery applications. In this work, two ultrasonic approaches were compared to establish their relative merits for this application: local ultrasonic resonance spectroscopy, and guided wave ultrasound. Benchtop experiments on batteries seeded with lithium chips emulating plating were used to demonstrate the two techniques. The results show the ability to identify and map local changes in cell structure.

Ultrasound↗

Reduced-area current collectors for rechargeable batteries

A novel electrode current collector design that can improve performance and extend cycle life for rechargeable batteries based on metal electrodeposition is disclosed. The novel electrode current collector has a reduced effective surface area that can help to balance efficiencies between battery electrodes and to ensure non-uniform electrodeposition of metal onto the anode current collector during charge. One result is mitigation of internal short circuits that can cause a battery to fail prematurely.

Ito, Yasumasa↗

Control of internal and external short circuits in lithium batteries using a composite thermal switch

A composite material has been developed, consisting of a blend of metal and fluorocarbon particles, which behaves as an electronic conductor at room temperature and which abruptly becomes an insulator at a predetermined temperature. This switching behavior results from the difference in thermal expansion coefficients between the conductive and non-conductive portions of the composite. This material was applied as a thin film between the carbon cathode in Li/SOCl2 cells, and the metallic cathode current collector. Using test articles incorporating this feature it was shown that lithium cells externally heated or internally heated during a short circuit lost rate capability and the ability to overheat well below the melting point of lithium (180 C). Thus, during an internal or external cell short circuit, the potential for thermal runaway involving reactions of molten lithium is avoided.

Mcdonald, Robert C.↗

Irreversible transport in the stratosphere by internal waves of short vertical wavelength

Measurements performed during stratospheric flights of the U-2 aircraft confirm that cross-jet transport is dominated by waves, not by large-scale circulations. Monotonic gradients of trace constituents normal to the jet axis, with upper stratospheric tracers increasing poleward and tropospheric tracers increasing equatorward, are augmented by large-scale confluence as the jet intensifies during cyclogenesis. These gradients are rotated, intensified, and significantly increased in areas as their mixing ratio surfaces are folded by the differential transport of a very low frequency transverse wave. The quasi-horizontal transport produces a laminar structure with stable layers rich in upper stratospheric tracers alternating vertically with less stable layers rich in tropospheric tracers. The transport proceeds toward irreversibility at higher frequency, shear-gravity waves extend the folding to smaller horizontal scales.

Danielsen, Edwin F.↗

Performance and Safety Tests on Samsung 18650 Li-ion Cells: Two Cell Designs

In order to meet the applications for space shuttle in future, two types of Samsung cells, with capacity 1800 mAh and 2000 mAh, have been investigated. The studies focused on: (1) Performance tests: completed 250 cycles at various combinations of charge/discharge C rates and discharge capacity measurements at various temperatures; and (2) Safety tests: overcharge and overdischarge, heat abuse, short circuit, internal and external short, and vibration, vacuum, and drop tests

Deng, Yi↗

2025 Intern Poster - Abbigail Short

The OSCC Coupling Shaft Handling Fixture, known as the "Puppy Dog Tool," was originally designed by hand in 1976. The initial design was difficult to read and replicate, lacking 3D modeling for simulations and testing. To modernize the tool, the original drawings were reviewed and recreated in Autodesk Inventor with increased spacing for clarity. Key improvements included adding a hook, modifying the top plate and main body connection, and introducing a guiding wall for the clamp. These changes enhanced durability and usability, preventing bending and facilitating easier assembly. The updated design preserved the tool's functionality while making it more robust and user-friendly for high-precision operations.

99 - GENERAL AND MISCELLANEOUS↗

Internal performance characteristics of short convergent-divergent exhaust nozzles designed by the method of characteristics

Internal performance data on a short exhaust nozzle designed by the method of characteristics were obtained over a range of pressure ratios from 1.5 to 22. The peak thrust coefficient was not affected by a shortened divergent section, but it occurred at lower pressure ratios due to reduction in expansion ratio. This nozzle contour based on characteristics solution gave higher thrust coefficients than a conical convergent-divergent nozzle of equivalent length. Abrupt-inlet sections permitted a reduction in nozzle length without a thrust-coefficient reduction.

Krull, H George↗

Reliability Models and Demonstration of a Fault-Tolerant Motor Concept for Vertical Takeoff and Landing Vehicles

This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.

Electric Motor↗

Modeling Extreme Deformations in Lithium Ion Batteries

A simultaneously coupled modeling approach to study the electrochemical and thermal behavior of lithium-ion batteries under large mechanical deformation has been developed. The thermo-electrochemical pseudo-2D (P2D) battery model is coupled with a mechanical material model. Mechanical, thermal, and electrochemical models are implemented as user-defined sub-routines in the commercial multi-physics code LS-DYNA. The mechanical strain experienced by anode, cathode and separator results in thickness and porosity changes in each layer which in turn influences electrochemical behavior. The evolution of concentration profiles and cell potential are studied under different mechanical loading conditions. Internal short-circuits caused by mechanical deformation and corresponding physical behaviors are also elucidated. We discuss the competing effects of improved transport at higher temperature due to the internal short-circuit versus a drop in the effective ionic conductivity and electrolyte diffusivity due to mechanical deformation.

47 OTHER INSTRUMENTATION↗

International Space Station Bipropellant Plume Contamination Model Update for Short Thruster Pulse Widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down data performance data gathered during thruster test programs, if available. The International Space Station (ISS) Bipropellant Plume Contamination Model developed by Boeing Space Environments is a semi-empirical model anchored in flight experiment data and has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS.[1] The current model utilizes flight experiment data from the Plume Impingement Contamination (PIC) and Shuttle Plume Impingement Flight Experiment (SPIFEX) studies, which include Orbiter 3870 N Primary Reaction Control System (PRCS) and Russian 130 N thrusters operating in pulse mode with 80-100 ms.[2] As the next generation of crew and cargo visiting vehicles are developed and arrive at ISS, minimum pulse widths of vehicle thrusters used for ISS proximity operations have decreased significantly below 80 ms. An update to the ISS Bipropellant Contamination Model is needed to prevent potential under-prediction of thruster plume-induced contamination for these very short pulse widths. Contamination due to thruster plumes occurs in the liquid phase (i.e., unburned or partially burned propellant in the plume). Liquid phase releases primarily occur during thruster start-up and shut-down phases, with the steady state phase contributing a small amount to the total contaminant mass released. The current ISS Bipropellant Plume Contamination Model includes functional dependencies on thruster parameters (thrust, mass flow rate, specific impulse (Isp)), distance to receiver surface, and angle off plume centerline. For modeling purposes, contaminant mass released scales linearly with pulse width. This is a conservative approach for pulse widths greater than 80 ms but could under-predict contamination for very short pulse widths (i.e., with little or no steady state phase). This paper presents a model update to add a functional dependency on commanded pulse width to ensure the portion of the pulse spent in start-up and shut-down phases is appropriately modeled, when the majority of liquid phase contaminant mass is released. The updated model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations while providing a way to take advantage of thruster start-up and shut-down data gathered during test programs, if available. Developing the plume model for a specific thruster using the ISS Bipropellant Plume Contamination Model must be done in consideration of all available thruster performance data. Example thruster data will be used to illustrate this point and options for implementing the model update with existing ISS Bipropellant Plume Contamination Model code will be discussed.

plume contamination↗

International Space Station Bipropellant Plume Contamination Model Update for Short Thruster Pulse Widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down data performance data gathered during thruster test programs, if available.

bipropellant↗

International Space Station Bipropellant Plume Contamination Model update for short thruster pulse widths

The International Space Station (ISS) Bipropellant Plume Contamination Model has been a vital tool for characterizing the thruster plume-induced contamination environment at the ISS but was not intended to be used for very short thruster pulse widths. This paper presents an updated model that ensures full start-up and shut-down phases are modeled for each thruster firing, when the majority of liquid phase contaminant mass is released. The updated ISS Bipropellant Plume Contamination Model prevents potential under-prediction of thruster plume-induced contamination due to visiting vehicle proximity operations and provides a way to take advantage of thruster start-up and shut-down performance data gathered during thruster test programs, if available.

thruster plumes↗

Dataset of mechanically induced thermal runaway measurement and severity level on Li-ion batteries

The deployment of Li-ion batteries covers a wide range of energy storage applications, from mobile phones, e-bikes, electric vehicles (EV) and stationary energy storage systems. However, safety issue such as thermal runaway is always one of the most important concerns to prevent Li-ion batteries from further market penetration. A standardized single-side indentation test protocol was developed to mechanically induce an internal short-circuit. The cell voltage, compressive load, indenter stroke, and temperature at the indentation point are measured in time series. The test data of each cell, along with cell parameters such as dimensions, mass, chemistry, state of charge (SOC), capacity, are integrated together to calculate a thermal runaway severity score from 0 to100. Complete data collection process including the original measured record, test method, severity score calculation scheme is presented in this article. The thermal runaway severity analysis and the more than 100 tested Li-ion battery records provide a good data source for further comparison and ranking of thermal runaway risks.

25 ENERGY STORAGE↗

Mechanically induced thermal runaway severity analysis for Li-ion batteries

Thermal runaway is one of the most important safety concerns in the deployment of Li-ion batteries. For this study, we developed a standardized single-side indentation test protocol to induce an internal short-circuit. Cell voltage, temperature, and applied compressive force are monitored as a function of time. Each cell is given an observed hazard severity (OHS in five categories) modified from the EUCAR table. Meanwhile a calculated hazard severity (CHS) is obtained solely based on temperature and voltage curves. The calculation formula considers the cell temperature, rate of temperature increase, cell capacity, state of charge (SOC), voltage drop, and voltage drop rate. Each term is assigned with an appropriate weight to scale the calculated score from 0 to100. This method was applied to >100 Li-ion batteries with various SOCs and chemistries, and their OHS and CHS were displayed against SOC. The purpose is to provide battery designers, manufacturers, and end-users a clear comparison of thermal runaway severity of different batteries.

25 ENERGY STORAGE↗