Ultra-reliability and long-life
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ultra-reliability long-life missions space mission↗
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Long-life, lightweight solar array testing
A long duration test is in progress for comparing various methods of attaching interconnects to solar cells for near-earth-orbit spacecraft. This JPL- and NASA-sponsored project has been cycling modules at between -80 C and + 80 C since June 1983. As of April 1984, 29,000 cycles have been completed, and the cycling is continuing. Modules include examples of parallel gap and ultrasonic welding and of soldering as fabricated by the Space and Communications Group, Hughes Aircraft Company and by Spectroblab. Evaluation of module integrity has been made at periodic intervals. No measurable degradation has been detected to date.
Stofel, E. J.↗
Long life high reliability thermal control systems study data handbook
The development of thermal control systems with high reliability and long service life is discussed. Various passive and semi-active thermal control systems which have been installed on space vehicles are described. The properties of the various coatings are presented in tabular form.
Scollon, T. R., Jr.↗
Strategies to enable microsized alloy anodes for high-energy and long-life alkali-ion batteries
In this review, challenges and strategies to enable the use of micro-sized alloy anodes for alkali-ion batteries with high energy density and long cycle life are explored.
Daali, Amine↗
Long life, high speed, thrust-load ball bearings
Long-term bearing operation at three million DN can be achieved with high degree of reliability using full combination of sophisticated but currently available state-of-the-art bearing materials and designs, lubricants, and lubricating techniques.
Signer, H.↗
Reversible redox chemistry in azobenzene-based organic molecules for high-capacity and long-life nonaqueous redox flow batteries
Redox flow batteries (RFBs), often categorized as aqueous and nonaqueous systems, represent a type of large-scale energy storage technology for renewable energy resources. Redox-active organic molecules have recently drawn extensive interests in RFBs as promising active materials due to their elemental abundance, structural diversity and high tunability of properties, but employing organic molecules in nonaqueous systems is far limited in terms of useable capacity and cycling stability. Here we introduce a class of azobenzene-based organic compounds with the azo group as redox-active center in the p-conjugated structure as new active materials to realize high-performance nonaqueous RFBs with long cycling life and high capacity. By screening suitable organic solvents with high solubility and conductivity, the azobenzene organic molecule was capable to achieve a stable long cycling with a low capacity decay of 0.014% per cycle and 0.16% per day over 1000 cycles. And the stable cycling of electrolytes under a high concentration of 1 M was also realized, delivering a high reversible capacity of ~46 Ah L -1 . The unique lithium-coupled redox chemistry accompanied with a voltage increase was observed and revealed by experimental characterization and theoretical simulation. With the reversible two-electron redox activity of azo group in p-conjugated structures, azobenzene as an azo-aromatic molecule represents a class of promising redox-active organics for potential grid-scale energy storage systems.
25 ENERGY STORAGE↗
Mismatching integration-enabled strains and defects engineering in LDH microstructure for high-rate and long-life charge storage
Layered double hydroxides (LDH) have been extensively investigated for charge storage, however, their development is hampered by the sluggish reaction dynamics. Herein, triggered by mismatching integration of Mn sites, we configured wrinkled Mn/NiCo-LDH with strains and defects, where promoted mass & charge transport behaviors were realized. The well-tailored Mn/NiCo-LDH displays a capacity up to 518 C g -1 (1 A g -1 ), a remarkable rate performance (78%@100 A g -1 ) and a long cycle life (without capacity decay after 10,000 cycles). We clarified that the moderate electron transfer between the released Mn species and Co 2+ serves as the pre-step, while the compressive strain induces structural deformation with promoted reaction dynamics. Theoretical and operando investigations further demonstrate that the Mn sites boost ion adsorption/transport and electron transfer, and the Mn-induced effect remains active after multiple charge/discharge processes. This contribution provides some insights for controllable structure design and modulation toward high-efficient energy storage.
25 ENERGY STORAGE↗
Long Life DC brush motor for use on the Mars Surveyor Program
DC brush motors have several qualities which make them very attractive for space flight applications.
DC↗
A long-life lithium-oxygen battery via a molecular quenching/mediating mechanism
The advancement of lithium-oxygen (Li-O 2 ) batteries has been hindered by challenges including low discharge capacity, poor energy efficiency, severe parasitic reactions, etc. We report an Li-O 2 battery operated via a new quenching/mediating mechanism that relies on the direct chemical reactions between a versatile molecule and superoxide radical/Li 2 O 2 . The battery exhibits a 46-fold increase in discharge capacity, a low charge overpotential of 0.7 V, and an ultralong cycle life >1400 cycles. Featuring redox-active 2,2,6,6-tetramethyl-1-piperidinyloxy moieties bridged by a quenching-active perylene diimide backbone, the tailor-designed molecule acts as a redox mediator to catalyze discharge/charge reactions and serves as a reusable superoxide quencher to chemically react with superoxide species generated during battery operation. The all-in-one molecule can simultaneously tackle issues of parasitic reactions associated with superoxide radicals, singlet oxygen, high overpotentials, and lithium corrosion. The molecular design of multifunctional additives combining various capabilities opens a new avenue for developing high-performance Li-O 2 batteries.
25 ENERGY STORAGE↗
Nontraditional Approaches To Enable High-Energy and Long-Life Lithium–Sulfur Batteries
In this study, lithium-sulfur (Li-S) batteries are promising for automotive applications due to their high theoretical energy density (2600 Wh/kg). In addition, the natural abundance of sulfur could mitigate the global raw material supply chain challenge of commercial lithium-ion batteries that use critical elements, such as nickel and cobalt. However, due to persistent polysulfide shuttling and uncontrolled lithium dendrite growth, Li-S batteries using nonencapsulated sulfur cathodes and conventional ether-based electrolytes suffer from rapid cell degradation upon cycling. Despite significant improvements in recent decades, there is still a big gap between lab research and commercialization of the technology. To date, the reported cell energy densities and cycling life of practical Li-S pouch cells remain largely unsatisfactory. Traditional approaches to improving Li-S performance are primarily focused on confining polysulfides using electronically conductive hosts. However, these micro- and mesoporous hosts suffer from limited pore volume to accommodate high sulfur loading and the associated volume change during cycling. Moreover, they fail to balance adsorption-conversion of polysulfides during charge-discharge, leading to the formation of massive dead sulfur. Such hosts are themselves electrochemically inactive, which decreases the practical energy density. In contrast, a series of nontraditional approaches, paired with advances in multiscale mechanistic understanding, have recently demonstrated exciting performance outcomes not only in conventional coin cells but also in practical pouch cells. In this Account, we first introduce our novel cathode design strategies to overcome polysulfide shuttling and sluggish redox kinetics in thick S cathodes via selenium-sulfur chemistry and cathode host engineering. Next, we gain a mechanistic understanding of Li-S batteries in various types of electrolytes via a series of spectroscopic, nuclear magnetic resonance, and electrochemical methods. Meanwhile, a novel cathode solid electrolyte interphase encapsulation strategy via nonviscous highly fluorinated ether-based electrolyte is introduced. The established selection rule by investigating how solvating power retards the shuttle effect and induces robust cathode/solid-electrolyte interphase formation is also included. We then discuss how the synergistic interactions between rational cathode structures and electrolytes can be exploited to tailor the reaction pathways and kinetics of S cathodes under high mass loading and lean electrolyte conditions. In addition, a novel interlayer design to simultaneously overcome degradation processes (polysulfide shuttling and lithium dendrite formation) and accelerate redox reaction kinetics is presented. Finally, this Account concludes with an overview of the challenges and strategies to develop Li-S pouch cells with high practical energy density, long cycle life, and fast-charging capability.
25 ENERGY STORAGE↗
Long Life, High Energy Silver-Zinc Batteries
This viewgraph presentation includes: 1) an introduction to RBC Technologies; 2) Rechargeable Zinc Alkaline (RZA(tm)) Systems which include MnO2/Zn, Ni/Zn, Ag/Zn, and Zn/Air; and 3) RZA Silver/Zinc Battery Developments. Conclusions include the following: 1)Issues with long term wet life and cycle life of the silver/zinc battery system are being overcome through the use of new anode formulations and separator designs; 2) Performance may exceed 200 cycles to 80% of initial capacity and ultimate wet-life of > 36 months; and 3) Rechargeable silver/zinc batteries available in prismatic and cylindrical formats may provide a high energy, high power alternative to lithium-ion in military/aerospace applications.
Kainthla, Ramesh↗
Mechanistic understanding of aging behaviors of critical-material-free Li 4 Ti 5 O 12 //LiNi 0.9 Mn 0.1 O 2 cells with fluorinated carbonate-based electrolytes for safe energy storage with ultra-long life span
Behind-the-meter storage (BTMS) systems - a viable method to minimize potential risk of blackout events and stabilize the grid - require a different type of cost-effective energy storage with excellent safety, ultra-long (>20 years) cycle life and reasonable energy density compared that of electric vehicles. To increase the energy density and reduce the cost of a long-term cyclable lithium-titanate-based cell, it is required to employ a critical-material-free high voltage cathode and an electrolyte with good electrochemical and transport properties. In this report the long-term electrochemical performance and behaviors of selected critical-material-free Li 4 Ti 5 O 12 (LTO)//LiNi 0.9 Mn 0.1 O 2 (LNMO) full cells for BTMS applications are evaluated and analyzed in the optimized voltage range of 1.4-2.7 V at 45 degrees C with different fluorinated carbonate-based electrolytes. The fluoroethylene carbonate (FEC)-based electrolyte cell shows the highest capacity retention of 57.9% and Coulombic efficiency (CE) of 99.96% after 1000 cycles, potentially attributed to a dense, homogenous and less resistive LiF-rich solid-electrolyte interphase (SEI) layer formed on the surface of LTO that may mitigate electrolyte decomposition and maintain relatively low cell impedance during cycling. The 3,3,3-fluoroethylmethyl carbonate (F-EMC)-based electrolyte cell, however, presents the worst performance with lower capacity and a sharp decrease of CE, due to unstable and non-uniform SEI formation and continuous oxidative electrolyte decomposition. This mechanistic understanding of cell aging behaviors and failure mechanisms with detailed analysis of surface chemistry and electrode morphology can guide design of new electrode chemistries and electrolyte formulations for the development of BTMS batteries.
25 ENERGY STORAGE↗
Composite Lithium Metal Structure to Mitigate Pulverization and Enable Long‐Life Batteries
In lithium metal batteries, non‐uniform stripping of lithium results in pit formation, which promotes subsequent non‐uniform, dendritic deposition. This viscous cycle leads to pulverization of lithium which promotes cell shorting or capacity degradation, symptoms further exaggerated by high electrode areal loading and lean electrolytes. Here, to address this challenge, a composite lithium metal anode is engineered that contains uniformly distributed, nanometer‐sized carbon particles. This composite lithium is shown to strip more uniformly since the growth of non‐uniform pits is intercepted by the carbon particles. This mechanism is corroborated by a continuum electrochemical model. Subsequent lithium deposition on carbon particles is also found to be more uniform than on the surface with irregular pits. Notably, the pulverization rate of composite lithium is 26 times slower than that of commercial lithium. Moreover, in a Li‐S battery with sulfurized polyacrylonitrile cathode, the use of the composite anode extends the cycle life by three times when the areal capacity is 8 mAh cm −2 . The approach of using an engineered lithium composite structure to address challenges during both stripping and plating can inform future designs of lithium metal anodes for high areal capacity operations.
high areal capacity↗
Long-life assessment of graphite epoxy materials for Space Station Freedom pressure vessels
Graphite/epoxy composite overwrapped pressure vessels are being considered for use on Space Station Freedom because of their light weight and high efficiency. These composite pressure vessels weigh roughly one-third of comparable all-metal aluminum pressure vessels, and could result in a 15,000-lb weight saving for the propulsion and fluid management and distribution systems. These vessels must resist failures under sustained pressure loads for crew safety considerations and adequate protection of the space structure during their 30-yr life. Weibull statistical analysis techniques have been applied, and a model developed, for predicting long-term stress-rupture behavior based on published short-term test data on composite strands and pressure vessels. Graphite/epoxy materials are calculated to have a 99.99-percent probability of surviving stress rupture for 30 yr under a sustained load of 50 percent ultimate failure strength. Stress-rupture lifetimes are predicted to increase as the size of the pressure vessels increases in support of the viscoelastic load-transfer mechanism proposed for stress rupture of fiber/epoxy composite materials.
Thomas, Donald A.↗
Long life performance predictions of SiGe MHW-RTG.
Recent experimental investigations at JPL, Resalab and GGA are incorporated into an analytical model which predicts generator performance over long time periods. The important aging mechanisms considered are degradation in foil insulation conductivity due to reactions with Si sublimed from the hot shoe and SiO2 from the astroquartz layers; changes in hot shoe dimensions due to Si sublimation; changes in leg dimensions due to SiGe sublimation; baffling factors which are applied to the legs to correct the free sublimation model for various effects such as geometry, reactions with the astroquartz wrapping, and hot shoe Si generation; new bulk property changes due to dopant precipitation; and changes in radiation heat exchange due to gap streaming as leg material sublimes.
Caputo, R. S.↗
Ball Milling-Enabled Fe 2.4+ to Fe 3+ Redox Reaction in Prussian Blue Materials for Long-Life Aqueous Sodium-Ion Batteries
Aqueous Na-ion batteries using Prussian blue materials have inherent advantages on safety, material sustainability, and economic cost. However, it is challenging to obtain long term cycling stability because many redox reactions have poor intrinsic stability in water. In this report we demonstrate reversible Fe 2.4+ to Fe 3+ redox reaction of Prussian blue electrodes cycled in 17 m NaClO 4 water-in-salt electrolyte. The cubic phase c-Na 1.17 Fe[Fe(CN) 6 ]·0.35H 2 O) derived from monoclinic Prussian blue (m-Na 1.88 Fe[Fe(CN) 6 ]·0.7H 2 O) through ball milling delivers excellent cycling stability of >18,000 cycles with >90% capacity retention at 10C rate. The specific capacity is ~75 mAh/g and ~67 mAh/g at 1C and 10C rate, respectively. Systematic characterizations including electron microscopy, X-ray diffraction, Fourier-transform infrared spectroscopy, X-ray photoelectron spectroscopy, and X-ray absorption spectroscopy have verified the phase transition and iron oxidation state evolution, revealing the mechanism that enables the material’s high rate and long durability as the battery cathode.
25 ENERGY STORAGE↗
Lightweight long life heat exchanger
The design, fabrication, and evaluation of a full scale shuttle-type condensing heat exchanger constructed of aluminum and utilizing aluminum clad titanium parting sheets is described. A long term salt spray test of candidate parting sheet specimens is described. The results of an investigation into an alternate method of making composite sheet material are discussed.
Moore, E. K.↗
Studies of long-life pulsed CO2 laser with Pt/SnO2 catalyst
Closed-cycle CO2 laser testing with and without a catalyst and with and without CO addition indicate that a catalyst is necessary for long-term operation. Initial results indicate that CO addition with a catalyst may prove optimal, but a precise gas mix has not yet been determined. A long-term run of 10 to the 6th power pulses using 1.3% added CO and a 2% Pt on SnO2 catalyst yields an efficiency of about 95% of open-cycle steady-state power. A simple mathematical analysis yields results which may be sufficient for determining optimum running conditions. Future plans call for testing various catalysts in the laser and longer tests, 10 to the 7th power pulses. A Gas Chromatograph will be installed to measure gas species concentration and the analysis will be slightly modified to include neglected but possibly important parameters.
Sidney, Barry D.↗