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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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A mathematical model for the catastrophic failures (venting or explosion of the cell) in lithium thionyl chloride batteries is presented. The phenomenology of the various processes leading to cell failure is reviewed.
Advanced Air Mobility (AAM) is quickly developing as a new air transportation system that moves people and packages in the regions previously not / less served by the current aviation systems. Such AAM must operate safely despite the potential to encounter hazards and experience anomalies and failures in-flight. It becomes especially important to have systematic auto-mitigation strategies to perform safe contingency actions in AAM flight operations, as pilots have limited Situational Awareness (SA) and limited time to make prompt decisions when encountering failures/anomalies in high-density low altitude airspace. This paper presents Assured Contingency Landing Management (ACLM) with an online landing strategy selection to decide between the following three options when a contingency landing is required: (1) Return-to-launch landing site, (2) Land immediately at a nearby clear but unprepared site, (3) Land at a prepared landing site from the approximate footprint. Our presented algorithm shows a real-time auto-mitigation loop with multiple threads that run simultaneously to check controllability, reachability, and intermediate decisions to hold/ loiter or continue the flight plan as the landing strategy solution is being computed. Case study simulation is demonstrated with the safety-critical propulsion system and battery system and shows how different failure scenarios impact the landing strategy selection.
Data from life-cycle testing of 22-cell NiCd batteries designed for shuttle-service spacecrafts are analyzed, first by averaging battery cycle lives as a function of temperature and depth of discharge, and then by calculating single cell failure and survival probabilities as a function of temperature, depth of discharge, and number of operating cycles. The single cell data are used to calculate battery survival probabilities. A mathematical failure model which is a function of the quantity of charge through the battery and the temperature is characterized, suggesting a predictive capability for accurate estimation of energy storage subsystem life and performance of accelerated tests. The failure mechanism described is apparently independent of most charge-discharge parameters and common to most cell sizes.
In this article, lithium metal (Li 0 ) solid-state batteries encounter implementation challenges due to dendrite formation, side reactions, and movement of the electrode–electrolyte interface in cycling. Notably, voids and cracks formed during battery fabrication/operation are hot spots for failure. Here, a self-healing, flowable yet solid electrolyte composed of mobile ceramic crystals embedded in a reconfigurable polymer network is reported. This electrolyte can auto-repair voids and cracks through a two-step self-healing process that occurs at a fast rate of 5.6 µm h -1 . A dynamical phase diagram is generated, showing the material can switch between liquid and solid forms in response to external strain rates. The flowability of the electrolyte allows it to accommodate the electrode volume change during Li 0 stripping. Simultaneously, the electrolyte maintains a solid form with high tensile strength (0.28 MPa), facilitating the regulation of mossy Li 0 deposition. The chemistries and kinetics are studied by operando synchrotron X-ray and in situ transmission electron microscopy (TEM). Solid-state NMR reveals a dual-phase ion conduction pathway and rapid Li + diffusion through the stable polymer-ceramic interphase. This designed electrolyte exhibits extended cycling life in Li 0 –Li 0 cells, reaching 12 000 h at 0.2 mA cm -2 and 5000 h at 0.5 mA cm -2 . Furthermore, owing to its high critical current density of 9 mA cm -2 , the Li 0 –LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) full cell demonstrates stable cycling at 5 mA cm -2 for 1100 cycles, retaining 88% of its capacity, even under near-zero stack pressure conditions.
The data analysis of cycles to failure of silver-zinc electrochemical cells with competing failure modes is presented. The test ran 129 cells through charge-discharge cycles until failure; preliminary data analysis consisted of response surface estimate of life. Batteries fail through low voltage condition and an internal shorting condition; a competing failure modes analysis was made using maximum likelihood estimation for the extreme value life distribution. Extensive residual plotting and probability plotting were used to verify data quality and selection of model.
Lithium-ion (Li-ion) batteries can deliver electrical power across a large range of applications, and large format versions of these batteries are common in aerospace for their low mass and energy dense properties. Li-ion cells usage has increased as they are more power dense than fuel cells and have overall higher performance over lead-acid/NiCd batteries. However, Li-ion cells can experience Thermal Runaway (TR) via electro-chemical, mechanical, or thermal abuse. TR is a phenomenon where the stored energy in a cell is rapidly released along with vented gases and other effluents. A cell is generally determined to be in TR if its internal heat generation has surpassed its ability to dissipate that heat. If a Li-ion cell enters TR, propagation within the battery may occur. Propagation is the chain reaction that can occur to nearby cells due to a cell that has entered TR initially. Understanding a battery’s susceptiveness to propagation is necessary to evaluate risks associated with TR phenomenon. To determine if a battery is designed in a sufficient manner to prevent battery propagation if single cell TR occurs, testing and thermal analysis of the battery must be conducted. The presentation for TFAWS 2026 will cover considerations for battery TR thermal analysis, such as: testing methods, influences on the cells, failure mechanisms, and TR parameters. This presentation will include a walkthrough of an example battery TR thermal analysis, and the results thereof.
Autonomous operation is essential for the deployment of microreactors and fission batteries, both in terrestrial and space applications. For this reason, recent studies have investigated autonomous control by using adaptive model predictive control and multi-objective optimization for heat pipe–cooled microreactors under normal and heat pipe failure conditions. However, prototypes of microreactors and fission batteries do not exist yet, and even the design space has not been narrowed down conclusively, making the instrumentation and control system design difficult. For this reason, there is a need for flexible computational capabilities to create a numerical stand-in of potential microreactor and fission battery designs. The latter can be used to design and test control strategies to support autonomous operations. In this poster, we describe the initial implementation of a pluggable sensor system for the easy implementation of realistic sensor models in the multiphysics object-oriented simulation environment (MOOSE) framework. This new capability will enable MOOSE users to create a numerical stand-in of microreactors and fission batteries, ultimately allowing them to easily test new control algorithms, and instrumentation strategies for advanced systems in the design phase.
This study investigates the Li stripping-plating morphology and failure mechanisms in full cells consisting of a solid polymer electrolyte (SPE) with two commercial Li anodes: Li chip and Li foil. The primary identified failure mechanism of the SPE cell is capacity fade, regardless of the Li manufacturer. While the cathode’s role in capacity fade is evident, the Li anode significantly influences cycling performance, with Li foil cells cycling 50% longer than Li chip cells, a statistical difference. Further, post-mortem scanning electron microscopy and X-ray photoelectron spectroscopy results attribute the Li chip’s faster capacity fade to a loss of contact and continuous growth of the solid electrolyte interphase (SEI). Conversely, Li foil maintains consistent contact with the solid polymer, displaying a thin and stable SEI. Additionally, failure mechanisms between a gel electrolyte in previous work and the dry SPE are compared.
This presentation provides an overview of EVA batteries and introduces the concept of designing lithium ion batteries that resist the propagation of a single cell catastrophic failure. Thermal runaway initiation methods are briefly discussed, and the safe performance of the resulting designs is summarized. Approached in an incremental fashion, each subsequent battery design is introduced, ending with a current development for the Exploration EVA spacesuit. Challenges in achieving safe design performance with limited internal volume are briefly discussed and forward work is identified. Video examples of both propagating and non-propagating designs are included.
Several recently manufactured 50 and 60 ampere hour aerospace NiCd battery cell lots, produced by Gates Aerospace Batteries, are prone to premature on orbit performance degradation. The failure mechanism is cadmium migration, and the consequent development of soft shorts. A Martin Marietta Astronautics satellite program instituted an orbital management strategy for a set of these batteries that reduced the rate of degradation and brought the system to stable operation. This strategy involves: (1) minimizing the accumulated battery overcharge; (2) regular discharge exercises; and (3) periodic battery reconditioning. Because of changes in the NiCd cell manufacturing process, the actual performance of subsequent lots of NiCd cells is open to question. Future NiCd based power system designs should therefore allow for fine control of charge parameters, and an on orbit battery reconditioning capability. To minimize risk, it is much better to perform a full life test to qualify the cells before launch, rather than in parallel with orbital operations. If there are any changes in the manufacturing process of cells, it is extremely important to maintain very strong cognizance of secondary subcontractors, recognizing that the cell and battery manufacturing discipline is easily atrophied.
Electrical actuator systems are being pursued as alternatives to hydraulic systems to reduce maintenance time, weight and costs while increasing reliability. Additionally, safety and environmental hazards associated with the hydraulic fluids can be eliminated. For most actuation systems, the actuation process is typically pulsed with high peak power requirements but with relatively modest average power levels. The power-time requirements for electrical actuators are characteristic of pulsed power technologies where the source can be sized for the average power levels while providing the capability to achieve the peak requirements. Among the options for the power source are battery systems, capacitor systems or battery-capacitor hybrid systems. Battery technologies are energy dense but deficient in power density; capacitor technologies are power dense but limited by energy density. The battery-capacitor hybrid system uses the battery to supply the average power and the capacitor to meet the peak demands. It has been demonstrated in previous work that the hybrid electrical power source can potentially provide a weight savings of approximately 59% over a battery-only source. Electrochemical capacitors have many properties that make them well-suited for electrical actuator applications. They have the highest demonstrated energy density for capacitive storage (up to 100 J/g), have power densities much greater than most battery technologies (greater than 30kW/kg), are capable of greater than one million charge-discharge cycles, can be charged at extremely high rates, and have non-explosive failure modes. Thus, electrochemical capacitors exhibit a combination of desirable battery and capacitor characteristics.
MOLICEL rechargeable lithium cells were cycled in batteries using series, parallel, and series/parallel connections. The individual cell voltages and branch currents were measured to understand the cell interactions. The observations were interpreted in terms of the inherent characteristics of the Li/MoS2 system and in terms of a singular cell failure mode. The results confirm that correctly configured multicell batteries using MOLICELs have performance characteristics comparable to those of single cells.
The growing interest in sodium-ion batteries (SIBs) is fueled by their abundant resources and environmentally friendly nature, with amorphous silicon (a-Si) emerging as a promising anode material for enhancing capacity. However, the key challenge lies in sustaining reversible capacity during cycling. Here, in this work, we developed a multiscale electrochemical model incorporating an a-Si anode to elucidate the performance parameters of SIBs. Additionally, we integrated an electro-chemo-mechanical model at the particle level to capture stress generation, an essential factor in the degradation of high-capacity electrodes. Unlike existing models, our approach accounts for large-deformation chemo-mechanics at the particle scale and includes simulations under varying charge rates to explore multiscale behavior. The results reveal that coupled sodiation significantly prolongs complete cycling times and influences discharge dynamics, indicating that neglecting this coupling leads to an underestimation of actual capacity. Furthermore, we observed pronounced polarization effects at higher charge rates, resulting in heterogeneous stress distributions across the anode. With the identification of critical failure parameters for both active particles and binder materials, offering novel insights for mitigating degradation in high-capacity electrode systems.
A mathematical representation for the charge and discharge of a sodium-sulfur cell is developed. These equations are then used as the basis for a computerized model to examine the effects of cell arrangement in the design of a large multi-kilowatt battery from a group of hypothetical individual cells with known variations in their ampere hour capacity and internal resistance. The cycling characteristics of 216 individual cells arranged in six different configurations are evaluated with the view towards minimizing the adverse effects that are introduced due to the stoichastic aspects of groupings of cells, as well as the possibility of cell failures in both the open and shorted mode. Although battery systems based on sodium-sulfur cells are described in this example, any of the newer electrochemical systems can be fitted into this framework by making appropriate modifications to the basic equations.
A mathematical representation for the charge and discharge of a sodium-sulfur cell is developed. These equations are then used as the basis for a computerized model to examine the effects of cell arrangement in the design of a large multi-kilowatt battery from a group of hypothetical individual cells with known variations in their ampere hour capacity and internal resistance. The cycling characteristics of 216 individual cells arranged in six different configurations are evaluated with the view towards minimizing the adverse effects that are introduced due to the stochastic aspects of groupings of cells, as well as the possibility of cell failures in both the open and shorted mode. Although battery systems based on sodium-sulfur cells are described in this example, any of the newer electrochemical systems can be fitted into this framework by making appropriate modifications to the basic equations.
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.
Recent changes in manufacturing have resulted in nickel-hydrogen batteries that fail prematurely by electrical shorting. This failure is believed to be a result of a blistering problem in the nickel electrodes. In this study, the bending properties of nickel electrodes are investigated in an attempt to correlate the bending properties of the electrode with its propensity to blister. Nickel electrodes from three different batches of material were tested in both the as-received and impregnated forms. The effects of specimen curvature and position within the electrode on the bending strength were studied, and within-electrode and batch-to-batch variations were addressed. Bend strength was found to increase with the amount of surface loading.
Engineering unit submodule batteries (EUSB) the 360V, 28kWh EAPU battery were designed and assembled by COM DEV. These submodules consist of Sony Li-Ion 18650HC cells in a 5P-41S array yielding 180V, 1.4 kWh. Tests of these and of substrings and single cells at COM DEV and at JSC under various performance and abuse conditions demonstrated that performance requirements can be met. The thermal vacuum tests demonstrated that the worst case hot condition is the design driver. Deficiencies in the initial diode protection scheme of the battery were identified as a result of test failures. Potential solutions to the scheme are under development and will be presented.