Results for “life testing”

DOE OSTI2018

RESULTS OF ACCELERATED LIFE TESTING OF LCLS-II CAVITY TUNER MOTOR

An Accelerated Life Test (ALT) of the Phytron stepper motor used in the LCLS-II cavity tuner has been conducted at JLab. Since the motor will reside inside the cryomodule, any failure would lead to a very costly and arduous repair. As such, the motor was tested for the equivalent of 30 lifetimes before being approved for use in the production cryomodules. The 9-cell LCLS-II cavity is simulated by disc springs with an equivalent spring constant. Plots of the motor position vs. tuner position ' measured via an installed linear variable differential transformer (LVDT) ' are used to measure motor motion. The titanium spindle was inspected for loss of lubrication. The motor passed the ALT, and is set to be installed in the LCLS-II cryomodules.

Huque, Naeem↗

DOE OSTI2025

Characterization, Accelerated Life Testing, and Finite Element Modeling of Low Temperature Solder Wire Interconnect Degradation Mechanisms

Explore the source record for details and available documents.

Hartley, James Yuan [Sandia National Laboratories ↗

DOE OSTI2025

On the Efficacy of Repeat Voltage Holds for Conditioning and Calendar Life Testing of Graphite and Silicon Cells

Voltage-hold (V-hold) protocols have shown promise toward calendar lifetime analysis of cells with graphite (Gr) and silicon (Si) anodes. In this work, repeat V-holds are performed on Gr and Si cells paired with lithium iron phosphate cathodes to delineate their beneficial role in formation and conditioning. We find that V-hold at the top of charge supplements constant current cycling in conditioning the cell to higher capacities for both Gr and Si cells after the first V-hold. A reduced order model provides the irreversible capacity proportions of each V-hold. With each repeat V-hold, parasitic loss of lithium to the solid electrolyte interphase (SEI) decreases on both Gr and Si cells. Gr cells show the square-root-of-time capacity loss behavior within 200 h of V-hold, indicative of its fast relaxation and low impact of reference performance test cycles on the SEI growth. Lifetime estimates from repeat V-holds on Gr can reach years. Si exhibits longer transition times from kinetic to diffusion-limited SEI growth, evidenced by the 400 h and 200 h holds showing square-root-of-time and linear behavior, respectively. Lifetime predictions from repeat V-holds on Si only reach 1–2 months, highlighting its limitations. Recommended duration of V-holds for Si cells should be ≥400 h.

25 ENERGY STORAGE↗

DOE OSTI2016

LiNi 0.8 Co 0.2 O 2 -based high power lithium-ion battery positive electrodes analyzed by x-ray photoelectron spectroscopy: 3. Following calendar-life test for 12 weeks at 40 °C, 60% state-of-charge (3.747 V)

High-power lithium-ion batteries are rapidly replacing the nickel metal hydride batteries currently used for energy storage in hybrid electric vehicles. Widespread commercialization of these batteries for vehicular applications is, however, limited by calendar-life performance, thermal abuse characteristics, and cost. The Advanced Technology Development Program was established by the U.S. Department of Energy to address these limitations. An important objective of this program was the development and application of diagnostic tools that provide unique ways to investigate the phenomena that limit lithium-ion cell life, performance, and safety characteristics. This report introduces a set of six Surface Science Spectra xray photoelectron spectroscopy (XPS) comparison records of data collected from positive electrodes (cathode) harvested from cylindrically wound, 18650-type, 1 A h capacity cells. The cathodes included in this study are (1) fresh, (2) following three formation cycles, (3) following calendar-life test for 12 weeks at 40 C, 60% state-of-charge (SOC), (4) following calendar-life test for 8 weeks at 50 C, 60% SOC, (5) following calendar-life test for 8 weeks at 60 C, 60% SOC, and (6) following calendar-life test for 2 weeks at 70 C, 60% SOC.

energy conversion and storage↗

DOE OSTI2016

LiNi 0.8 Co 0.2 O 2 -based high power lithium-ion battery positive electrodes analyzed by x-ray photoelectron spectroscopy: 4. Following calendar-life test for 8 weeks at 50 °C, 60% state-of-charge (3.747 V)

High-power lithium-ion batteries are rapidly replacing the nickel metal hydride batteries currently used for energy storage in hybrid electric vehicles. Widespread commercialization of these batteries for vehicular applications is, however, limited by calendar-life performance, thermal abuse characteristics, and cost. The Advanced Technology Development Program was established by the U.S. Department of Energy to address these limitations. An important objective of this program was the development and application of diagnostic tools that provide unique ways to investigate the phenomena that limit lithium-ion cell life, performance, and safety characteristics. This report introduces a set of six Surface Science Spectra xray photoelectron spectroscopy (XPS) comparison records of data collected from positive electrodes (cathode) harvested from cylindrically wound, 18650-type, 1 A h capacity cells. The cathodes included in this study are (1) fresh, (2) following three formation cycles, (3) following calendar-life test for 12 weeks at 40 C, 60% state-of-charge (SOC), (4) following calendar-life test for 8 weeks at 50 C, 60% SOC, (5) following calendar-life test for 8 weeks at 60 C, 60% SOC, and (6) following calendar-life test for 2 weeks at 70 C, 60% SOC.

25 ENERGY STORAGE↗

DOE OSTI2016

LiNi 0.8 Co 0.2 O 2 -based high power lithium-ion battery positive electrodes analyzed by x-ray photoelectron spectroscopy: 5. Following calendar-life test for 8 weeks at 60 °C, 60% state-of-charge (3.747 V)

High-power lithium-ion batteries are rapidly replacing the nickel metal hydride batteries currently used for energy storage in hybrid electric vehicles. Widespread commercialization of these batteries for vehicular applications is, however, limited by calendar-life performance, thermal abuse characteristics, and cost. The Advanced Technology Development Program was established by the U.S. Department of Energy to address these limitations. An important objective of this program was the development and application of diagnostic tools that provide unique ways to investigate the phenomena that limit lithium-ion cell life, performance, and safety characteristics. This report introduces a set of six Surface Science Spectra xray photoelectron spectroscopy (XPS) comparison records of data collected from positive electrodes (cathode) harvested from cylindrically wound, 18650-type, 1 A h capacity cells. The cathodes included in this study are (1) fresh, (2) following three formation cycles, (3) following calendar-life test for 12 weeks at 40 C, 60% state-of-charge (SOC), (4) following calendar-life test for 8 weeks at 50 C, 60% SOC, (5) following calendar-life test for 8 weeks at 60 C, 60% SOC, and (6) following calendar-life test for 2 weeks at 70 C, 60% SOC.

25 ENERGY STORAGE↗

DOE OSTI2016

LiNi 0.8 Co 0.2 O 2 -based high power lithium-ion battery positive electrodes analyzed by x-ray photoelectron spectroscopy: 6. Following calendar-life test for 2 weeks at 70 °C, 60% state-of-charge (3.747 V)

High-power lithium-ion batteries are rapidly replacing the nickel metal hydride batteries currently used for energy storage in hybrid electric vehicles. Widespread commercialization of these batteries for vehicular applications is, however, limited by calendar-life performance, thermal abuse characteristics, and cost. The Advanced Technology Development Program was established by the U.S. Department of Energy to address these limitations. An important objective of this program was the development and application of diagnostic tools that provide unique ways to investigate the phenomena that limit lithium-ion cell life, performance, and safety characteristics. This report introduces a set of six Surface Science Spectra xray photoelectron spectroscopy (XPS) comparison records of data collected from positive electrodes (cathode) harvested from cylindrically wound, 18650-type, 1 A h capacity cells. The cathodes included in this study are (1) fresh, (2) following three formation cycles, (3) following calendar-life test for 12 weeks at 40 C, 60% state-of-charge (SOC), (4) following calendar-life test for 8 weeks at 50 C, 60% SOC, (5) following calendar-life test for 8 weeks at 60 C, 60% SOC, and (6) following calendar-life test for 2 weeks at 70 C, 60% SOC.

25 ENERGY STORAGE↗

DOE OSTI2017

High Pressure Hydrogen Pressure Relief Devices: Accelerated Life Testing and Application Best Practices

Pressure relief devices (PRDs ) are used to protect high pressure systems from burst failure caused by overpressurization. Codes and standards require the use of PRDs for the safe design of many pressurized systems. These systems require high reliability due to the risks associated with a burst failure. Hydrogen service can increase the risk of PRD failure due to material property degradation caused by hydrogen attack. The National Renewable Energy Laboratory (NREL) has conducted an accelerated life test on a conventional spring loaded PRD. Based on previous failures in the field, the nozzles specific to these PRDs are of particular interest. A nozzle in a PRD is a small part that directs the flow of fluid toward the sealing surface to maintain the open state of the valve once the spring force is overcome. The nozzle in this specific PRD is subjected to the full tensile force of the fluid pressure. These nozzles are made from 440C material, which is a type of hardened steel that is commonly chosen for high pressure applications because of its high strength properties. In a hydrogen environment, however, 440C is considered a worst case material since hydrogen attack results in a loss of almost all ductility and thus 440C is prone to fatigue and material failure. Accordingly, 440C is not recommended for hydrogen service. Conducting an accelerated life test on a PRD with 440C material provides information on necessary and sufficient conditions required to produce crack initiation and failure. The accelerated life test also provides information on other PRD failure modes that are somewhat statistically random in nature.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Highly accelerated life testing (HALT): A review from a statistical perspective

Despite its use in one form or another for at least four decades, HALT and related techniques [e.g., highly accelerated-stress screening (HASS) and stress audits (HASA)] are not well understood within the statistical community and remain controversial. This largely reflects a conflict in motivation between engineers, testing under harsh conditions to discover and eliminate failure modes, and statisticians, taking a more cautious approach to develop quantitative estimates of parameters such as mean time between failures (MTBF). Here, this review article will clarify HALT concepts and methods and explain where it fits within the universe of methods that involve the application of accelerating factors to compress the time required to evaluate or enhance product reliability. A major distinction is between methods such as HALT, a high-stress test-analyze-fix-test iterative process directed at improving reliability by discovering and fixing weak points in a design, and quantitative accelerated life testing (QALT), whose goal is the estimation of product life for a fixed design. We discuss methods such as physics of failure that offer some hope of bridging the gap between the qualitative nature of HALT, and purely quantitative statistical methods. We present a variety of engineering applications of HALT including metal fatigue, piping and pressure vessels, structural damage, radiation damage, and rotating machinery. We also discuss potential synergies between HALT and QALT, such as rapid identification, through HALT, of failure modes requiring quantitative analysis. For further study, extensive references to the applicable literature are provided as well as an appendix that describes related methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Characterization and Accelerated Life Testing of a New Solid Oxide Electrolysis Cell

The project aims to develop mechanistic degradation models that realistically predict long-term Solid Oxide Electrolysis Cell (SOEC) durability, using input data from accelerated electrochemical life testing combined with quantitative microstructural and microchemical evaluation. A promising SOEC type will be further developed. The understanding achieved by combining experimental results and theory will be used to guide improvements in long-term SOEC durability, and validate that this technology can reach DOE H 2 production cost and durability targets. Planned outcomes include: (1) new experimental accelerated testing data on SOEC degradation at the oxygen electrode, fuel electrode, and electrolyte; (2) predictive theory of degradation developed based on the accelerated test data; (3) new electrode materials and processing methods that minimize degradation rate; (4) determination of the impact of SOEC electrolyte thickness and electrode composition/microstructure on performance and degradation; (5) determination of the operating conditions where degradation is minimized; and (6) validation of degradation models for extrapolating accelerated test data to predict long-term durability.

08 HYDROGEN↗

DOE OSTI2021

Silicon Consortium Project: No-Go on Moir Interferometry for Measuring SEI Strain as a Probe for Calendar Life Testing

Silicon is a promising candidate as a next generation anode to replace or complement graphite electrodes due to its high energy density and low lithiation potential. When silicon is lithiated, it experiences over 300% expansion which stresses the silicon as well as its solid electrolyte interphase (SEI) leading to poor performance. The use of nano-sized silicon has helped to mitigate volume expansion and stress in the silicon, yet the silicon SEI is still both mechanically and chemically unstable. Identifying the mechanical failure mechanism of the SEI will help enhance calendar and cycle life performance through improved SEI design. In situ moiré interferometry was investigated to try and track the in-plane strain in the SEI and silicon electrode for this purpose. Moiré can detect on the order of 10 nm changes in displacement and is therefore a useful tool in the measurement of strain. As the sample undergoes small deformations, large changes in the moiré fringe allow for measurements of displacement below the diffraction limit of light. Figure 1a shows how the moiré fringe changes as the sample grating deforms. As the sample contracts or expands, the frequency of the moiré fringe changes, and this change is proportional to the strain in the sample.

36 MATERIALS SCIENCE↗

DOE OSTI2024