Fast Diagnosis of Failure Mechanisms and Lifetime Prediction of Li Metal Batteries
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99 GENERAL AND MISCELLANEOUS↗
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Satellite lifetime prediction
Satellite lifetime predictions are critically dependent on the ability to forecast future solar and geomagnetic activity. These quantities are inputs to the atmospheric model with which values of atmospheric density are computed along a projected orbital path. Density values are combined with the predicted ballistic coefficient timeline to compute drag and predict decay histories. The major uncertainty in making predictions that pertain to the time periods that are years in the future is in the solar and geomagnetic activity projections, although the ballistic coefficient is also frequently in doubt. The study concludes that while present density models are adequate for planning, the inputs to them, particularly solar/geomagnetic activity indices, are unreliable.
Wittenstein, Gerald↗
Long-term orbital lifetime predictions
Long-term orbital lifetime predictions are analyzed. Predictions were made for three satellites: the Solar Max Mission (SMM), the Long Duration Exposure Facility (LDEF), and the Pegasus Boiler Plate (BP). A technique is discussed for determining an appropriate ballistic coefficient to use in the lifetime prediction. The orbital decay rate should be monitored regularly. Ballistic coefficient updates should be done whenever there is a significant change in the actual decay rate or in the solar activity prediction.
Dreher, P. E.↗
Skylab orbital lifetime prediction and decay analysis
A record (from preflight planning to earth impact) of skylab's orbital lifetime predictions, its actual decay and analysis are presented. Skylab provided a unique opportunity to develop, confirm and check out procedures and computer programs used for predicting lifetime and reentry. It provided verification of aerodynamic environment which was predicted for several aerodynamic configurations. It also provided data on the density model's reaction to rapidly changing solar flux over relatively short time periods. The effects of solar flux (and the uncertainty in the solar flux predictions) on orbital lifetime are discussed.
Dreher, P. E.↗
Lifetime predictions for the Solar Maximum Mission (SMM) and San Marco spacecraft
Lifetime prediction techniques developed by the Goddard Space Flight Center (GSFC) Flight Dynamics Division (FDD) are described. These techniques were developed to predict the Solar Maximum Mission (SMM) spacecraft orbit, which is decaying due to atmospheric drag, with reentry predicted to occur before the end of 1989. Lifetime predictions were also performed for the Long Duration Exposure Facility (LDEF), which was deployed on the 1984 SMM repair mission and is scheduled for retrieval on another Space Transportation System (STS) mission later this year. Concepts used in the lifetime predictions were tested on the San Marco spacecraft, which reentered the Earth's atmosphere on December 6, 1988. Ephemerides predicting the orbit evolution of the San Marco spacecraft until reentry were generated over the final 90 days of the mission when the altitude was less than 380 kilometers. The errors in the predicted ephemerides are due to errors in the prediction of atmospheric density variations over the lifetime of the satellite. To model the time dependence of the atmospheric densities, predictions of the solar flux at the 10.7-centimeter wavelength were used in conjunction with Harris-Priester (HP) atmospheric density tables. Orbital state vectors, together with the spacecraft mass and area, are used as input to the Goddard Trajectory Determination System (GTDS). Propagations proceed in monthly segments, with the nominal atmospheric drag model scaled for each month according to the predicted monthly average value of F10.7. Calibration propagations are performed over a period of known orbital decay to obtain the effective ballistic coefficient. Progagations using plus or minus 2 sigma solar flux predictions are also generated to estimate the despersion in expected reentry dates. Definitive orbits are compared with these predictions as time expases. As updated vectors are received, these are also propagated to reentryto continually update the lifetime predictions.
Smith, E. A.↗
Investigating explainable transfer learning for battery lifetime prediction under state transitions
Battery lifetime prediction at early cycles is crucial for researchers and manufacturers to examine product quality and promote technology development. Machine learning has been widely utilized to construct data-driven solutions for high-accuracy predictions. However, the internal mechanisms of batteries are sensitive to many factors, such as charging/discharging protocols, manufacturing/storage conditions, and usage patterns. These factors will induce state transitions, thereby decreasing the prediction accuracy of data-driven approaches. Transfer learning is a promising technique that overcomes this difficulty and achieves accurate predictions by jointly utilizing information from various sources. Hence, we develop two transfer learning methods, Bayesian Model Fusion and Weighted Orthogonal Matching Pursuit, to strategically combine prior knowledge with limited information from the target dataset to achieve superior prediction performance. From our results, our transfer learning methods reduce root-mean-squared error by 41% through adapting to the target domain. Furthermore, the transfer learning strategies identify the variations of impactful features across different sets of batteries and therefore disentangle the battery degradation mechanisms and the root cause of state transitions from the perspective of data mining. These findings suggest that the transfer learning strategies proposed in our work are capable of acquiring knowledge across multiple data sources for solving specialized issues.
25 ENERGY STORAGE↗
Measurement requirements and techniques for degradation studies and lifetime prediction testing of photovoltaic modules
Tests of weathering and aging behavior are being developed to characterize the degradation and predict the lifetimes of low-cost photovoltaic arrays. Environmental factors which affect array performance include UV radiation, thermal energy, water, oxygen (generally involved in synergistic effects with UV radiation or high temperatures), physical stress, pollutants (oxides of nitrogen, sulfur dioxide and ozone), abrasives and dirt. A survey of photovoltaic array testing has shown the need to establish quantitative correlations between certain measurable properties (carbonyl formation, glass transition temperature, and molecular weight change) and modes of degradation and failure.
Noel, G. T.↗
Tensile Property and Lifetime Prediction for Low-Temperature Aged Uranium-Niobium Alloys
Thermal aging models and lifetime predictions for uranium-niobium (U-Nb) alloys were created using an approach similar to those previously employed. Lifetime estimates for generic U-6Nb components were thus updated; the reported value being 800 years. This update represents a small change in lifetime vs. that of the 2012 assessment (540 years). This lifetime estimate emerged from consideration of several model fits specific to the aging datasets and properties chosen. Aging was quantified using quasi-static tensile properties measured on specimens artificially aged for up to 10 years. The major change relative to the most recent 2012 LANL assessment was that a more comprehensive body of U-Nb literature data was mined, in addition to being augmented by the latest LANL and UK AWE data. The tensile data compilation was published separately (LANL report LA-14493, December 2016). Recognizing the chemical banding of industrially produced U-6Nb, models were developed for the mid-range (6 wt.%) and extrema (4 and 8 wt.%) compositions. Lifetime estimates were calculated for all three alloy classes (4, 6, 8 wt.% nominal) and two measures of total tensile elongation (TE) to failure, namely TE-ext. — extensometer method, and TE-NCD — normalized crosshead displacement method. The conservative assumption was made that whichever composition (4, 6, or 8 wt.% Nb) and property (TE-ext or TE-NCD) was the first to cross the ductility failure threshold would limit the lifetime of the entire component. Tensile strength properties did not figure into the lifetime predictions, but could be useful as age-sensitive diagnostics and were also modeled. Of these, only first yield strength is expected to show a change at 40°C aging vs. time = 0 over the ~100-year timespan of engineering interest. Second yield strength evolves more slowly, and ultimate tensile strength slower still. Among all the models, the apparent activation energies for aging were mostly in the narrow 29– 37 kcal/mol range, which is close to that for diffusion of Nb in gamma-uranium. This agreement may be coincidental. The data from recent long-term aging studies substantially improved the model fit quality and robustness of the lifetimes. Appendices document sensitivity studies of the model fits and lifetimes with respect to using more limited datasets. These results highlight the limitations of relying solely on data from scattered literature studies and smaller datasets more generally.
36 MATERIALS SCIENCE↗
Worldwide Physics-Based Lifetime Prediction of c-Si Modules Due to Solder-Bond Failure
Lifetime prediction of the fielded c-Si solar modules due to location-specific weather conditions has been an important topic of photovoltaic research and the economic viability of solar energy. Data analytic techniques such as the performance ratio method, Statistical clear sky model, and Suns-Vmp methods quantify the degradation from measured data of a solar farm, however, the nonlinear time-dependence and correlated degradations make it difficult to use the empirical degradation rates for ultimate lifetime projection. In this article, we propose a complementary physics-based model to predict the solder bond failure caused by mechanical stress associated with the variations of the temperature. Integrating the worldwide weather information from NASA/NSRDB databases, the model predicts the location-specific output-power degradation and the lifetime of a module due to solder bond failure. The model parameters are calibrated against qualification tests involving thermal cycling of specific batches of modules from a specific technology/manufacturer. The results may be summarized as: 1) Modules installed at higher latitudes show a longer lifetime due to reduced damage accumulation. 2) The reduction of temperature fluctuation close to large bodies of water, such as seashores, increases solder bond lifetime significantly. 3) Relatively speaking, modules installed close to the Tropic of Cancer/Capricorn (23.5 degrees North/South) suffer from a higher solder bond damage and have a shorter lifetime, suggesting a conservative design. This model should serve as a building block of a comprehensive reliability framework that can predict the lifetime of a module that experiences simultaneous and correlated degradation mechanisms involving yellowing, corrosion, and potential-induced degradation.
14 SOLAR ENERGY↗
Lifetime Predictions of a Titanium Silicate Glass with Machined Flaws
A dynamic fatigue study was performed on a Titanium Silicate glass to assess its susceptibility to delayed failure and to compare the results with those of a previous study. Fracture mechanics techniques were used to analyze the results for the purpose of making lifetime predictions. The material strength and lifetime was seen to increase due to the removal of residual stress through grinding and polishing. Influence on time-to-failure is addressed for the case with and without residual stress present. Titanium silicate glass otherwise known as ultra-low expansion (ULE)* glass is a candidate for use in applications requiring low thermal expansion characteristics such as telescope mirrors. The Hubble Space Telescope s primary mirror was manufactured from ULE glass. ULE contains 7.5% titanium dioxide which in combination with silica results in a homogenous glass with a linear expansion coefficient near zero. delayed failure . This previous study was based on a 230/270 grit surface. The grinding and polishing process reduces the surface flaw size and subsurface damage, and relieves residual stress by removing the material with successively smaller grinding media. This results in an increase in strength of the optic during the grinding and polishing sequence. Thus, a second study was undertaken using samples with a surface finish typically achieved for mirror elements, to observe the effects of surface finishing on the time-to-failure predictions. An allowable stress can be calculated for this material based upon modulus of rupture data; however, this does not take into account the problem of delayed failure, most likely due to stress corrosion, which can significantly shorten lifetime. Fortunately, a theory based on fracture mechanics has been developed enabling lifetime predictions to be made for brittle materials susceptible to delayed failure. Knowledge of the factors governing the rate of subcritical flaw growth in a given environment enables the development of relations between lifetime, applied stress and failure probability for the material under study. Dynamic fatigue is one method of obtaining the necessary information to develop these relationships. In this study, the dynamic fatigue method was used to construct a time-to-failure diagram for polished ULE glass.
Tucker, Dennis S.↗
Variation of parameters for long periodic terms in predicting lifetimes of Venus orbiters
Parameter variation for long periodic terms in predicting lifetimes of Venus orbiters
Kaufman, B.↗
A Satellite Mortality Study to Support Space Systems Lifetime Prediction
Estimating the operational lifetime of satellites and spacecraft is a complex process. Operational lifetime can differ from mission design lifetime for a variety of reasons. Unexpected mortality can occur due to human errors in design and fabrication, to human errors in launch and operations, to random anomalies of hardware and software or even satellite function degradation or technology change, leading to unrealized economic or mission return. This study focuses on data collection of public information using, for the first time, a large, publically available dataset, and preliminary analysis of satellite lifetimes, both operational lifetime and design lifetime. The objective of this study is the illustration of the relationship of design life to actual lifetime for some representative classes of satellites and spacecraft. First, a Weibull and Exponential lifetime analysis comparison is performed on the ratio of mission operating lifetime to design life, accounting for terminated and ongoing missions. Next a Kaplan-Meier survivor function, standard practice for clinical trials analysis, is estimated from operating lifetime. Bootstrap resampling is used to provide uncertainty estimates of selected survival probabilities. This study highlights the need for more detailed databases and engineering reliability models of satellite lifetime that include satellite systems and subsystems, operations procedures and environmental characteristics to support the design of complex, multi-generation, long-lived space systems in Earth orbit.
Fox, George↗
Filter replacement lifetime prediction
Systems for predicting a filter lifetime. A filter monitoring system includes a filter effectiveness history based on contaminant sensor information associated with a filter received from one or more contaminant sensors. A lifetime module is configured to determine a rate of filter consumption based on the filter effectiveness history and to determine a remaining filter lifetime based on the determined rate of filter consumption.
42 ENGINEERING↗
Effects of applied stress and grain size on creep-rupture lifetime prediction for Haynes 282 alloy
A multiple-heat set of tensile and creep-rupture data generated from a single laboratory was used to establish and evaluate predictive equations for the average creep-limited lifetime of an aged wrought Haynes 282 alloy using two different time- and temperature-compensated parametric models (those of Larson and Miller and Wilshire et al.). The range of temperatures and stresses used to produce the creep-rupture data used in the analyses revealed that two distinct regimes, above and below the proportional limit, were necessary for more accurate predictions of creep lifetimes over the range of conditions studied. Furthermore, a 2x difference in grain size amongst the three heats revealed a breakdown in the relationship between ultimate tensile strength and creep-rupture time, thus impacting the predictive ability of the Wilshire model. Finally, lifetime predictions based on the formulations from the respective models were compared to other available Haynes 282 datasets and found to reasonably replicate the experimental trends established in other studies.
36 MATERIALS SCIENCE↗
Atmospheric drag model calibrations for spacecraft lifetime prediction
Although solar activity prediction uncertainty normally dominates decay prediction error budget for near-Earth spacecraft, the effect of drag force modeling errors for given levels of solar activity needs to be considered. Two atmospheric density models, the modified Harris-Priester model and the Jacchia-Roberts model, to reproduce the decay histories of the Solar Mesosphere Explorer (SME) and Solar Maximum Mission (SMM) spacecraft in the 490- to 540-kilometer altitude range were analyzed. Historical solar activity data were used in the input to the density computations. For each spacecraft and atmospheric model, a drag scaling adjustment factor was determined for a high-solar-activity year, such that the observed annual decay in the mean semimajor axis was reproduced by an averaged variation-of-parameters (VOP) orbit propagation. The SME (SMM) calibration was performed using calendar year 1983 (1982). The resulting calibration factors differ by 20 to 40 percent from the predictions of the prelaunch ballistic coefficients. The orbit propagations for each spacecraft were extended to the middle of 1988 using the calibrated drag models. For the Jaccia-Roberts density model, the observed decay in the mean semimajor axis of SME (SMM) over the 4.5-year (5.5-year) predictive period was reproduced to within 1.5 (4.4) percent. The corresponding figure for the Harris-Priester model was 8.6 (20.6) percent. Detailed results and conclusions regarding the importance of accurate drag force modeling for lifetime predictions are presented.
Binebrink, A. L.↗
Experimental Aging and Lifetime Prediction in Grid Applications for Large-Format Commercial Li-Ion Batteries
Due to the growth of electric vehicle and stationary energy storage markets, the production and use of lithium-ion batteries has grown exponentially in recent years. For many of these applications, large-format lithium-ion batteries are being utilized, as large cells have less inactive material relative to their energy capacity and require fewer electrical connections to assemble into packs. And especially for stationary energy storage systems, where energy delivered is the only revenue source, the economics of these battery systems is highly dependent on cell lifetime. However, testing of large-format lithium-ion batteries is time consuming and requires high current channels and large testing chambers, making information on the performance of commercial, large-format lithium-ion batteries hard to come by. Here, accelerated aging test data from four commercial large-format lithium-ion batteries is reported. These batteries span both NMC-Gr and LFP-Gr cell chemistries, pouch and prismatic formats, and a range of cell designs with varying power capabilities. Accelerated aging test results are analyzed to examine both cell performance, in terms of efficiency and thermal response under load, as well as cell lifetime. Cell thermal response is characterized by measuring temperature during cycle aging, which is used to calculated a normalized thermal resistance value that may help estimate both cell cooling needs or to help extrapolate aging test results to different thermal environments. Cell lifetime is evaluated qualitatively, considering simply the average calendar and cycle life across a range of conditions, as well as quantitatively, using statistical modeling and machine-learning methods to identify predictive aging models from the accelerated aging data. These predictive aging models are then used to investigate cell sensitivities to stressors, such as cycling temperature, voltage window, and C-rate, as well as to predict cell lifetime in various stationary storage applications. Results from this work show that cell lifetime and sensitivity to aging conditions varies substantially across commercial cells, necessitating testing for specific cell formats to make quantitative lifetime predictions. That being said, all commercial cells tested here are predicted to reach at least 10-year lifetimes for stationary storage applications. Based on the aging test results and modeling, some cells are expected to be relatively insensitive to temperature and use-case, making them suited for simple use cases with little or no thermal management and simple controls, while the lifetime of other cells could be extended to 20+ years if operated with thermal management and degradation-aware controls.
battery↗
Real-Time Lifetime Prediction of Semiconductor Devices Using Hardware-in-the-Loop
This paper presents a unique approach to enable real-time lifespan prediction of semiconductor power modules using a Hardware-in-the-Loop (HIL) system. By integrating the module's overall loss characteristics-specifically switching and conduction losses-with a thermoelectric model of the thermal management system, this research demonstrates that the model can dynamically estimates the junction temperature profile of the semiconductor devices in response to a changing torque demand profile for the motor drive system. This capability enables continuous monitoring of the module's operational time and cumulative stress induced on the devices to compute accumulated remaining lifetime or time-to-failure (TTF). This study provides an architectural framework for the HIL system with high-fidelity component models of multiple physical domains, allowing simulation of dynamic behaviors of a closely-coupled motor drive system. The advanced real-time computation and measurement functionalities of the HIL system allow for both dynamic lifetime calculations based on simulated data and aggregate lifetime predictions utilizing historical data. Moreover, this paper details an algorithm that not only computes cumulative damage but also synthesizes these data into a comprehensive aggregated lifetime metric. This methodology can enhance the maintenance scheduling strategies and operational reliability of semiconductor devices in critical applications, ultimately extending their service life while optimizing performance.
hardware-in-the-loop (HIL)↗
Reliability and Lifetime Prediction Model of Sintered Silver Under High-Temperature Cycling
Although excellent reliability has been reported for sintered silver as a die-attach material under both thermal and power cycling loads in power electronics applications, the promise of this material as a large-area attachment at temperatures beyond 200 degrees C needs to be investigated. This paper presents insights into the thermomechanical behavior and reliability of sintered silver under extreme thermal cycling conditions. In this study, we bonded sintered silver samples and subjected it to a thermal cycling profile of -40 °C to 200 °C with high ramp rates. We periodically monitored samples under thermal cycling to detect the presence of any failure mechanisms using a scanning acoustic microscope. We also included 95Pb5Sn solder in the study to obtain reference data. Results show the occurrence of cracks in sintered silver followed by a rapid rate of crack growth that exceeded the failure criterion in just 50 cycles. The predominant failure mechanism we observed was adhesive failure. As a large-area attachment, solder exhibited a higher reliability than sintered silver but failed within 100 cycles. Finally, we performed thermomechanical modeling to compute strain energy density values and correlated these with the experimentally observed crack growth rates to formulate a lifetime prediction model for sintered silver.
30 DIRECT ENERGY CONVERSION↗