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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 19 records

Primary lithium cell life studies

One solution for providing a truly independent power source is to package, within the critical subsystem element, a primary battery that can remain dormant for time periods as long as the mission life, which can be 10-15 years, maximum. When primary power from the spacecraft solar array/battery system is interrupted, the backup battery system, which is connected through a diode to the power input line, would automatically support the load to avoid a power interruption to the critical load for a time period long enough to ensure that ground control could access the satellite and correct the anomaly by sending appropriate commands to the spacecraft. Critical subsystems identified for the application are telemetry and command circuits, volatile computer memory, attitude control circuits, and some critical payloads. Due to volume packaging and weight restrictions that exist on most spacecraft, coupled with the long storage periods required, lithium cell technology was selected for the backup power source. Because of the high energy density (200-400 Wh/kg), long shelf life, and load capability, soluble cathode primary lithium technology was chosen. The most important lithium cell properties that require detail characterization for this application are capacity loss, shelf life, and the voltage delay mechanism. These are functions of storage time and temperature. During storage, a passive film builds up on the lithium electrode. The film protects the lithium electrode from progressive capacity decay but requires time to break down when a load is applied. This phenomenon results in a depressed voltage during the period of film breakdown which can last from fractions of a second to minutes.

Capulli, John↗

Multilayer Volume Holographic Optical Memory

We demonstrate a scheme for volume holographic storage based on the features of shift selectivity of a speckle reference wave hologram. The proposed recording method allows more efficient use of the recording medium and increases the storage density in comparison with spherical or plane-wave reference beams. Experimental results of multiple hologram storage and replay in a photorefractive crystal of iron-doped lithium niobate are presented. The mechanism of lateral and longitudinal shift selectivity are described theoretically and shown to agree with experimental measurements.

Markov, Vladimir↗

Mg2Si As Li-Intercalation Host For Li Cells

Compound Mg2Si shows promise as lithium-intercalation host for ambient-temperature rechargeable lithium electrochemical cells. As anode reactant material, LiXMg2Si chemically stable in presence of organic electrolyte used in such cells and stores large amounts of lithium. Intercalation reactions highly reversible at room temperature. Also retains sufficient mechanical strength during charge/discharge cycling. Lithium cells containing LixMg2Si anodes prove useful in spacecraft, military, communications, automotive, and other applications in which high energy-storage densities of lithium cells in general and rechargeability of cells needed.

Huang, Chen-Kuo↗

Freeze Casting of LAGP for 3D Textured Solid-State Structural Electrolytes

In this study, all-solid-state structural lithium-ion batteries, a type of load bearing electrochemical energy storage that provides systems-level weight savings is being pursued for the realization of inherently safe next generation hybrid-electric and all-electric green aerospace propulsion systems. Currently investigated all-solid-state batteries do not meet the requirements for specific power and mechanical stability. To address these issues, freeze casting of lithium aluminum germanium phosphate (LAGP) electrolyte material has been explored for the creation of a textured 3D electrolyte scaffold with large interfacial surface area for high power discharge and hierarchical porosity for accommodation of active material volume changes during electrochemical cycling. We report the effects of freeze casting processing parameters on the microstructural development and mechanical performance of the scaffolds, characterized through scanning electron microscopy and ring-on-ring mechanical testing. Slurry composition and casting parameters such as solids loading, casting speed, tape angle, and temperature gradients have been modified to determine the impact on density, lamellar morphology, and final load-bearing performance.

ceramics↗

Critical technology experiment results for lightweight space heat receiver

Critical technology experiments have been performed on thermal energy storage modules in support of the NASA Advanced Solar Dynamic Brayton Heat Receiver Program. The modules, wedge-shaped canisters containing lithium fluoride (LiF), were designed to minimize the mechanical stresses that occur during the phase change of the LiF. Nickel foam inserts were placed in two of the test canisters to provide thermal conductivity enhancement and to distribute the void volume throughout the canister. A procedure was developed for reducing the nickel oxides on the nickel foam to enhance the wicking ability of the foam. The canisters were filled with LiF and closure-welded at the NASA Lewis Research Center. Two canisters, one with a nickel foam insert, the other without an insert, were thermally cycled in various orientations in a fluidized bed furnace. Computer-aided tomography was successfully used to nondestructively determine void locations in the canisters. Finally, canister dimensional stability was measured after thermal cycling with an inspection fixture.

Schneider, Michael G.↗

Properties and Performance Attributes of Novel Co-Extruded Polyolefin Battery Separator Materials: Mechanical Properties - Part 1

As NASA prepares for its next era of manned spaceflight missions, advanced energy storage technologies are being developed and evaluated to address future mission needs and technical requirements and to provide new mission-enabling technologies. Cell-level components for advanced lithium-ion batteries possessing higher energy, more reliable performance and enhanced, inherent safety characteristics are actively under development within the NASA infrastructure. A key component for safe and reliable cell performance is the cell separator, which separates the two energetic electrodes and functions to prevent the occurrence of an internal short-circuit while enabling ionic transport. Recently, a new generation of co-extruded separator films has been developed by ExxonMobil Chemical and introduced into their battery separator product portfolio. Several grades of this new separator material have been evaluated with respect to dynamic mechanical properties and safety-related performance attributes. This paper presents the results of these evaluations in comparison to a current state-ofthe-practice separator material. The results are discussed with respect to potential opportunities to enhance the inherent safety characteristics and reliability of future, advanced lithium-ion cell chemistries.

Baldwin, Richard S.↗

Analysis, design, and experimental results for lightweight space heat receiver canisters, phase 1

Critical technology experiments have been performed on thermal energy storage modules in support of the Brayton Advanced Heat Receiver program. The modules are wedge-shaped canisters designed to minimize the mechanical stresses that occur during the phase change of the lithium fluoride phase change material. Nickel foam inserts were used in some of the canisters to provide thermal conductivity enhancement and to distribute the void volume. Two canisters, one with a nickel foam insert, and one without, were thermally cycled in various orientations in a fluidized bed furnace. The only measurable impact of the nickel foam was seen when the back and short sides of the canister were insulated to simulate operation in the advanced receiver design. In tests with insulation, the furnace to back side delta T was larger in the canister with the nickel foam insert, probably due to the radiant absorptivity of the nickel. However, the differences in the temperature profiles of the two canisters were small, and in many cases the profiles matched fairly well. Computed Tomography (CT) was successfully used to nondestructively demarcate void locations in the canisters. Finally, canister dimensional stability, which was measured throughout the thermal cycling test program with an inspection fixture was satisfactory with a maximum change of 0.635 mm (0.025 in.).

Schneider, Michael G.↗

Development and Application of a Novel Calorimetry Technique for the Study of Lithium-Ion Cell Thermal Runaway

Lithium-ion battery technology is widely used and is attractive due to demonstrated specific energies in the 200-300 W-hr/kg range. The excellent, mass-efficient energy storage capability of lithium-ion batteries has led to their use on many aerospace platforms. However, lithium-ion batteries can exhibit thermal runaway behavior wherein stored electrochemical energy is released rapidly as a result of thermal or mechanical failure, electrochemical abuse, internal or external short circuiting. A single cell undergoing thermal runaway within a battery has the potential to induce thermal runaway in adjacent cells if heat dissipation is not properly managed and can result in a catastrophic failure of the battery. Designing batteries that are resistant to thermal runaway propagation requires an understanding of, not only, total energy yield but also the means by which that energy is liberated from the cell. While Accelerating Rate Calorimetry and other techniques provide total thermal runaway energy yield, they do not provide the fractional breakdown of energy liberated via conduction through the cell casing from that which is vented from the cell as hot gases and effluents. Such data are needed to inform battery thermal design and analysis. To measure the total energy yield, the fraction conducted through the cell casing, and the fraction lost due to gases and effluents, NASA developed Fractional Thermal Runaway Calorimetry (FTRC). Two calorimeters have been developed and demonstrated, the Small-format- and Large-format Fractional Thermal Runaway Calorimeters (S-FTRC and L-FTRC, respectively). The technique has been successfully applied to small- and large-format cells (2.4-3.5 Ah and >100 Ah capacity, respectively) and has given new insights into Li-ion cell thermal runaway. Development of the calorimeters is discussed and results from the initial thermal runaway testing campaigns are presented.

Lithium-Ion Cell↗

Solid State Ultracapacitor

NASA analyzes, tests, packages, and fabricates electrical, electronic, and electromechanical (EEE) parts used in space vehicles. One area that NASA wishes to advance is energy storage and delivery. Currently, space vehicles use rechargeable batteries that utilize silver zinc or lithium ion electrochemical processes. These current state-of-the-art rechargeable batteries cannot be rapidly charged, contain harmful chemicals, and suffer from early wear-out mechanisms. A solid state ultracapacitor is an EEE part that offers significant advantages over current electrochemical and electrolytic devices. The objective of this research is to develop an internal barrier layer ultracapacitor (IBLC) using novel dielectric materials as a battery replacement with a focus on these advantages: longer life, lower mass-toweight ratio, rapid charging, on-demand pulse power, improved on-pad standby time without maintenance, and environmental friendliness. The approach is unique in two areas. A deposition technique is used that has been shown to produce a more uniformly coated nanoparticle than sol-gel, which has resulted in colossal permittivities. These particles are then distributed in an ink formulation developed at NASA Marshall Space Flight Center (MSFC) and deposited utilizing a 3D aerosol jet technique. This additive manufacturing technique controls layer thickness, resulting in extremely large capacitance and energy density.

Rolin, Terry D.↗

Failure Mechanisms of Ni-H2 and Li-Ion Batteries Under Hypervelocity Impacts

Lithium-Ion (Li-Ion) batteries have yielded significant performance advantages for many industries, including the aerospace industry, and have been selected to replace nickel hydrogen (Ni-H2) batteries for the International Space Station (ISS) program to meet the energy storage demands. As the ISS uses its vast solar arrays to generate its power, the solar ar-rays meet their sunlit power demands and supply excess power to battery packs for power de-livery on the sun obscured phase of the approximate 90 minute low Earth orbit. These large battery packs are located on the exterior of the ISS, and as such, the battery packs are ex-posed to external environment threats like naturally occurring meteoroids and artificial orbital debris (MMOD). While the risks from these solid particle environments has been known and addressed to an acceptable risk of failure through shield design, it is not possible to completely eliminate the risk of loss of these assets on orbit due to MMOD, and as such, failure consequences to the ISS have been considered.

Miller, J. E.↗

Failure Mechanisms of Ni-H2 and Li-Ion Batteries Under Hypervelocity Impacts

Lithium-Ion (Li-Ion) batteries have yielded significant performance advantages for many industries, including the aerospace industry, and have been selected to replace nickel hydrogen (Ni-H2) batteries for the International Space Station (ISS) program to meet the energy storage demands. As the ISS uses its vast solar arrays to generate its power, the solar arrays meet their sunlit power demands and supply excess power to battery packs for power delivery on the sun obscured phase of the approximate 90 minute low Earth orbit. These large battery packs are located on the exterior of the ISS, and as such, the battery packs are exposed to external environment threats like naturally occurring meteoroids and artificial orbital debris (MMOD). While the risks from these solid particle environments has been known and addressed to an acceptable risk of failure through shield design, it is not possible to completely eliminate the risk of loss of these assets on orbit due to MMOD, and as such, failure consequences to the ISS have been considered.

Miller, J. E.↗

Fabricating Solid-State Batteries for Electric Aviation

All-solid-state lithium batteries are widely reputed as the next major step in energy storage technology on account their drastically improved safety over wet cells, as solid electrolytes lack the volatile compounds in wet electrolytes that make them combustible. This enhanced safety enables a far wider range of products and vehicles to go fully electric and aligns with future NASA missions that require high performing, reliable, and safe batteries. However, they currently face issues with implementation in consumer products due to the often-poor mechanical properties of the solid electrolyte and relative difficulty to manufacture. Typical solid-state electrolyte challenges were bypassed by incorporating a range of polymeric binders into a solid electrolyte suspension and cast onto a composite carbon-sulfide cathode to create a single bilayer film. The resulting films display superior flexibility and durability compared to solid-electrolyte films typically discussed in literature without compromising the thinness of the films. The bilayer film was then punched into 12.7 cm diameter discs and 4 cm by 5 cm sheets, pressed, and assembled into coin cells and pouch cells respectively.

Batteries↗

Safety testing of lithium cells

Safety testing is intended to simulate, under laboratory conditions and controls, situations that will subject a cell to externally induced stress. The stresses can occur at any time during the useful life of the cell, from the time of manufacture until it is expended during mission deployment. Abuse testing can be divided into three major categories: Electrical, Mechanical, and Thermal. Although electrical abuses are generally found to occur during handling or deployment, Mechanical and Thermal stresses can be induced during transportation and storage. Therefore, it would be prudent to include predicted environmental exposure as part of the test plan. In the selection of a test program. specific test requirements should be tailored to meet the predicted mission requirements.

Liberto, Nick↗

Properties and Performance Attributes of Novel Co-extruded Polyolefin Battery Separator Materials: Electrical Properties - Part 2

As NASA prepares for its next era of manned spaceflight missions, advanced energy storage technologies are being developed and evaluated to address and enhance future mission needs and technical requirements. Cell-level components for advanced lithium-ion batteries possessing higher energy, more reliable performance and enhanced, inherent safety characteristics have been under development within the NASA infrastructure. A key component for safe and reliable cell performance is the cell separator, which separates the two energetic electrodes and functions to inhibit the occurrence of an internal short circuit but preserves an ionic current. Recently, a new generation of co-extruded separator films has been developed by ExxonMobil Chemical and introduced into their battery separator product portfolio. Several grades of this new separator material were evaluated with respect to dynamic mechanical properties and safety-related performance attributes, and the results of these evaluations were previously reported in "Part 1: Mechanical Properties" of this publication. This current paper presents safety-related performance results for these novel materials obtained by employing a complementary experimental methodology, which involved the analysis of separator impedance characteristics as a function of temperature. The experimental results from this study are discussed with respect to potential cell safety enhancement for future aerospace as well as for terrestrial energy storage needs, and they are compared with pertinent mechanical properties of these materials, as well as with current state-of-the practice separator materials.

Baldwin, Richard S.↗

High Temperature Thermosetting Polyimide Nanocomposites Prepared with Reduced Charge Organoclay

The naturally occurring sodium and calcium cations found in bentonite clay galleries were exchanged with lithium cations. Following the cation exchange, a series of reduced charge clays were prepared by heat treatment of the lithium bentonite at 130 C, 150 C, or 170 C. Inductively coupled plasma (ICP) analysis showed that heating the lithium clay at elevated temperatures reduced its cation exchange capacity. Ion exchange of heat-treated clays with either a protonated alkyl amine or a protonated aromatic diamine resulted in decreasing amounts of the organic modifier incorporated into the lithium clay. The level of silicate dispersion in a thermosetting polyimide matrix was dependent upon the temperature of Li-clay heat treatment as well as the organic modification. In general, clays treated at 150 C or 170 C, and exchanged with protonated octadcylamine or protonated 2,2'-dimethlybenzidine (DMBZ) showed a higher degree of dispersion than clays treated at 130 C, or exchanged with protonated dodecylamine. Dynamic mechanical analysis showed little change in the storage modulus or T(sub g) of the nanocomposites compared to the base resin. However, long term isothermal aging of the samples showed a significant decrease in the resin oxidative weight loss. Nanocomposite samples aged in air for 1000 hours at 288 C showed of to a decrease in weight loss compared to that of the base resin. This again was dependent on the temperature at which the Li-clay was heated and the choice of organic modification.

Campbell, Sandi↗

3D Printed TiO 2 Negative Electrodes for Sodium-Ion and Lithium-ion Batteries using Vat Photopolymerization

Additive manufacturing, also called 3D printing, represents a unique approach to develop three dimensional shape-conformable batteries with enhanced electrodes, specific surface area, improved ion diffusion, and power. For the first time, the formulation of a composite photocurable resin loaded with battery electrochemically active components was designed to feed a vat photopolymerization (VPP) 3D printer. In direct alignment with NASA’s Artemis mission goals to develop sustainable lunar energy storage infrastructure necessary to support long-term human operations, TiO 2 was here selected as an active material for the negative electrode for sodium-ion and lithium-ion batteries due to its abundance on the lunar surface. The TiO 2 loading in the composite photocurable resin and in the resulting VPP-printed negative electrode was increased as high as possible to enhance the electrochemical performance, while simultaneously ensuring the printability and acceptable mechanical strength for sample handling. The effect of thermal post-processing on the electrical, electrochemical and mechanical performance is reported. Finally, a configurational study is implemented to identify the impact of two different electrode designs (cubic and gyroid lattice unit cells) on the electrochemical performance. This work addresses the difficulties related to the introduction of solid particles within a VPP photocurable resin and the need for a compromise between the electrochemical performances and printability to obtain fully functional VPP-printed electrodes.

sodium-ion battery↗

Sintered Cathodes for All-Solid-State Structural Lithium-Ion Batteries

All-solid-state structural lithium ion batteries serve as both structural load-bearing components and as electrical energy storage devices to achieve system level weight savings in aerospace and other transportation applications. This multifunctional design goal is critical for the realization of next generation hybrid or all-electric propulsion systems. Additionally, transitioning to solid state technology improves upon battery safety from previous volatile architectures. This research established baseline solid state processing conditions and performance benchmarks for intercalation-type layered oxide materials for multifunctional application. Under consideration were lithium cobalt oxide and lithium nickel manganese cobalt oxide. Pertinent characteristics such as electrical conductivity, strength, chemical stability, and microstructure were characterized for future application in all-solid-state structural battery cathodes. The study includes characterization by XRD, ICP, SEM, ring-on-ring mechanical testing, and electrical impedance spectroscopy to elucidate optimal processing parameters, material characteristics, and multifunctional performance benchmarks. These findings provide initial conditions for implementing existing cathode materials in load bearing applications.

Ceramics↗

Microstructure Quantification and Random Forest Regression Models for Li4Ti5O12–Ni Property Prediction

All-solid-state structural lithium-ion batteries are sought to enable all-electric propulsion in next generation aerospace concepts through improved safety and systems level weight savings. In this work, the influence of processing conditions on microstructural evolution was evaluated for anode composites of strain-free Li4Ti5O12 and metallic nickel current collector. Beyond size distributions, this study explored methods of quantifying microstructural features that describe changes in the spatial distribution and coalescence of nickel particles as a function of sample composition and sintering conditions. Processing-microstructure-property relationships were described by microstructure quantifiers including nickel particle count per area, nearest neighbor distance distribution, and edge-to-edge distance distribution. Machine learning methods were applied to compare the relative influence of processing conditions and microstructural features on electrical conductivity and mechanical strength to optimize for simultaneous energy storage and load bearing performance. Insights gained from this work inform future evaluation of alternative energy storage materials and microstructures for multifunctional performance, and generation of microstructural descriptors strengthens modeling across length scales.

anode↗