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Thin-Film Embedded Sensors for Battery Health Monitoring

Hybrid or all-electric aircraft are being developed as the next generation of aircraft to both allow new forms of aviation and decrease environmental impact. Since these types of aircraft are based on high-capacity battery technology, safe operation of these batteries becomes increasingly important. In particular, the potential for battery failure due to uncontrolled chemical reactions resulting in thermal runaway, catastrophic failure, and battery fires must be addressed in order for such battery technology to have the level of safety needed for standard aviation implementation. Efforts to ensure battery safety often involve engineering solutions that seek to contain rather than prevent such events by early detection. Such approaches increase the system weight and decrease the power per unit mass provided by the battery system. Existing methods for measuring battery parameters to determine the battery state-of-health are limited. These methods include electrical measurements of the cell current and/or voltage output as well as temperature measurements taken externally on the cell surface. Such external temperature measurements are limited in their ability to provide early warning of impending battery failure. In response, an effort to develop sensors operating internal to battery for health monitoring has been ongoing in the NASA Sensor-based Prognostics to Avoid Runaway Reactions & Catastrophic Ignition (SPARRCI) project. The basic approach associated with this sensor work is the deposition of thin film sensors on the battery separator located between the anode and cathode of the battery. These thin film sensors are then monitored to determine changes in battery parameters and health. Microfabrication techniques are employed to minimize the overall impact of the sensors on battery operation through the implementation of sensors with minimal size, weight, and power consumption. The thickness of the films, which are fabricated through physical vapor deposition (sputtering), are on the order of thousands of angstroms and can have minimal surface area. Thin film sensors for system health management have been implemented for a many decades on complex components for aerospace applications. However, the application of thin films of this type on a battery separator for internal battery monitoring applications has not previously been demonstrated to our knowledge. This paper describes the development of sensors for the internal battery monitoring through the use of thin film sensor technology. Thin metal films were successfully deposited on a battery separator polymer material with good adherence and electrical continuity. Multiple types of sensors have been deposited, as well as lead connections from the sensor to the edge of the separator material. The ability of these thin film sensors immersed in electrolyte to perform multiple types of battery parameter measurements has been demonstrated. For example, a multiparameter sensor system measured multiple properties simultaneously inside of a pouch cell over a wide temperature range. Further, real time measurement of interior temperature changes in a battery pouch cell with an integrated interior temperature sensor was demonstrated. These changes include detecting a fault in the battery (shorting) in situ with rapid response time (less than a minute) corresponding to a more limited response by a temperature sensor mounted externally. Other aspects of monitoring battery health were also explored, such as real-time measurement of simulated dendrite growth/metal deposition by sensor on separator material demonstrated. Future efforts will include improvements in the durability of the sensor structure to allow introduction of the approach into standard battery fabrication techniques. Overall, this work is a step forward in providing a method to prevent catastrophic battery failures and provide a foundation for safer, lighter, and higher energy batteries for the electric aircraft industry.

thin film battery health↗

NASA NTRS2015

Direct Drive Solar-Powered Arcjet Thruster

Electric thrusters typically require a power processing unit (PPU) to convert the spacecraft-provided power to the voltage and current that a thruster needs for operation. NASA Marshall Space Flight Center has initiated fundamental studies on whether an arcjet thruster can be operated directly with the power produced by solar arrays without any additional conversion. Elimination of the PPU significantly reduces system-level complexity of the propulsion system, and lowers developmental cost and risk. The proposed work will aim to refine the proof-of-concept presently being assembled and begin to identify and address technical questions related to power conditioning and noise suppression in the system, and heating of the thruster in long-duration operation. The apparatus proposed for investigation has a target power level of 400 to 1,000 W. The proposed direct-drive arcjet is potentially a highly scalable concept, applicable to spacecraft with up to hundreds of kilowatts and beyond. The design of the arcjet built for this effort was based on previous low power (1 kW class) arcjets.1-3 It has a precision machined 99.95% pure tungsten anode that also serves as the nozzle with a 0.040-in- (1-mm-) diameter, 0.040-in-long constrictor region. An additional anode with a 0.020-in- (0.5-mm-) diameter, 0.020-inlong constrictor region was purchased, but has not yet been used. The cathode is a 0.125-in-diameter tungsten welding electrode doped with lanthum-oxygen; its tip was precision ground to a 308deg angle and terminates in a blunt end. The two electrodes are separated by a boron-nitride insulator that also serves as the propellant manifold; it ends in six small holes which introduce the propellant gas in the diverging section of the nozzle, directly adjacent to the cathode. The electrodes and insulator are housed in a stainless-steel outer body, with a Macor insulator at the mid-plane to provide thermal isolation between the front and back halves of the device. The gas seals were made using Grafoil gaskets. Figure 1(a) shows the assembled thruster; figure 1(b) shows the thruster in the vacuum chamber with electrical and propellant connections.

Polzin, Kurt↗

NASA NTRS2021

Effect of Preconditioning on Post-Soldering Failures in Tantalum Capacitors

Soldering have a strong effect on performance and reliability of most surface mount technology components, including tantalum capacitors. High quality tantalum capacitors are likely the only type of components where soldering simulation is the first step during screening. Nevertheless, post-soldering failures of tantalum capacitors do happen and require additional analysis. Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs also in chip tantalum capacitors. The sensitivity of parts to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors, and standard J-STD-020 is applicable partially only. In this work, the effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have been studied using 22 types of polymer and 11 types of MnO2 cathodes tantalum capacitors including single and multianode parts. The amount of moisture released during soldering has been estimated by measurements of mass and capacitance variations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more susceptible to catastrophic short circuit failures and their ignition is possible during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption corresponding to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage. Recommendations for testing to establish MSL and for baking to reduce the probability of failures are suggested.

tantalum polymer capacitors↗

NASA NTRS2016

Engineering Model Propellant Feed System Development for an Iodine Hall Thruster Demonstration Mission

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cu cm and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high (Delta)v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. 3, 4 Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature (< 100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp −6) torr at −75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. In the present paper, we describe the design and testing of the engineering model propellant feed system for iSAT (see Fig. 1). The feed system is based around an iodine propellant reservoir and two proportional control valves (PFCVs) that meter the iodine flow to the cathode and anode. The flow is split upstream of the PFCVs to both components can be fed from a common reservoir. Testing of the reservoir is reported to demonstrate that the design is capable of delivering the required propellant flow rates to operate the thruster. The tubing and reservoir are fabricated from hastelloy to resist corrosion by the heated gaseous iodine propellant. The reservoir, tubing, and PFCVs are heated to ensure the sublimed propellant will not re-deposit within the feed system. Heating is accomplished through a number of individual zones to control the overall power expended on heating the system and insulation is employed to minimize the amount of power used to heat the system prior to thruster operation.

Polzin, Kurt A.↗

NASA NTRS1995

Linear operating region in the ozone dial photon counting system

Ozone is a relatively unstable molecule found in Earth's atmosphere. An ozone molecule is made up of three atoms of oxygen. Depending on where ozone resides, it can protect or harm life on Earth. High in the atmosphere, about 15 miles up, ozone acts as a shield to protect Earth's surface from the sun's harmful ultraviolet radiation. Without this shield, we would be more susceptible to skin cancer, cataracts, and impaired immune systems. Closer to Earth, in the air we breathe, ozone is a harmful pollutant that causes damage to lung tissue and plants. Since the early 1980's, airborne lidar systems have been used for making measurements of ozone. The differential absorption lidar (DIAL) technique is used in the remote measurement of O3. This system allows the O3 to be measured as function of the range in the atmosphere. Two frequency-doubled Nd:YAG lasers are used to pump tunable dye lasers. The lasers are operating at 289 nm for the DIAL on-line wavelength of O3, and the other one is operated at 300 nm for the off-line wavelength. The DIAL wavelengths are produced in sequential laser pulses with a time separation of 300 micro s. The backscattered laser energy is collected by telescopes and measured using photon counting systems. The photon counting system measures the light signal by making use of the photon nature of light. The output pulse from the Photo-Multiplier Tube (PE), caused by a photon striking the PMT photo-cathode, is amplified and passed to a pulse height discriminator. The peak value of the pulse is compared to a reference voltage (discrimination level). If the pulse amplitude exceeds the discrimination level, the discriminator generates a standard pulse which is counted by the digital counter. Non-linearity in the system is caused by the overlapping of pulses and the finite response time of the electronics. At low count rates one expects the system to register one event for each output pulse from the PMT corresponding to a photon incident upon the photocathode, however, at higher rates the limitations of the discrimination/counting system will cause the observed count rate to be non-linear with respect to the true count rate. Depending on the pulse height distribution and the discriminator level, the overlapping of pulses (pulse pile-up) can cause count loss or even an additional apparent count gain as the signal levels increase. Characterization of the system, including the pulse height distribution, the signal to noise ratio, and the effect of the discriminator threshold level, is critical in maximizing the linear operating region of the system, thus greatly increasing the useful dynamic range of the system.

Andrawis, Madeleine↗

NASA NTRS2009

High-Efficiency Artificial Photosynthesis Using a Novel Alkaline Membrane Cell

A new cell designed to mimic the photosynthetic processes of plants to convert carbon dioxide into carbonaceous products and oxygen at high efficiency, has an improved configuration using a polymer membrane electrolyte and an alkaline medium. This increases efficiency of the artificial photosynthetic process, achieves high conversion rates, permits the use of inexpensive catalysts, and widens the range of products generated by this type of process. The alkaline membrane electrolyte allows for the continuous generation of sodium formate without the need for any additional separation system. The electrolyte type, pH, electrocatalyst type, and cell voltage were found to have a strong effect on the efficiency of conversion of carbon dioxide to formate. Indium electrodes were found to have higher conversion efficiency compared to lead. Bicarbonate electrolyte offers higher conversion efficiency and higher rates than water solutions saturated with carbon dioxide. pH values between 8 and 9 lead to the maximum values of efficiency. The operating cell voltage of 2.5 V, or higher, ensures conversion of the carbon dioxide to formate, although the hydrogen evolution reaction begins to compete strongly with the formate production reaction at higher cell voltages. Formate is produced at indium and lead electrodes at a conversion efficiency of 48 mg of CO2/kilojoule of energy input. This efficiency is about eight times that of natural photosynthesis in green plants. The electrochemical method of artificial photosynthesis is a promising approach for the conversion, separation and sequestration of carbon dioxide for confined environments as in space habitats, and also for carbon dioxide management in the terrestrial context. The heart of the reactor is a membrane cell fabricated from an alkaline polymer electrolyte membrane and catalyst- coated electrodes. This cell is assembled and held in compression in gold-plated hardware. The cathode side of the cell is supplied with carbon dioxide-saturated water or bicarbonate solution. The anode side of the cell is supplied with sodium hydroxide solution. The solutions are circulated past the electrodes in the electrochemical cell using pumps. A regulated power supply provides the electrical energy required for the reactions. Photovoltaic cells can be used to better mimic the photosynthetic reaction. The current flowing through the electrochemical cell, and the cell voltage, are monitored during experimentation. The products of the electrochemical reduction of carbon dioxide are allowed to accumulate in the cathode reservoir. Samples of the cathode solution are withdrawn for product analysis. Oxygen is generated on the anode side and is allowed to vent out of the reservoir.

Narayan, Sri↗

NASA NTRS2021

Effect of Soldering on Polymer and MnO2 Tantalum Capacitors

Soldering might have a strong effect on performance and reliability of most surface mount technology components, including tantalum capacitors. High quality tantalum capacitors are likely the only type of components where soldering simulation is the first step during screening. Nevertheless, post-soldering failures of tantalum capacitors happen and require additional analysis. Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs also in chip tantalum capacitors. The sensitivity of parts to the presence of moisture during soldering is characterized by the moisture sensitivity level (MSL); however, contrary to PEMs, there is no standard procedure for establishing MSL for tantalum capacitors. The effect of absorbed moisture on soldering related degradation and failures in tantalum capacitors have not been studied properly yet, and there is no sufficient information regarding the difference in the sensitivity to soldering between polymer and MnO2 tantalum capacitors. In this work, 16 types of polymer and 9 types of MnO2 cathodes tantalum capacitors with different moisture content have been tested before and after reflow soldering. The level of moisture release after soldering has been estimated and thermo-mechanical analysis used to assess deformation of capacitors during soldering simulations. Results show that moisture uptake in similar parts is approximately two times greater in polymer than in MnO2 capacitors. Cracking of the case and degradation of parameters can occur in both types of parts, but MnO2 capacitors are much more likely to fail catastrophically with a short circuit and possible ignition during the first power-on cycle. This type of failure in MnO2 capacitors is lot-related, can occur even at derated voltages and relatively low levels of moisture sorption corresponding to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage. Recommendations for baking and testing to establish MSL are suggested.

Alexander Teverovsky↗

NASA NTRS2007

Detailed Studies of Pixelated CZT Detectors Grown with the Modified Horizontal Bridgman Method

The detector material Cadmium Zinc Telluride (CZT) achieves excellent spatial resolution and good energy resolution over a broad energy range, several keV up to some MeV. Presently, there are two main methods to grow CZT crystals, the Modified High-Pressure Bridgman (MHB) and the High-Pressure Bridgman (HPB) process. The study presented in this paper is based on MHB CZT substrates from the company Orbotech Medical Solutions Ltd. [Orbotech Medical Solutions Ltd., 10 Plaut St., Park Rabin, P.O. Box 2489, Rehovot, Israel, 76124]. Former studies have shown that high-work-function materials on the cathode side reduce the leakage current and, therefore, improve the energy resolution at lower energies. None of the studies have emphasized on the anode contact material. Therefore, we present in this paper the result of a detailed study in which for the first time the cathode material was kept constant and the anode material was varied. We used four different anode materials: Indium, Titanium, Chromium and Gold, metals with work-functions between 4.1 eV and 5.1 eV. The detector size was 2.0 x 2.0 x 0.5 cu cm with 8 x 8 pixels and a pitch of 2.46 mm. The best performance was achieved with the low-work-function materials Indium and Titanium with energy resolutions of 2.0 keV (at 59 keV) and 1.9 keV (at 122 keV) for Titanium and 2.1 keV (at 59 keV) and 2.9 keV (at 122 keV) for Indium. Taking into account the large pixel pitch of 2.46 mm, these resolutions are very competitive in comparison to those achieved with detectors made of material produced with the more expensive conventional HPB method. We present a detailed comparison of our detector response with 3D simulations. The latter comparisons allow us to determine the mobility-lifetime-products (mu tau-products) for electrons and holes. Finally, we evaluated the temperature dependency of the detector performance and ls-products. For many applications temperature dependence is important, therefore, we extended the scope of our study to temperatures as low as -30 C. There are two important results. The breakdown voltage increases with decreasing temperature, and electron mobility-lifetime-product decreases by about 30% over a range from 20 C to -30 C. The latter effect causes the energy resolution to deteriorate, but the concomitantly increasing breakdown voltage makes it possible to increase the applied bias voltage and restore the full performance

Jung, I.↗

NASA NTRS2010

Direct Electrolysis of Molten Lunar Regolith for the Production of Oxygen and Metals on the Moon

When considering the construction of a lunar base, the high cost ($ 100,000 a kilogram) of transporting materials to the surface of the moon is a significant barrier. Therefore in-situ resource utilization will be a key component of any lunar mission. Oxygen gas is a key resource, abundant on earth and absent on the moon. If oxygen could be produced on the moon, this provides a dual benefit. Not only does it no longer need to be transported to the surface for breathing purposes; it can also be used as a fuel oxidizer to support transportation of crew and other materials more cheaply between the surface of the moon, and lower earth orbit (approximately $20,000/kg). To this end a stable, robust (lightly manned) system is required to produce oxygen from lunar resources. Herein, we investigate the feasibility of producing oxygen, which makes up almost half of the weight of the moon by direct electrolysis of the molten lunar regolith thus achieving the generation of usable oxygen gas while producing primarily iron and silicon at the cathode from the tightly bound oxides. The silicate mixture (with compositions and mechanical properties corresponding to that of lunar regolith) is melted at temperatures near 1600 C. With an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in production of molten metallic products at the cathode and oxygen gas at the anode. The effect of anode material, sweep rate, and electrolyte composition on the electrochemical behavior was investigated and implications for scale-up are considered. The activity and stability of the candidate anode materials as well as the effect of the electrolyte composition were determined. Additionally, ex-situ capture and analysis of the anode gas to calculate the current efficiency under different voltages, currents and melt chemistries was carried out.

Sirk, Aislinn H. C.↗

NASA NTRS2015

Propulsion System Testing for the Iodine Satellite (iSAT) Demonstration Mission

CUBESATS are relatively new spacecraft platforms that are typically deployed from a launch vehicle as a secondary payload, providing low-cost access to space for a wide range of end-users. These satellites are comprised of building blocks having dimensions of 10x10x10 cm cu and a mass of 1.33 kg (a 1-U size). While providing low-cost access to space, a major operational limitation is the lack of a propulsion system that can fit within a CubeSat and is capable of executing high delta v maneuvers. This makes it difficult to use CubeSats on missions requiring certain types of maneuvers (i.e. formation flying, spacecraft rendezvous). Recently, work has been performed investigating the use of iodine as a propellant for Hall-effect thrusters (HETs) 2 that could subsequently be used to provide a high specific impulse path to CubeSat propulsion. 3, 4 Iodine stores as a dense solid at very low pressures, making it acceptable as a propellant on a secondary payload. It has exceptionally high ρIsp (density times specific impulse), making it an enabling technology for small satellite near-term applications and providing the potential for systems-level advantages over mid-term high power electric propulsion options. Iodine flow can also be thermally regulated, subliming at relatively low temperature (less than 100 C) to yield I2 vapor at or below 50 torr. At low power, the measured performance of an iodine-fed HET is very similar to that of a state-of-the-art xenon-fed thruster. Just as importantly, the current-voltage discharge characteristics of low power iodine-fed and xenon-fed thrusters are remarkably similar, potentially reducing development and qualifications costs by making it possible to use an already-qualified xenon-HET PPU in an iodine-fed system. Finally, a cold surface can be installed in a vacuum test chamber on which expended iodine propellant can deposit. In addition, the temperature doesn't have to be extremely cold to maintain a low vapor pressure in the vacuum chamber (it is under 10(exp -6) torr at −75 C), making it possible to 'cryopump' the propellant with lower-cost recirculating refrigerant-based systems as opposed to using liquid nitrogen or low temperature gaseous helium cryopanels. An iodine-based system is not without its challenges. The primary challenge is that the entire feed system must be maintained at an elevated temperature to prevent the iodine from depositing (transitioning from the gas phase directly back into the solid phase), which will block the propellant feed lines. Furthermore, deposition will occur unless the temperature in the lines is not greater than the temperature of the propellant reservoir. The flow rate can be controlled by adjusting the heating applied to the reservoir, but as with any thermal control there is a relatively slow response to changes in the heating rate. In the present paper, we describe the propulsion and propellant feed system for the iodine satellite (iSAT) flight demonstration mission. The system is based around the Busek BHT-200 Hall thruster, which has been modified for chemical compatibility with iodine vapor. While the gross propellant flow rate is maintained by the heated propellant reservoir, the flow to the anode and cathode are adjusted using two heated Vacco proportional flow control valves (PFCV), which provide very fast response on the flow rate adjustment. The flight mission design layout will be presented, showing how the system will be packaged into the overall 12-U spacecraft and the techniques being employed to protect the remaining spacecraft hardware from the propulsion system (e.g., plasma impingement, iodine deposition, thermal loads). In addition to the flight system design, results of testing the thruster and cathode with both operating on iodine propellant are presented. The tests are conducted on a thrust stand (see Fig. 1) in a large vacuum chamber containing a beam dump chilled to below -100 C to 'cryopump' the propellant. The thruster performance during these tests is presented, with these data used to evaluate the feed system and guide further refinements. Results of relatively long duration testing are presented to demonstrate the capability to operate for the length of the iSAT mission and to perform a number of re-starts as will be required by the mission concept of operations.

Polzin, Kurt A.↗