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At least 595 records · Page 33

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NASA NTRSDate not supplied

Comparative Analysis of Thermal Runaway Heat Output as a Function of Trigger Mechanism and Cell Format

High demand for energy storage systems across many fields drives the need for safe and reliable Li-ion batteries. In order to assess the risk of using such batteries in various applications, many types of abuse tests have been developed to push battery cells to their limits and learn how they fail. In this work, internal short circuit (ISC) tests, nail penetration tests, and thermal tests were used to trigger thermal runaway in D-cell, 18650, and 21700 Li-ion cells. High-speed radiography was used to gain insight to the propagation of thermal runaway throughout the cell, while calorimetric and thermal data were recorded in real time. Post-test disassembly of the calorimeter allowed for any mass ejected from the cell to be analyzed and the distribution of mass through the calorimeter to be determined. The impact of cell geometry and trigger mechanism on post-test mass distribution, thermal runaway propagation and internal cell temperature are discussed.

Lithium-ion battery; thermal runaway; calorimetry;↗

NASA NTRSDate not supplied

Battery Failure Databank

The Battery Failure Databank contains thermal runaway results gathered from nearly 300 small format fractional thermal runaway calorimetry (S-FTRC) experiments. A majority of these experiments were conducted at synchrotron facilities where high-speed x-ray videography was conducted of the cell while tested inside of the S-FTRC. The databank is a two-component system which consists of a Microsoft ExcelTM spreadsheet which provides S-FTRC results in tabular format and a radiographic video library containing the high-speed x-ray videos. Overall, the databank provides thermal results from S-FTRC experiments conducted on a mixture of commercially available lithium-ion (Li-ion) cells and specialized Li-ion test cells with varying cell format (18650, 21700, and D-cell) and trigger mechanism (heaters, heaters plus internal short circuiting device, and nail penetration). The radiography video component provides insight into the initiation and propagation of TR in the cells, in addition to consequences of TR measured by the FTRC. Fractions of mass ejected for the cell types are separated into regimes based on the different failure modes of the cells, such as purely venting, partial ejection, and total ejection. With knowledge of the rate and characterization of the internal degradation of the cells during TR, and the amounts of mass ejected and unrecovered, the extent of TR, and therefore the mitigation of TR, is revealed relative to cell types and failure modes.

Lithium-ion battery↗

NASA NTRS2020

Popcorning Failures in Polymer and MnO2 Tantalum Capacitors

Popcorning is a well-known effect in plastic encapsulated microcircuits (PEM) and it occurs in chip tantalum capacitors. The sensitivity of components 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 capacitors. In this work, 16 types of polymer and 9 types of MnO2 tantalum capacitors with different moisture content have been tested before and after reflow soldering. The level of moisture release during soldering has been estimated and thermo-mechanical analysis used to assess deformation of capacitorsduring 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 that corresponds to room conditions. Baking before soldering is an effective measure to prevent failures even in lots susceptible to popcorning damage.

Capacitor↗

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 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 NTRSDate not supplied

Design Considerations for Practical Li-S Batteries for Electric Aviation

The development of high-energy, high-safety, and high-power batteries beyond electric automotive standards is critical for future electric aviation applications. Non-volatile solid-state electrolytes (SSE) offer many promising advantages over traditional flammable liquid electrolytes. Solid-state electrolytes may be an enabling technology for certain battery chemistries by preventing detrimental interactions with liquid electrolytes, for example prevention of the dissolution of intermediates in lithium-sulfur common in traditional liquid organic solvents. However, significant manufacturing challenges must be overcome before the adoption of such technology. This research was conducted to identify processing techniques for producing solid-state battery components with practical dimensions and weights for enabling high specific energy cells. Traditional research has identified a range of very high theoretical ionic conductivities but are impractical due to their instability or inability to be manufactured. Electrolytes explored in this study were produced as sulfide-polymer composites with densified thicknesses below 40 micron using a tape-casting technique and thermoplastic elastomer binder. The combination of high chemical compatibility and flexibility produced robust films that had moderate impact on the ionic conductivity but was capable of dramatically reducing the parasitic mass. Despite minimal conductivity losses, films were produced 10-15 times thinner than comparable bulk powder electrolytes thus leading to overall lower film resistance. Conductivity is maintained above 0.2mS/cm for composite electrolytes. Through the analysis of materials based on their physical properties, such as density, practical cells can be designed. Based on this, low density sulfide-solid-state electrolytes are a promising candidate for achieving the energy and safety metrics for electric aviation, however, further optimization of cathode microstructure and composite processing will be required to achieve the high power metrics and will be the focus of further studies. Additionally, fabrication challenges arise when utilizing metallic lithium foil, due to its soft nature, as overflow and mechanical short circuit can occur on assembly which remains a challenge to overcome before metallic lithium anodes can be fully realized.

batteries↗

NASA NTRS2021

Challenges with Heat Flux Calorimeters used in Arc Jets

Occasionally large errors have occurred in some of the calorimeters used in the arc jet facilities. Some slug calorimeters would measure twice the expected heat flux and some Coaxial TC calorimeters would measure half the expected heat flux. While these errors in heat flux measurements are easy to identify and discard / dismiss, the concern is that less spectacular errors are difficult to detect. This inspired a critical look at the calorimetry used to measure stagnation heat flux in the NASA Ames Arc Jet facilities. Numerous sources of error were investigated, and the culprit in the case of slug calorimeters was determined to be leaks in the stagnation calorimeter assembly resulting in flow along the side of the slug. In the case of the coaxial TC calorimeter, it is hypothesized that in some calorimeters there is a partial electrical short circuit in the Coaxial TC sensor element somewhere in the middle of the calorimeter.

Calorimeter↗

NASA NTRS2022

The Promise of Alloy Anodes for Solid-State Batteries

Solid-state batteries are anext-generation technology that could featureimproved safety and energy density, but reliably integrating high-capacity electrode materials to enable high energy while retaining stablelong-termcycling remains a challenge. Anode materials that alloy with lithium, such as silicon, tin, and aluminum,offer high capacity that canyield high-energy battery cells. The use of alloy anodes in solid-state batteries potentially offers major mechanistic benefits compared to other anode contendersand battery systems, such as lithium metal in solid-state architectures or alloys in liquid-electrolyte batteries. This perspective discusseskey advantagesof alloy anode materials for solid-state batteries, including the avoidance of the short circuiting observed with lithium metal and the chemo-mechanical stabilization of the solid-electrolyte interphase (SEI). We further discuss open research questions and challenges in engineering alloy-anode-based solid-state batteries, with the goal of advancing our understanding and control of alloy anode materialswithin solid-state architectures toward commercial application.

John A Lewis↗

NASA NTRS2023

Metrics for Anomalous Charging currents in Polymer Tantalum Capacitors

Anomalous charging currents (ACC) in polymer tantalum capacitors may appear as a temporary short circuit that can last for dozens of milliseconds, cause failures to the parts, or cause malfunctions to fast operating electronic systems. Currently, there is no standard technique or set of metrics to evaluate the level of ACC which compares results obtained by different users and manufacturers. In this work, ACC in different types of capacitors were characterized by analysis of current transients during the constant voltage ramp or power surge testing (PST) techniques. It is shown that although the shape of transients may vary at different test conditions, the transfer charge and energy remain practically the same. The level of ACC is characterized by the energy dissipated in the part during PST. Variations of the dissipated energy with moisture content, test temperature, and voltage are evaluated. Effects of different reflow soldering conditions and long-term (up to 3000 hours) storage at 125 °C are discussed.

polymer tantalum capacitor↗

NASA NTRS2023

Evaluation of Ultrasonic Battery Inspection Techniques

Lithium metal batteries are prone to subtle defects such as internal dendrites, which can cause internal short circuits and lead to catastrophic ignition. These defects are often undetectable by battery management systems, prompting the need to advance nondestructive evaluation (NDE) techniques for battery applications. In this work, two ultrasonic approaches were compared to establish their relative merits for this application: local ultrasonic resonance spectroscopy, and guided wave ultrasound. Benchtop experiments on batteries seeded with lithium chips emulating plating were used to demonstrate the two techniques. The results show the ability to identify and map local changes in cell structure.

Ultrasound↗

NASA NTRS2023

Evaluation of Ultrasonic Battery Inspection Techniques

Ultrasound↗

NASA NTRSDate not supplied

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↗

NASA NTRSDate not supplied

An Electron Backscatter Diffraction (EBSD)-Based Automated Tool for Ceramic Capacitor Grain Size Analysis

Ceramic capacitors continue to be recurring problem parts for NASA, despite best efforts to screen out potential defects and failures through environmental and electrical testing and nondestructive inspection techniques such as acoustic microscopy. The physical properties of ceramic capacitors necessitates thin dielectric layers capable of withstanding significant electric fields. Any defects in those ceramic layers can result in reduced insulation resistance failure modes including short circuit failures, so the quality and consistency of the dielectric material is critical. The size of the individual ceramic grains in the dielectric material is a critical parameter. However, judging “grain size” is not so simple—in a single capacitor there can be wide variation in grain sizes observed. It is theorized that by studying the grain size distributions of “known good” and “known bad” lots of capacitors, some conclusions could be drawn that would allow us to better predict to the reliability of future lots based on grain size distributions. The initial goal of this effort was to find or develop an automated tool that could inspect a capacitor and return grain size distribution results.

Robert Hodson↗

NASA NTRSDate not supplied

Predictability of the Minimum Sea Ice Extent from Late Winter Fram Strait Ice Export: Model vs Observations

Late winter coastal divergence along the Eurasian coastline (referred to as the ice factory) – or the Fram Strait ice export, a proxy for coastal divergence in the ice factory – is a skillful predictor of the minimum sea ice extent (Williams et al., 2016; Brunette et al., 2018; Sesternikov and, 1979). Coastal divergence leads to the formation of coastal polynya where new ice grows but to a thickness that is not large enough to survive the following summer melt. This signal is then amplified by the ice albedo feedback and leads to more open water at the end of the summer melt season. In this thesis project, we will identify if this source of predictive skill in the seasonal forecast of the minimum sea ice extent is present in General Circulation Models, more precisely in the CESM2-LE, GISS-E2.1-G, GFDL FLOR-LE, CNRM-CM6-1 and the CanESM5. Since even small biases in the large-scale atmospheric circulation simulated by a model can short circuit this coupling between dominant modes of atmospheric variability (NAO and AO), coastal divergence along the Eurasian coastline, Fram Strait ice export and therefore seasonal forecasting skill of the model, failure to reproduce this coupling observed in the real Arctic will be used to identify biases in GCM. Preliminary results show that subtle changes in the large-scale atmospheric circulation leads to opposite statistical relationship between Fram Strait ice area export, coastal divergence along the Eurasian coastline, and seasonal predictability of the minimum sea ice extent both in the CESM2-LE and the GISS-E2.1-G models. Differences are linked with the partitioning between recirculation within the Beaufort Gyre, ice exported through Fram Strait and ridging north of the Canadian Arctic Archipelago.

Sea ice↗

NASA NTRSDate not supplied

NOAA-17 Break-up Engineering Investigation

The NOAA-17 weather satellite operated in polar orbit near 800 km from 2002 until it was decommissioned in April 2013. The spacecraft broke up almost eight years later in March 2021 producing about 100 trackable objects. This follows the breakups of similar spacecraft NOAA-16, DMSP F11, and DMSP F13 which also produced between 80 and 500 trackable objects. An investigation was made into the cause of the breakup and recommend how to better operate or decommission spacecraft in the future. The NOAA-17 breakup was found to be a single, localized debris event; there is likely no catastrophic damage to the whole spacecraft. NOAA-17 debris is very much in family with NOAA-16 debris, and DMSP F11 and F13 are very much in family with each other and share similarities with NOAA-16 and 17; it is likely all four share the same breakup cause. DMSP F13 breakup occurred simultaneous with a known battery overcharge and therefore battery rupture is most likely intermediate cause of all four of the breakups. This is a low confidence assessment, however, since other debris sources cannot be definitively ruled out. No root cause was found as the NOAA-17 batteries were all confirmed to have been disconnected from the charge path as intended. Possible conditions for reconnection are all unlikely including short circuits and ground commanding. All 25 related spacecraft pose a risk of similar breakups for decades to come and are a threat to the critical 800-850 km polar orbit regime; even appropriately decommissioned spacecraft appear to be at risk. Recommendations include an update to the decommissioning procedure and consideration of further investigations and active debris removal, consistent with national policy.

Scott Hull↗

NASA NTRS2021

NOAA-17 Break-up Engineering Investigation Board Final Report

The NOAA-17 break-up was found to be a single, localized debris event producing about100 trackable pieces; there is likely no catastrophic damage to the whole spacecraft. NOAA-17 debris is very much in family with NOAA-16 debris, and DMSP F11 and F13 are very much in family with each other and share similarities with NOAA-16 and 17; it is likely all four (“The Big Four”) share the same debris source. DMSP F13 break-up occurred simultaneous with a known battery overcharge and therefore battery rupture is most likely intermediate cause of the Big Four break-ups; this is a low confidence assessment since other debris sources cannot be definitively ruled out. No root cause was found as the NOAA-17 batteries were all confirmed to have been disconnected from the charge path as intended. Possible conditions for reconnection are all unlikely including short circuits and commanding from a “bad actor.” All related spacecraft pose a risk of similar break-ups for decades to come and are a threat to the critical 800-850 km polar orbit regime; even appropriately decommissioned spacecraft appear to be at risk. Recommendations include an update to the decommissioning procedure and consideration of further investigations and active debris removal, consistent with national policy.

Maggie Atkinson↗

NASA NTRS2010

NASA Engineering and Safety Center Technical Bulletin No. 10-01: Power MOSFET Thermal Instability

In the quest for faster switching times and lower “on resistance” the Metal-Oxide Semiconductor Field-Effect Transistor (MOSFET), produced since 1998, has achieved most intended goals. Unfortunately, lower “on resistance” and higher switching speeds in the designs now being produced allow the charge carrier dominated region to develop conditions that could lead to thermal runaway. Temperatures above 450º C on any location within the part can cause the metals to begin migrating causing a fatal short circuit.

Metal-Oxide Semiconductor Field-Effect Transistor ↗

NASA NTRSDate not supplied

Cold Metal Transfer (CMT) Wire-Arc Additive Manufacturing (WAAM)

Aluminum has been identified as a compound within regolith and is likely to become a core component of our infrastructure on the lunar surface as in-situ resource utilization (ISRU) capabilities are advanced Large-scale components, outfitting, and repairs of aluminum materials can be fabricated with robotic wire arc additive manufacturing (WAAM) in order to inhabit the moon’s surface long term WAAM is a high value process for lunar advanced manufacturing as it does not require special containment to reduce explosion hazards such as powder-based additive processes and feedstock The welding process of cold metal transfer (CMT) is a relatively new variation of gas metal arc welding (GMAW, also known as MIG) that relies on the detection of a short circuit in the welding process to control the deposition droplet action, resulting in lower heat input and splatter compared to conventional MIG welding The past year was spent developing the CMT-WAAM process for aluminum materials, tested specialty feedstock, tested within the high vacuum environment, and advanced the MSFC capability to perform complex toolpathing from solid models Upcoming and future work includes large depositions working towards material certification for multiple feedstocks, in-situ monitoring, work to use recycled materials for the AM feedstock, and the design and fabrication of a parabolic flight experiment payload.

cold metal transfer↗