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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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The experimental design, parameters, and testing of a modified NASA standard nickel-cadmium cell are discussed. Modifications regarding positive plate loading levels and nickel attack levels, loading levels for the negative plates, interelectrode spacing, and the positive electrode impregnation process are addressed.
The results of initial characterization testing of 75 Ah actively cooled bipolar battery designs and 10 boilerplate nickel-hydrogen battery designs are presented. The results demonstrate the extended cycle life capability of the Ah batteries and the high capacity utilizations at various discharge rates of the nickel-hydrogen batteries.
The hardware and software design of a nickel-hydrogen (Ni-H2) battery simulator (BS) with application to the NASA Earth Observation System (EOS) satellite is presented. The battery simulator is developed as a part of a complete testbed for the EOS satellite power system. The battery simulator involves both hardware and software components. The hardware component includes the capability of sourcing and sinking current at a constant programmable voltage. The software component includes the capability of monitoring the battery's ampere-hours (Ah) and programming the battery voltage according to an empirical model of the nickel-hydrogen battery stored in a computer.
Eddy current methods have been applied to characterize the effect of magnetic treatments on component service-life extension. Coil impedance measurements were acquired and analyzed on nickel 200 specimens that have been subjected to many mechanical and magnetic engineering processes: annealing, applied strain, magnetic field, shot peening, and magnetic field after peening. Experimental results have demonstrated a functional relationship between coil impedance, resistance and reactance, and specimens subjected to various engineering processes. It has shown that magnetic treatment does induce changes in electromagnetic properties of nickel 200 that then exhibit evidence of stress relief. However, further fundamental studies are necessary for a thorough understanding of the exact mechanism of the magnetic field processing effect on machine-tool service life.
A review of our studies on the elucidation of the self-discharge mechanism of the Ni/H2 battery and methods to inhibit this phenomena is presented. The results show that (1) the rate of heat generation from nickel hydroxide powders and from electrodes increases with increase of hydrogen pressure, simultaneously, the open-circuit potential of the nickel hydroxide electrode is shifted in a negative direction more rapidly, indicating the transformation of NiOOH to Ni(OH)2; (2) heat generation rates measured in the microcalorimeter are considerably faster for electrolyte starved electrodes than for electrolyte-flooded electrodes; (3) there is a good correlation between the extent of self-discharge, as determined by heat generation in microcalorimetric measurement and capacity change; and (4) the self-discharge in Ni/H2 battery occurs via direct reduction of the active material by pressurized hydrogen. The addition of cadmium to the electrode reduces the self-discharge.
An investigation was conducted using static capsules fabricated from "L" nickel tubing to determine the effect of temperature level, temperature gradient, and test duration on corrosion and mass transfer by molten sodium hydroxide under free-convection conditions. A base temperature range from 1000 degrees to 1600 degrees F with temperature differences to 500 degrees was studied. The rate of mass transfer was found to be strongly dependent on both temperature level and gradient. The rate shows little tendency to decrease for test durations up to 200 hours, although the concentration of nickel in the melt approaches a limited value after 100 hours.
A 3.5 inch rabbit-ear-terminal nickel-hydrogen cell was designed and tested to deliver high capacity at steady discharge rates up to and including a C rate. Its specific energy yield of 60.6 wh/kg is believed to be the highest yet achieved in a slurry-process nickel-hydrogen cell, and its 10 C capacity of 113.9 AH the highest capacity yet of any type in a 3.5 inch diameter size. The cell also demonstrated a pulse capability of 180 amps for 20 seconds. Specific cell parameters and performance are described. Also covered is an episode of capacity fading due to electrode swelling and its successful recovery by means of additional activation procedures.
Eagle-Picher currently has several advanced nickel-hydrogen (NiH2) cell component and battery designs under development including common pressure vessel (CPV), single pressure vessel (SPV), and dependent pressure vessel (DPV) designs. A CPV NiH2 battery, utilizing low-cost 64 mm (2.5 in.) cell diameter technology, has been designed and built for multiple smallsat programs, including the TUBSAT B spacecraft which is currently scheduled (24 Nov. 93) for launch aboard a Russian Proton rocket. An advanced 90 mm (3.5 in.) NiH2 cell design is currently being manufactured for the Space Station Freedom program. Prototype 254 mm (10 in.) diameter SPV batteries are currently under construction and initial boilerplate testing has shown excellent results. NiH2 cycle life testing is being continued at Eagle-Picher and IPV cells have currently completed more than 89,000 accelerated LEO cycles at 15% DOD, 49,000 real-time LEO cycles at 30 percent DOD, 37,800 cycles under a real-time LEO profile, 30 eclipse seasons in accelerated GEO, and 6 eclipse seasons in real-time GEO testing at 75 percent DOD maximum. Nickel-metal hydride battery development is continuing for both aerospace and electric vehicle applications. Eagle-Picher has also developed an extensive range of battery evaluation, test, and analysis (BETA) measurement and control equipment and software, based on Hewlett-Packard computerized data acquisition/control hardware.
A 50 Ampere-hour nickel-hydrogen cell with a single-layer Zircar separator stack design was fully charged and then discharged at a 2C current rate to an end voltage of 1 volt. This extreme test resulted in high temperatures which were recorded at three locations on the cell, i.e., the cell wall, the boss (barrel of the compression seal), and a terminal. The results provide new information about the high-temperature and high-discharge-rate capabilities of nickel-hydrogen cells. This information also adds to the growing data base for single-layer zirconium-oxide-cloth (Zircar) separator cell designs.
The George C. Marshall Space Flight Center is working to characterize aerospace AB5 Nickel Metal Hydride (NiMH) cells. The cells are being evaluated in terms of storage, low earth orbit (LEO) cycling, and response to parametric testing (high rate charge and discharge, charge retention, pulse current ability, etc.). Cells manufactured by Eagle Picher are the subjects of the evaluation. There is speculation that NiMH cells may become direct replacements for current Nickel Cadmium cells in the near future.
Battery management during prelaunch activities has always required special attention and careful planning. The transition from nickel-cadium to nickel-hydrogen batteries, with their high self discharge rate and lower charge efficiency, as well as longer prelaunch scenarios, has made this aspect of spacecraft battery management even more challenging. The AXAF-I Program requires high battery state of charge at launch. The use of active cooling, to ensure efficient charging, was considered and proved to be difficult and expensive. Alternative approaches were evaluated. Optimized charging, in the absence of cooling, appeared promising and was investigated. Initial testing was conducted to demonstrate the feasibility of the 'Adiabatic Charging' approach. Feasibility was demonstrated and additional testing performed to provide a quantitative, parametric data base. The assumption that the battery is in an adiabatic environment during prelaunch charging is a conservative approximation because the battery will transfer some heat to its surroundings by convective air cooling. The amount is small compared to the heat dissipated during battery overcharge. Because the battery has a large thermal mass, substantial overcharge can occur before the cells get too hot to charge efficiently. The testing presented here simulates a true adiabatic environment. Accordingly the data base may be slightly conservative. The adiabatic charge methodology used in this investigation begins with stabilizing the cell at a given starting temperature. The cell is then fully insulated on all sides. Battery temperature is carefully monitored and the charge terminated when the cell temperature reaches 85 F. Charging has been evaluated with starting temperatures from 55 to 75 F.
Nickel electrodes using fibrous substrates have poorer initial utilization of the active material than those using conventional nickel sinter substrates. Previous investigators had shown that utilization can be dramatically improved by dipping these electrodes in a cobalt solution immediately after the electrochemical impregnation, before formation and cycling is carried out. The present study looked at the gas evolution behavior of dipped and undipped electrodes, impedance curves, and the charge-discharge curves to try to understand the reasons for the improvement in utilization. Impedance measurements under open circuit conditions indicate that some of the improvement is due to a reduction in the ohmic resistance of the surface layer of the particles, in agreement with earlier work. The charge-discharge curves suggest that there may also be an additional increase in the ohmic resistance of the surface layer of the undipped electrode during charging.
A study was undertaken to examine the capacity maintenance features of SUPER nickel-cadmium cells when stored for extended periods to determine whether the features change when the same kinds of positive plates as that used in nickel-hydrogen cells are used, The cells maintained their capacity when stored at 0 C in the discharged state and at 0 C in the charged state by continuously trickle charging. There was a capacity loss when stored in the open-circuit condition at 28 C. A cycling test at 17% depth of discharge for 2400 cycles using cells stored at various conditions showed that cells maintained good end of discharge voltage regardless of their storage history. However, the EOD voltages of stored cells were lower by 10 mV compared to those of fresh cells. The capacity at the end of the cycling test decreased for the stored cells by 2-7 Ah. The storage related capacity loss is lower for SUPER Ni-Cd cells compared to that of Ni-H2 cells containing a hydrogen precharge. The results suggest the pivotal role of hydrogen pressure in the capacity loss phenomenon.
The objectives of the project were to test the Nickel-Hydrogen Cell to: (1) verify the Aerospace Cell Flight Worthiness, (2) Elucidate the Aerospace Cell Thermal Behavior, (3) Develop the Aerospace Battery Assembly Design(s) and In-orbit Battery Management plan(s) and (4) Understand the Aerospace Cell Failure Mechanism. The tests included the LEO and GEO Life cycle tests, Calorimetric Analysis, Destructive Physical analysis, and special tests. Charts show the Mission Profile Cycling Data, Stress Cycling Data. The test data complies with the mission requirements, validating the flight worthiness of batteries. The nominal stress and mission profile cycling performance test shows the charge voltage as high as 1.60V and recharge ratio greater than 1.05. It is apparent that the electrochemical signatures alone do not provide conclusive proof for Nickel precharge. The researchers recommend a gas and positive plate analyses for further confirmation.
High Cycle Fatigue (HCF) induced failures in aircraft gas-turbine engines is a pervasive problem affecting a wide range of components and materials. HCF is currently the primary cause of component failures in gas turbine aircraft engines. Turbine blades in high performance aircraft and rocket engines are increasingly being made of single crystal nickel superalloys. Single-crystal Nickel-base superalloys were developed to provide superior creep, stress rupture, melt resistance and thermomechanical fatigue capabilities over polycrystalline alloys previously used in the production of turbine blades and vanes. Currently the most widely used single crystal turbine blade superalloys are PWA 1480/1493 and PWA 1484. These alloys play an important role in commercial, military and space propulsion systems. PWA1493, identical to PWA1480, but with tighter chemical constituent control, is used in the NASA SSME (Space Shuttle Main Engine) alternate turbopump, a liquid hydrogen fueled rocket engine. Objectives for this paper are motivated by the need for developing failure criteria and fatigue life evaluation procedures for high temperature single crystal components, using available fatigue data and finite element modeling of turbine blades. Using the FE (finite element) stress analysis results and the fatigue life relations developed, the effect of variation of primary and secondary crystal orientations on life is determined, at critical blade locations. The most advantageous crystal orientation for a given blade design is determined. Results presented demonstrates that control of secondary and primary crystallographic orientation has the potential to optimize blade design by increasing its resistance to fatigue crack growth without adding additional weight or cost.
High-cycle fatigue-induced failures in turbine and turbopump blades is a pervasive problem. Single-crystal nickel turbine blades are used because of their superior creep, stress rupture, melt resistance, and thermomechanical fatigue capabilities. Single-crystal materials have highly orthotropic properties making the position of the crystal lattice relative to the part geometry a significant and complicating factor. A fatigue failure criterion based on the maximum shear stress amplitude on the 24 octahedral and 6 cube slip systems is presented for single-crystal nickel superalloys (FCC crystal). This criterion greatly reduces the scatter in uniaxial fatigue data for PWA 1493 at 1,200 F in air. Additionally, single-crystal turbine blades used in the Space Shuttle main engine high pressure fuel turbopump/alternate turbopump are modeled using a three-dimensional finite element (FE) model. This model accounts for material orthotrophy and crystal orientation. Fatigue life of the blade tip is computed using FE stress results and the failure criterion that was developed. Stress analysis results in the blade attachment region are also presented. Results demonstrate that control of crystallographic orientation has the potential to significantly increase a component's resistance to fatigue crack growth without adding additional weight or cost.
Constant-Kmax fatigue crack growth tests were performed on two finegrain nickel-base alloys Inconel 718 (DA) and Ren 95 to determine if these alloys exhibit near-threshold time-dependent crack growth behavior observed for fine-grain aluminum alloys in room-temperature laboratory air. Test results showed that increases in K(sub max) values resulted in increased crack growth rates, but no evidence of time-dependent crack growth was observed for either nickel-base alloy at room temperature.
The Constellation-X mission, planned for launch in 2011, will feature an array of hard-x ray telescopes with a total collecting area goal of 1500 square centimeters at 40 keV. Various technologies are currently being investigated for the optics of these telescopes including multilayer-coated Eletroformed-Nickel-Replicated (ENR) shells. The attraction of the ENR process is that the resulting full-shell optics are inherently stable and offer the promise of good angular resolution and enhanced instrument sensitivity. The challenge for this process is to meet a relatively tight weight budget with a relatively dense material (rho nickel = 9 grams per cubic centimeters.) To demonstrate the viability of the ENR process we are fabricating a prototype HXT mirror module to be tested against a competing segmented-glass-shell optic. The ENR prototype will consist of 5 shells of diameters from 150 mm to 280 mm and of 426 mm total length. To meet the stringent weight budget for Con-X, the shells will be only 150 micron thick. The innermost of these will be coated with Iridium, while the remainder will be coated with graded-density multilayers. Mandrels for these shells are currently under fabrication (Jan 03), with the first shells scheduled for production in February 03. A tentative date of late Summer has been set for prototype testing. Issues currently being addressed are the control of stresses in the multiplayer coating and ways of mitigating their effects on the figure of the necessarily thin shells. Also, the fabrication, handling and mounting of these shells without inducing permanent figure distortions. A full status report on the prototype optic will be presented along with test results as available.