Small Fractional Thermal Runaway Calorimeter
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As the energy storage devices continue to "pack" more energy in a small space, any damage, battery component failure, manufacturing defect, or electrically abusing the battery can lead to catastrophic thermal runaway events. A catastrophic thermal event in a cell leads to high temperature, in some instances spewing of battery materials due to gas development from side reactions initiated due to high internal temperatures. Also, a thermal runaway event can propagate from a single "failed" cell to the pack in a battery pack, leading to a more significant event. Mitigating a thermal runaway event is important in the commercial and automotive sectors. However, preventing such events in an electric aircraft (or air taxis) is paramount due to the lack of alternatives in the event of a failure. Battery prognostics algorithms allow the prediction of state-of-charge (SOC) and end-of-life (EOL) of a Li-ion battery in a UAV (unmanned air vehicle) [1]. For this presentation, we will extend this two-level battery predictive algorithm to predict SOC, EOL, and estimated maximum temperature during a simulated flight. The model is extended by integrating a lumped physics-driven thermal model for high current densities [2]. The parameters used to control SOC and EOL are maximum storable charge, time constant for Li-ion diffusivity in the carbon particles, and internal cell resistance. Cycling leads to an increase in the heat generated by an aged Li-ion cell with a LiyCoO2 (LCO) cathode and a LixC6 (MCMB) anode. The aging of a cell leads to increase in SEI layer thickness, the diffusion time for the lithium ions inside the electrodes, and the local reaction rates, in addition to the thermodynamic abuse caused by fixed cycling voltages controlled by a Battery Management System. As the battery ages, the cell resistance increases, while the onset temperature of the thermal runaway decreases (depends on the cell chemistry and cell abuse history). Any large deviation of the cell temperature from the estimated (expected) value can identify a faulty cell. Since SEI decomposition has the lowest onset temperature in the series of reactions leading to thermal runaway, the model considers the self-heating rate of the SEI decomposition as onset temperature (similar to Ref. [3]). The parameters in the Arrhenius equation for the SEI heating rate depend on the number of cycles, the cell's operating temperature, and the cell's abuse history [4,5]. Coupling the electrochemical, thermal, and aging model allow the prognostic algorithm to estimate a typical cell voltage and temperature as a function of age (cycling and calendar), whose departure from measured values from the BMS is used to identify a safety event. In addition, we will present the results from two simulated flight scenarios for a UAV: typical and extreme, since the power requirements vary significantly during take-off, landing, and changing altitudes, while the power requirements remain low during the cruise. For this presentation, the power requirement for a battery pack in a UAV is scaled to a single cell. This cell is cycled through a simulated profile, and the data is collected and used to predict a safety event.
A decision-directed receiver (DDR) uses previous outputs (decisions) to estimate unknown parameters and, on the basis of these estimates, modifies the detector structure for subsequent decisions. Although the DDR is less complex to instrument than other adaptive schemes, inherent in the decision-directed approach is the possibility of a runaway. This occurs when the detector commits a sequence of decision errors resulting in a degradation of parameter estimates, which, in turn, results in a further deterioration of detector performance. Because of the dependencies introduced by the learning process, runaway is difficult to analyze. In this paper, a DDR with unknown a priori probabilities is considered. The priors are estimated by the relative frequency of decisions of that event. For binary detection, it is shown that there is a positive probability of a runaway (the estimates converge to 1 or 0), which equals 1 if the signal-to-noise ratio is below a critical value. A tight bound on the probability of a runaway is obtained by approximating the learning process by a random walk with independent increments. The analysis demonstrates that a runaway is quite improbable even for moderate signal-to-noise ratios. The analysis is extended to multiple signals and to the situation where the estimates of the priors are updated continuously through exponential weighting rather than allowed to converge.
Computer simulations of the evolution of the earth's atmospheric composition and surface temperature have been carried out. The program took into account changes in the solar luminosity, variations in the earth's albedo, the greenhouse effect, variation in the biomass, and a variety of geochemical processes. Results indicate that prior to two billion years ago the earth had a partially reduced atmosphere, which included N2, CO2, reduced carbon compounds, some NH3, but no free H2. Surface temperatures were higher than now, due to a large greenhouse effect. When free O2 appeared the temperature fell sharply. Had earth been only slightly further from the sun, runaway glaciation would have occurred at that time. Simulations also indicate that a runaway greenhouse would have occurred early in earth's history had earth been only a few percent closer to the sun. It therefore appears that, taking into account the possibilities of either runaway glaciation or a runaway greenhouse effect, the continuously habitable zone about a solar-type star is rather narrow, extending only from roughly 0.95 to 1.01 AU.
Earth has approximately 60 bars of carbon dioxide tied up in carbonate rocks, or roughly 2/3 the amount of CO2 of Venus' atmosphere. Two different lines of evidence, one based on thermodynamics and the other on geochemical cycles, indicate that a substantial fraction of this CO2 may have resulted in the atmosphere during the first few hundred million years of the Earth's history. A natural question which arises concerning this hypothesis is whether this would have resulted in a runaway greenhouse affect. One-dimensional radiative/convective model calculations show that the surface temperature of a hypothetical primitive atmosphere containing 20 bars of CO2 would have been less than 100C and no runaway greenhouse should have occurred. The climatic stability of the early atmosphere is a consequence of three factors: (1) reduced solar luminosity at that time; (2) an increase in planetary albedo caused by Rayleigh scattering by CO2; and (3) the stabilizing effects of moist convection. The latter two factors are sufficient to prevent a CO2-induced runaway greenhouse on the present Earth and for CO2 levels up to 100 bars. It is determined whether a runaway greenhouse could have occurred during the latter stages of the accretion process and, if so, whether it would have collapsed once the influx of material slowed down.
Earth has approximately 60 bars of carbon dioxide tied up in carbonate rocks, or roughly 2/3 the amount of CO2 of the atmosphere of Venus. Two different lines of evidence, one based on thermodynamics and the other on geochemical cycles, indicate that a substantial fraction of thes CO2 may have resided in the atmosphere during the first few hundred million years of the Earth's history. A natural question which arises is whether this much CO2 would have resulted in a runaway greenhouse effect. One dimensional radiative/convective model calculations presented showed that the surface temperature of a hypothetical primitive atmosphere containing 20 bars of CO2 was less than 100 C; thus no runaway greenhouse effect would have occurred. The climatic stability of the early atmosphere is a consequence of three factors: reduced solar luminosity at that time, an increase in planetary albedo caused by Rayleigh scattering by CO2, and the stabilizing effects of a moist convection. The latter two factors are sufficient to prevent a CO2 induced runaway greenhouse effect on the present Earth as well, for CO2 levels up to 100 bars. Further studies are being undertaken to determine whether a runaway greenhouse effect could have occurred during the latter stages of the accretion process and, if so, whether it would have collapsed one the influx of material slowed down.
If the dark halo of the Galaxy is comprised of massive black holes (MBHs), then those within approximately 1 kpc will spiral to the center, where they will interact with one another, forming binaries which contract, owing to further dynamical friction, and then possibly merge to become more massive objects by emission of gravitational radiation. If successive mergers would invariably lead, as has been proposed by various authors, to the formation of a very massive nucleus of 10(exp 8) solar mass, then the idea of MBHs as a dark matter candidate could be excluded on observational grounds, since the observed limit (or value) for a Galactic central black hole is approximately 10(exp 6.5) solar mass. But, if successive mergers are delayed or prevented by other processes, such as the gravitational slingshot or rocket effect of gravitational radiation, then a large mass accumulation will not occur. In order to resolve this issue, we perform detailed N-body simulations using a modfied Aarseth code to explore the dynamical behavior of the MBHs, and we find that for a 'best estimate' model of the Galaxy a runaway does not occur. The code treates the MBHs as subject to the primary gravitational forces of one another and to the smooth stellar distribution, as well as the secondary perturbations in their orbits due to another and to the smooth stellar distribution, as well as the secondary perturbations in their orbits due to dynamical friction and gravitational radiation. Instead of a runaway, three-body interactions between hard binaries and single MBHs eject massive objects before accumulation of more than a few units, so that typically the center will contain zero, one, or two MBHs. We study how the situation depends in detail on the mass per MBH, the rotation of the halo, the mass distribution within the Galaxy, and other parameters. A runaway will most sensitively depend on the ratio of initial (spheroid/halo) central mass densities and secondarily on the typical values for the mass per MBH, with the rough dividing line, using Galactic parameters, being M(sub BH) less than or = 10(exp 6.5) solar mass. Using parameters from Lacey & Ostriker (1985) and our most accurate model for Galaxy, no runaway occurs.
The one-dimensional radiative-convective equilibrium model with an explicit hydrologic cycle introduced in part 1 is used to study the sensitivity of the model's atmosphere to large changes in the solar forcing, when various cumulus convection parameterizations are used. When the concentration of the absorbing as in the atmosphere is temperature dependent, equilibrium is impossible for values of the solar forcing larger than a critical value. This result is referred to as a runaway greenhouse. The cumulus convection parameterization schemes currently in use in global climate models (GCMs) employ different assumptions about moistening. This causes the critical solar forcing above which a runaway greenhouse occurs to be very sensitive to the cumulus convection scheme employed. Furthermore, we show that the sensitivity of the equilibrium temperature to changes in the solar forcing depends crucially on the microphysics of cumulus convection. For fixed cloud conditions, the critical forcing for a runaway greenhouse to occur is between approximately 1.22 and 1.49 times the global mean value for the Earth, and for clear sky conditions, it is a few percent lower. The runaway greenhouse in the experiments with the mass flux schemes generally occurs more rapidly than in the experiments with the adjustment schemes. In addition, the inability of the hard convective adjustment scheme to produce an efficient vertical transport of moisture, together with the saturation requirement for convection to occur, leads to the breakdown of the radiative-convective equilibria when other processes are not available to provide the necessary vertical transport of water vapor.
The purpose of this innovation is to use microstrain gauges to monitor minute changes in temperature along with material properties of the metal cans and pouches used in the construction of lithium-ion cells. The sensitivity of the microstrain gauges to extremely small changes in temperatures internal to the cells makes them a valuable asset in controlling the hazards in lithium-ion cells. The test program on lithium-ion cells included various cell configurations, including the pouch type configurations. The thermal properties of microstrain gauges have been found to contribute significantly as safety monitors in lithium-ion cells that are designed even with hard metal cases. Although the metal cans do not undergo changes in material property, even under worst-case unsafe conditions, the small changes in thermal properties observed during charge and discharge of the cell provide an observable change in resistance of the strain gauge. Under abusive or unsafe conditions, the change in the resistance is large. This large change is observed as a significant change in slope, and this can be used to prevent cells from going into a thermal runaway condition. For flexible metal cans or pouch-type lithium-ion cells, combinations of changes in material properties along with thermal changes can be used as an indication for the initiation of an unsafe condition. Lithium-ion cells have a very high energy density, no memory effect, and almost 100-percent efficiency of charge and discharge. However, due to the presence of a flammable electrolyte, along with the very high energy density and the capability of releasing oxygen from the cathode, these cells can go into a hazardous condition of venting, fire, and thermal runaway. Commercial lithium-ion cells have current and voltage monitoring devices that are used to control the charge and discharge of the batteries. Some lithium-ion cells have internal protective devices, but when used in multi-cell configurations, these protective devices either do not protect or are themselves a hazard to the cell due to their limitations. These devices do not help in cases where the cells develop high impedance that suddenly causes them to go into a thermal runaway condition. Temperature monitoring typically helps with tracking the performance of a battery. But normal thermistors or thermal sensors do not provide the accuracy needed for this and cannot track a change in internal cell temperatures until it is too late to stop a thermal runaway.
This Fall I worked on two different projects that culminated into a redesign of the spacesuit LLB (long life battery). I also did some work on the PLSS (personal life support system) battery with EC. My first project was redlining the work instruction for completing DPAs (destructive physical analysis) on battery cells in the Branch. The purpose of this document is to create a standard process and ensure that the data is collected in the same way, no matter who carries out the analysis. I observed three DPAs, conducted one with help, and conducted two on my own, all while taking notes on the procedure. These notes were used to write the final work instruction, which will become the Branch standard. My second project continued the work of the Summer co-op before me. I tested aluminum heat sinks for their ability to provide good thermal conduction and structural support during a thermal runaway event. The heat sinks had been designed by the previous Summer co-op, but there was not much time for testing before he left. We thus ran tests with a heater on the bottom of a trigger cell to try to drive thermal runaway and ensure that it will not propagate to adjacent cells. We also ran heat-to-vent tests in an oven to see if the assembly provided structural support and prevented sidewall rupture during thermal runaway. These tests were carried out at ESTA (Energy Systems Test Area) and are providing very promising results, indicating that safe, high performing (>180 Wh/kg) designs are possible. My main project was a redesign of the LLB (Lightweight Lithium Battery). Another summer intern had done some testing and concluded that there was no simple fix to mitigate thermal runaway propagation hazards in the existing design. The only option was a clean sheet redesign of the battery. I was given a volume and ideal energy density, and the rest of the design was up to me. First, I created new heat sink banks in CREO, using the information gathered in the metal heat sink tests from the summer intern. After this, I made capture plates to hold the cells in place, and I worked on nickel bussings for the electrical connections between the cells. Finally, I designed the test box enclosure that included sections for flame arresting materials. The battery brick design, which is the heart of the battery, promises to become the first for a manned spacecraft application to achieve > 180 Wh/kg. My work in redlining the DPA work instructions will also be used in selecting the cells for the battery. We had a few options for cells that would provide the necessary power output and needed to make a choice. We repeatedly charged and discharged cells for around a month until they went through 100 lifecycles. The plan was to compare the DPA results on fresh and cycled cells from each manufacturer to see if cycling introduces any differences. After the complete LLB design was approved, the parts were ordered and testing should begin the first week of December. Cutting open a cell for DPA After photo from oven heat-to-vent test
This fall I was working on two different projects that culminated into a redesign of the spacesuit LLB (long life battery). I also did some work on the PLSS (personal life support system) battery with EC. My first project was redlining the work instruction for completing DPAs (destructive physical analysis) on battery cells in the department. The purpose of this document is to create a standard process and ensure that the data in the same way no matter who carries out the analysis. I observed three DPAs, conducted one with help, and conducted two on my own all while taking notes on the procedure. These notes were used to write the final work instruction that will become is the department standard. My second project continued the work of the summer co-op before me. I was testing aluminum heat sinks for their ability to provide good thermal conduction and structural support during a thermal runaway event. The heat sinks were designed by the summer intern but there was not much time for testing before he left. We ran tests with a heater on the bottom of a trigger cell to try to drive thermal runaway and ensure that it will not propagate to adjacent cells. We also ran heat-to-vent tests in an oven to see if the assembly provided structural support and prevented sidewall rupture during thermal runaway. These tests were carried out at ESTA (energy systems test area) and are providing very promising results that safe, high performing (greater than 180 Wh/kg) designs are possible. My main project was a redesign of the LLB battery. Another summer intern did some testing and concluded that there was no simple fix to mitigate thermal runaway propagation hazards in the current design. The only option was a clean sheet redesign of the battery. I was given a volume and ideal energy density and the rest of the design was up to me. First, I created new heat sink banks in Creo using the information gathered in the metal heat sink tests from the summer intern. After this, I made capture plates to hold the cells in place and I worked on nickel bussings for the electrical connections between the cells. Finally, I designed the test box enclosure that included sections for flame arresting materials. The battery brick design, which is the heart of the battery, promises to become the first for a manned spacecraft application to achieve greater than 180 Wh/kg. My work in redlining the DPA work instructions will also be used in selecting the cells for the battery. We had a few options of cells that would provide the necessary power output and needed to make a choice. We repeatedly charged and discharged cells for around a month until they went through 100 lifecycles. The plan is to compare the DPA results on fresh and cycled cells from each manufacturer to see if cycling introduces any differences. After the complete LLB design was approved, the parts were ordered and testing should begin the first week of December. Some of my side projects included working on the CAD data for the PLSS with EC and attending the NASA Aerospace Battery Workshop in Huntsville. I was also a member of the Tours and Lectures Committee for the USRA and Pathways interns. I coordinated Apollo Evening and was on the committee for touring KSC and seeing an Atlas 5 launch. I really enjoyed my time at JSC and I would like to continue working for NASA or another aerospace company in the future. I have worked other internships prior to this, but I think the heavy research and development focus is the best fit for me. I originally thought I would need to go to grad school to work in an environment like this, but I now see it is possible with a bachelor’s degree and hard work. I would like to go into the workforce and maybe continue my education with night classes.
When developing this course several years back I asked myself, "What do I think the TFAWS community needs to know about lithium-ion batteries and why should they care?" I think the answers to these questions can be boiled down to the following statements: 1. Lithium-ion (Li-ion) battery electrical performance and efficiency are heavily driven by thermal conditions. 2. Li-ion battery assemblies can experience single cell thermal runaway events which can lead to cell-to-cell propagation; these are thermally driven failure events that can be controlled with effective thermal management systems. 3. Knowledge of BOTH Li-ion battery fundamentals AND traditional thermal design principles are required to develop safe battery assemblies that are both gravimetrically and volumetrically optimized.This year the Short Course on Lithium-ion Batteries will be presented in a 2-part series. The first portion, "Fundamentals, Battery Safety, and Thermal Runaway," will focus on educating participants on the fundamental aspects of Li-ion batteries and on battery safety related topics (i.e. thermal runaway, cell-to-cell propagation, safe handling practices, et...). The second portion, "Practical Thermal Simulation Techniques," will provide participants with a real time demonstration of how to use Thermal Desktop to model of Li-ion battery assemblies. This part of the lesson will cover geometry simplification, mesh development, boundary conditions, and heat loads for both nominal operations (charge and discharge) and for thermal runaway events.
NASA seeks to demonstrate a path for achieving safe, high power, and high performing Li-ion battery designs for the purpose of establishing design guidelines for our aeronautic and spacecraft applications. Safe means passively resistant to thermal runaway propagation of any single cell catastrophic thermal runaway. High power means capable of 3C continuous discharge without overheating. High performing means achieving > 160 Wh/kg, 200 Wh/L. The biggest challenge has been balancing a high flux light weight path for cell heat dissipation during the high rate discharge that minimizes thermal gradients between cells and also protects adjacent cells from the heat load of thermal runaway cell. Our solution includes an oscillating heat pipe spine that contacts every 18650 cell in the pack and careful cell design selection to maximize the range of initial temperatures conditions where the battery can safely complete the 3C discharge.