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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Power MOSFET Thermal Instability Operation Characterization Support

Metal-oxide semiconductor field-effect transistors (MOSFETs) are used extensively in flight hardware and ground support equipment. In the quest for faster switching times and lower "on resistance," the MOSFETs designed from 1998 to the present have achieved most of their intended goals. In the quest for lower on resistance and higher switching speeds, the designs now being produced allow the charge-carrier dominated region (once small and outside of the area of concern) to become important and inside the safe operating area (SOA). The charge-carrier dominated region allows more current to flow as the temperature increases. The higher temperatures produce more current resulting in the beginning of thermal runaway. Thermal runaway is a problem affecting a wide range of modern MOSFETs from more than one manufacturer. This report contains information on MOSFET failures, their causes and test results and information dissemination.

Shue, John L.↗
NASA NTRSDate not supplied

Predicting Thermal Response in a Li-ion Cell on a UAV Fight Profile

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.

Li-ion↗
NASA NTRS2013

Deleterious Thermal Effects due to Randomized Flow Paths in Pebble Bed, and Particle Bed Style Reactors

Reactor fuel rod surface area that is perpendicular to coolant flow direction (+S) i.e. perpendicular to the P creates areas of coolant stagnation leading to increased coolant temperatures resulting in localized changes in fluid properties. Changes in coolant fluid properties caused by minor increases in temperature lead to localized reductions in coolant mass flow rates leading to localized thermal instabilities. Reductions in coolant mass flow rates result in further increases in local temperatures exacerbating changes to coolant fluid properties leading to localized thermal runaway. Unchecked localized thermal runaway leads to localized fuel melting. Reactor designs with randomized flow paths are vulnerable to localized thermal instabilities, localized thermal runaway, and localized fuel melting.

Moran, Robert P.↗
DOE OSTI2023

Dispersion of stored energy within a battery system at risk of failure

A method and system for dispersing stored energy in an energy storage system to delay or arrest propagation of thermal runaway and thermally-induced cascading failures. The system includes a plurality of battery sub-assemblies and DC-DC converters connected to a shared DC bus through which energy may be exchanged. The system may be interfaced to an AC power grid or DC power system through an additional power converter. The method of dispersing stored energy uses this system to charge and discharge sub-assemblies such that the system is less susceptible to propagation of thermal runaway. The method determines, based on awareness of current system state, battery types, and electrical and thermal structure, the sequence of charging and discharging actions to best inhibit thermal runaway while preserving the system's ability to perform subsequent energy redistribution.

Mueller, Jacob↗
NASA NTRS2019

Safe, High Power/Voltage Battery Module Design Challenges

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.

Thermal runaway↗
NASA NTRS2019

Short Course on Lithium-Ion Batteries: Fundamental Concepts, Battery Safety, and Modeling Techniques

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.

Walker, William↗
DOE OSTI2020

Passive Mitigation of Cascading Propagation in Multi-Cell Lithium Ion Batteries

The heat generated during a single cell failure within a high energy battery system can force adjacent cells into thermal runaway, creating a cascading propagation effect through the entire system. This work examines the response of modules of stacked pouch cells after thermal runaway is induced in a single cell. The prevention of cascading propagation is explored on cells with reduced states of charge and stacks with metal plates between cells. Reduced states of charge and metal plates both reduce the energy stored relative to the heat capacity, and the results show how cascading propagation may be slowed and mitigated as this varies. These propagation limits are correlated with the stored energy density. Results show significant delays between thermal runaway in adjacent cells, which are analyzed to determine intercell contact resistances and to assess how much heat energy is transmitted to cells before they undergo thermal runaway. A propagating failure of even a small pack may stretch over several minutes including delays as each cell is heated to the point of thermal runaway. This delay is described with two new parameters in the form of gap-crossing and cell-crossing time to grade the propensity of propagation from cell to cell.

25 ENERGY STORAGE↗
DOE OSTI2022

Waste Control Specialists Technical Review Team Report

1. Modeling of Drum 68660 and the WCS Drums: A calibrated model of Los Alamos National Laboratory (LANL) Drum 68660 indicates that pressurization of the drum by restriction of drum venting could have led to the thermal runaway reaction at the Waste Isolation Pilot Plant (WIPP) in 2014, supporting the hypothesis that the contents of the drum were not fundamentally different from the overall remediated nitrate salt (RNS) waste stream. 2. Nitric Acid Reactions and Aging of the Waste: The stability of the WCS RNS waste with respect to autocatalytic thermal runaway due to nitric acid chemistry should increase over time as the nitric acid is depleted from chemical reactions in the drum. However, this cannot be confirmed because of the lack of long-term experimental data on the impact of aging on the reactivity of RNS waste. The calibrated model indicates that the waste drums retain most of their reactive components, metal nitrate salts and sWheat Scoop ® , even after eight years. 3. Pressure Effects and Runaway Reactions: The calibrated model indicates that if the drums and standard waste boxes (SWBs) are not allowed to pressurize during transport or storage and they are stored at historical WIPP repository temperatures, then an autocatalytic thermal runaway event is not expected to occur. Since the cause of Drum 68660 pressurization is not known, decision makers are not able to tailor mitigating strategies to the initiating event. Consequently, mitigating strategies must consider all feasible internal and external events that could lead to the pressurization of the drums. 4. Temperature Effects and Runaway Reactions: Temperature also has a strong influence on the stability of the waste. The calibrated model indicates that cooling the drums or SWBs can reduce the possibility of autocatalytic thermal runaway reactions. Simulations suggest that for a drum with a plugged vent, the probability of thermal runaway may be reduced or eliminated if wastes are maintained at or below 43 °F through active cooling measures from the initiation of transport until emplacement at WIPP.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2011

Thermal Properties of Microstrain Gauges Used for Protection of Lithium-Ion Cells of Different Designs

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.

Jeevarajan, Judith↗
DOE OSTI2025

Development of copper thiolate organometallic compound as thermal sensitive coating for energy storage system safety

Safety and reliability are primary concerns for the deployment of lithium-ion batteries, especially in electric vehicles (EV) and larger-scale energy storage systems (ESS). Current technology in battery management systems (BMS) includes cell voltage monitoring and positioning temperature sensors in selected locations. For a system with hundreds to thousands of individual batteries, single-point temperature monitoring is inadequate to detect hot spots and cell overheating, which could lead to thermal runaway. Here, we have developed a temperature-sensitive copper-thiol compound that can be directly coated onto battery pouch foils to enable early detection of thermal runaway. Upon reaching specific temperatures, this compound releases a sulfur-containing detectable gas, which can be identified using chemically specific gas sensors to trigger an early warning signal. Such a signal propagate through air offers broad signal coverage and enables a more comprehensive approach to large-area temperature monitoring. The Cu-ethanethiol coating is designed to release volatile gases when the substrate surface temperature exceeds 70 °C, with continuous outgassing as the temperature increases. The compound is composed of Cu, S, Cl, hydrocarbons and trace amounts of oxygen. Upon heating, the oxidation state of Cu(I) transitions to Cu (II), accompanied by gas release. Thermogravimetric analysis coupled with mass spectrometry correlated well with the onset of gas release temperature and emission of sulfur-containing volatile gases. Additionally, an acrylic overcoat is applied to enhance the adhesion of the thermally sensitive compound film to the battery pouch foil. This coating is expected to offer an additional safety layer for ESS, alerting possible thermal runaway events before a failure occurs, thereby allowing sufficient time to implement a mitigation plan.

Early warning systems↗
NASA NTRS2015

[Redesign of the Spacesuit Long Life Battery and the Personal Life Support System Battery]

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.

Scharf, Stephanie↗