NiCd battery failure analysis
The failure of a nickel cadmium battery undergoing tests is discussed. Reasons for the complete destruction of the battery while undergoing preparation for thermal vacuum testing are given.
Sense, K. A.↗
SEARCH · Engineering Papers
Results for “Battery failure analysis”
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
The 1984 Goddard Space Flight Center Battery Workshop
Various topics related to spacecraft power supply systems are discussed. Regenerative fuel cells, lithium molybdenum batteries, nickel hydrogen batteries, nickel cadmium batteries, failure analysis, and performance testing are covered.
Morrow, G. W.↗
Battery Virtual Cell Module Failure Propagation Thermal Analysis
Explore the source record for details and available documents.
Battery failure↗
Time-to-failure analysis for NiCd batteries in a CPS orbit
Cells operating at five degrees Celsius or less, and going to 60 to 65 percent depth of discharge, were studied as to whether they could achieve a useful working life of 7.5 years in a GPS orbit. The characteristics of various orbits were compared and it is noted that the GPS orbit experiences only 220 cycles a year and must be treated as a geosynchronous rather than a low Earth orbit. Cell degradation is considered to be the result of both trickle-charge degradation and degradation due to cycling. Time-to-failure values are presented for selected temperatures and depth of discharges.
Sense, K. A.↗
Analysis of nickel-cadmium battery reliability data containing zero failures
An analysis of reliability data on Nickel-Cadmium (NiCd) batteries (for use in spacecraft) is presented. The data were collected by Gates Aerospace and represent a substantial reliability database. The data were taken from the performance of 183 satellites which were in operation from between .1 and 22 years, for a total of 278 million cell-hours of operation.
Denson, William K.↗
Failure analysis of the lithium battery: A study of the header deposit on the cell top and diffusion within the electrode glass seal using nuclear microanalysis and FFTIR spectroscopy
The Solid Rocket Booster Range Safety System (SRBRSS) uses a lithium/poly-carbon monofluoride primary battery as a source of electrical power. After cell fabrication and activation, some battery cells have shown self discharge. One possible source of this cell discharge has been suggested to be the formation and growth of a conducting crystallized chemical compound across the glass bead insulator, electrically shorting the glass bead to the casing. This laboratory has begun an analysis of this compound, the glass seal holding the cathode into place, and the cell electrolyte, using Fast Fourier Transform Infrared (FFTIR) Analysis, Rutherford Backscattering Spectroscopy (RBS), and Nuclear Reaction Microanalysis. Preliminary measurements have confirmed the existence of lithium, nitrogen, fluorine, and oxygen on a reddish-brown deposit covering parts of the glass seal holding the positive electrode in place. Cells using Li metal electrodes, have many advantages over conventional primary batteries. One principal disadvantage of using Li batteries on a commercial basis would be the environmental impact of the fluorocarbon material. Another would be the relatively high expense of (CF)n.
Hassan, Razi A.↗
Nickel-cadmium battery test project - Relationship between operation, life, and failure mechanism. Volume 3 - Analysis of the cells and their components
Nickel cadmium batteries operated in related cycling schemes with resulting dry separators
Halpert, G.↗
In Flight Performance of a Six Ampere-hour Nickel-cadmium Battery in Low Earth Orbit
Flight data for 17,000 orbital cycles are reviewed and summarized. The nickel cadmium battery system operated without failure or abnormality. Battery trend analysis used in determining the feasibility of extending mission life is discussed. The life test data for 20% depth of discharge indicates design life requirements would be reached even at a deeper depth of discharge.
Mcdermott, J. K.↗
Cycles till failure of silver-zinc cells with competing failure modes - Preliminary data analysis
The data analysis of cycles to failure of silver-zinc electrochemical cells with competing failure modes is presented. The test ran 129 cells through charge-discharge cycles until failure; preliminary data analysis consisted of response surface estimate of life. Batteries fail through low voltage condition and an internal shorting condition; a competing failure modes analysis was made using maximum likelihood estimation for the extreme value life distribution. Extensive residual plotting and probability plotting were used to verify data quality and selection of model.
Sidik, S. M.↗
Thermal Analysis on Large Format Lithium-Ion Batteries in Thermal Runaway
Lithium-ion (Li-ion) batteries can deliver electrical power across a large range of applications, and large format versions of these batteries are common in aerospace for their low mass and energy dense properties. Li-ion cells usage has increased as they are more power dense than fuel cells and have overall higher performance over lead-acid/NiCd batteries. However, Li-ion cells can experience Thermal Runaway (TR) via electro-chemical, mechanical, or thermal abuse. TR is a phenomenon where the stored energy in a cell is rapidly released along with vented gases and other effluents. A cell is generally determined to be in TR if its internal heat generation has surpassed its ability to dissipate that heat. If a Li-ion cell enters TR, propagation within the battery may occur. Propagation is the chain reaction that can occur to nearby cells due to a cell that has entered TR initially. Understanding a battery’s susceptiveness to propagation is necessary to evaluate risks associated with TR phenomenon. To determine if a battery is designed in a sufficient manner to prevent battery propagation if single cell TR occurs, testing and thermal analysis of the battery must be conducted. The presentation for TFAWS 2026 will cover considerations for battery TR thermal analysis, such as: testing methods, influences on the cells, failure mechanisms, and TR parameters. This presentation will include a walkthrough of an example battery TR thermal analysis, and the results thereof.
Lithium Ion Batteries↗
Cycles till failure of silver-zinc cells with completing failures modes: Preliminary data analysis
One hundred and twenty nine cells were run through charge-discharge cycles until failure. The experiment design was a variant of a central composite factorial in five factors. Preliminary data analysis consisted of response surface estimation of life. Batteries fail under two basic modes; a low voltage condition and an internal shorting condition. A competing failure modes analysis using maximum likelihood estimation for the extreme value life distribution was performed. Extensive diagnostics such as residual plotting and probability plotting were employed to verify data quality and choice of model.
Sidik, S. M.↗
Analysis and evaluation of spacecraft battery life test data /phase 2/ Summary report
Nickel-cadmium spacecraft battery cell life tests with reliability analysis of acceptance data and failure analysis
Kent, J. R.↗
Evaluation program for secondary spacecraft cells
A life cycle test of secondary electric batteries for spacecraft applications was conducted. A sample number of nickel cadmium batteries were subjected to general performance tests to determine the limit of their actual capabilities. Weaknesses discovered in cell design are reported and aid in research and development efforts toward improving the reliability of spacecraft batteries. A statistical analysis of the life cycle prediction and cause of failure versus test conditions is provided.
Christy, D. E.↗
NiCd cell reliability in the mission environment
This paper summarizes an effort by Gates Aerospace Batteries (GAB) and the Reliability Analysis Center (RAC) to analyze survivability data for both General Electric and GAB NiCd cells utilized in various spacecraft. For simplicity sake, all mission environments are described as either low Earth orbital (LEO) or geosynchronous Earth orbit (GEO). 'Extreme value statistical methods' are applied to this database because of the longevity of the numerous missions while encountering relatively few failures. Every attempt was made to include all known instances of cell-induced-failures of the battery and to exclude battery-induced-failures of the cell. While this distinction may be somewhat limited due to availability of in-flight data, we have accepted the learned opinion of the specific customer contacts to ensure integrity of the common databases. This paper advances the preliminary analysis reported upon at the 1991 NASA Battery Workshop. That prior analysis was concerned with an estimated 278 million cell-hours of operation encompassing 183 satellites. The paper also cited 'no reported failures to date.' This analysis reports on 428 million cell hours of operation emcompassing 212 satellites. This analysis also reports on seven 'cell-induced-failures.'
Denson, William K.↗
Application of cryptanalytic techniques to the analysis of NiCd space batteries
By using Bi-gram and Tri-gram tables, a pattern can be formed to determine failure modes and mechanisms. Computer programs provide accurate predictions of cell failure several thousand cycles before actual failure.
Epstein, S.↗
Nickel-Hydrogen Cell Testing Experience, NASA/Goddard Space Flight Center
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.
Rao, Gopalakrishna M.↗
NiCd space battery test data analysis project, phase 2 Quarterly report, 1 Jan. - 30 Apr. 1967
Cryptanalytic technique for evaluating nickel- cadmium battery cell failure characteristic data
FAILURE↗
Can Cell to Cell Thermal Runaway Propagation be Prevented in a Li-ion Battery Module?
Increasing cell spacing decreased adjacent cell damage center dotElectrically connected adjacent cells drained more than physically adjacent cells center dotRadiant barrier prevents propagation when fully installed between BP cells center dotBP cells vent rapidly and expel contents at 100% SOC -Slower vent with flame/smoke at 50% -Thermal runaway event typically occurs at 160 degC center dotLG cells vent but do not expel contents -Thermal runaway event typically occurs at 200 degC center dotSKC LFP modules did not propagate; fuses on negative terminal of cell may provide a benefit in reducing cell to cell damage propagation. New requirement in NASA-Battery Safety Requirements document: JSC 20793 Rev C 5.1.5.1 Requirements - Thermal Runaway Propagation a. For battery designs greater than a 80-Wh energy employing high specific energy cells (greater than 80 watt-hours/kg, for example, lithium-ion chemistries) with catastrophic failure modes, the battery shall be evaluated to ascertain the severity of a worst-case single-cell thermal runaway event and the propensity of the design to demonstrate cell-to-cell propagation in the intended application and environment. NASA has traditionally addressed the threat of thermal runaway incidents in its battery deployments through comprehensive prevention protocols. This prevention-centered approach has included extensive screening for manufacturing defects, as well as robust battery management controls that prevent abuse-induced runaway even in the face of multiple system failures. This focused strategy has made the likelihood of occurrence of such an event highly improbable. b. The evaluation shall include all necessary analysis and test to quantify the severity (consequence) of the event in the intended application and environment as well as to identify design modifications to the battery or the system that could appreciably reduce that severity. In addition to prevention protocols, programs developing battery designs with catastrophic failure modes should take the steps necessary to assess the severity of a possible thermal runaway event. Programs should assess whether there are reasonable design changes that could appreciably affect the severity of the outcome. Evaluation should include environmental effects to surrounding hardware (i.e., temperature, pressure, shock), contamination effects due to any expelled contaminates, and venting propulsive effects when venting overboard.
Jeevarajan, Judith↗