Five cells provided by NASA's Goddard Space Flight Center were evaluated at room temperature and pressure (25 C plus or minus 2 C) with discharges at the 2 hour rate. Measurements of the cell containers following test, indicated an average increase of .006 inches at the plate thickness. Average end of charge voltages and pressures, and capacity output in ampere hours were determined. Three cells exceeded the voltage requirements of 1.52 volts during both c/10 charges at 20 C. All cells exceeded the voltage requirement of 1.52 volts during the 0 C overcharge test, although their end charges were below 1.50 volts. The pressure requirement of 65 psia was exceeded by both pressure transducer cells during c/10 charges at 25 C and 20 C and also during the 0 C overcharge test. The cells with pressure transducers reached a pressure of 20 psia before reaching the voltage limit of 1.550 volts during the pressure versus capacity test, and exhibited a pressure decay of 2 psia during the last 30 minutes of the 1 hour open circuit stand. Average capacity was 51.3 ampere hours

Harkness, J. D.

English

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https://ntrs.nasa.gov/search.jsp?R=19800023381 2020-03-21T15:51:37+00:00Z
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WEAPONS QUALITY ENGINEERING CENTER
NWSC Crane;, Indiana
INITIAL EVALUATION TESTS
of
GENERAL ELECTRIC COMPANY
40,0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
for the
TRACKING DATA RELAY SATELLITE SYSTEM
(r4A,,;)I-Cis- 1u 101b)	 iSYALUA'I'.FO ii k% Itl) y ^ Ail ) (JLt
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('k..LL:i POli '1'Ii r: (Na ys.i, '4oapoi1.3 au j, l i k)L'1'. (;cellt.'.r,
prepared for
GODDARD SPACE FLIGHT CENTER
Contract S-53741 G
~Y
V1 J
..,.s
t -.,S.--Ki ^' awtl	 1^
DEPARTMENT OF THE NAVY
NAVAL WEAPONS SUPPORT CENTER
WEAPONS QUALITY ENGINEERING CENER
CRANE, INDIANA 47522
EVALUATION PROGRAM
FOR
SECONDARY SPACECRAFT CELLS
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
40.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TRACKING DATA RELAY SATELLITE SYSTEM
WQEC/C 78-416	 21 December 1978
PREPARED BY
P
-X-4,04.-
JD. HARKNESS
PREPARED UNDER THE DIRECTION OF	 APPROVED BY
D. E. MAINS, Manager
	
. tG MILEY
Satellite & Shipboard Battery Branch
Enclosure (1)
WQEC/C 78-416
REPORT BRIEF
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
40.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TDRSS SATELLITE
Ref: (a) NASA Purchase Order 5-53742AG, Modification Number 17
(b) Initial Evaluation Test Procedure for Nickel-Cadmium Sealed Space
Cells: NAD 3053-TP324 10 Apr 1973
I. TEST ASSIGNMENT BK;rEF
A. The purpose of this evaluation test program is to insure that
all cells put into the life cycle program are of high quality by the
screening of cells found to have electrolyte leakage, internal shorts,
low capacity, or inability of any cell to recover its open-circuit
voltage above 1.150 volts during the internal short test.
B. The five cells were provided by the National Aeronautics and
Space Administration, Goddard Space Flight Center (GSFC), to NAVWPNSUPPCEN
Crane for evaluation on a synchronous orbit life test. The cells were
manufactured for TRW at the same time and from the same materials
as Engineering Cells (Lot 1) manufactured for the Tracking Data
Relay Satellite System (TDRSS) program. They were manufactured in
accordance with TRW Part/Material Control Document "Battery Cells 40 ah",
Number 8E0ll and General Electric MCD 232A2222AA-80.(See Appendix I for
detailed cell description). The cells were identified by the
manufacturer's catalog numbers 42B040AB03-Gl and G2. These cells are
rated at 40.0 ampere-hours, contain double ceramic seals, and the G2 type
cells (2) have pressure transducers. Testing was funded in accordance
with reference (a).
C. Test limits specify those values at which a cell -s to be ter-
minated from charge or discharge. Requirements are referenced to as
normally expected values based on past performance of aerospace nickel-
cadmium cells with demonstrated life characteristics. A requirement
does not constitute a limit for discontinuance from test.
II. SUMMARY OF RESULTS
A. Measurements of the cell containers, following test, indicated
an average increase of .006 inches in the plate stack thickness.
B. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
k1.
WQEC/C 78-416
Charge, Volts PSIA ah Out
c/20 for 48 hrs @ 25° C 1.438 39 51.2
c/10 for 24 hrs @ 250 C 1.447 80 48.5
c/10 for 24 hrs @ 20° C 1.467 80 50.1
c/10 for 24 hrs @ 20° C* 1.467 85 44.5
c/40 for 20 hrs @ 20° C** 1.369 7 14.5
c/20 foor 60 hrs @ 0° C 1.493 68 47.1
c/10 for 24 hrs @ 35° C 1.401 58 49.4
*Charge retention test
**Charge efficiency test, 20.0 ah input
C. Three cells exceeded the voltage requirement of 1.48 volts during
both c/10 charges at 20° C. Their peak voltages were 1.480 to 1.482
volts.
D. All cells exceeded the voltage requirement of 1.52 volts during
the 0° C overcharge test although their end-of-charge voltages were below
1.50 volts. Peak voltages were 1.523 to 1.52.7 volts.
E. The pressure requirement of 65 psia was exceeded by both pressure
transducer cells during the c/10 charges at 25° C and 20° C and also during
the 0° C overcharge test.
F. The average cell voltage at the end of one week open-circuit-
stand, during the charge retention test, was 1.312 volts.
G. The 24-hour average cell voltage following the 16-hour short period,
during the internal short test, was 1.236 volts.
H. The cells, with pressure transducers, reached a pressure of 20
psia before reaching the voltage limit of 1.550 volts during the pressure
versus capacity test. The average ampere-hours in and voltage at this
pressure were 61.5 ah and 1.537 volts respectively. The cells exhibited a
pressure decay of 2 psia during the last 30 minutes of the 1-hour open-
circuit stand. Average capacity out was 51.3 ampere-hours.
III. RECOMMENDATIONS
A. Manufacturing processes and controls should be such to prevent
swelling of the plate stack, thereby preventing cell case distortion.
B. It was recommended that these cells be placed on a synchronous
orbit life test.
C. In December 1978, one pack (232A) began synchrounous orbit life
test with its first eclipse season.
ii
-4
WQEC/C 78-416
RESULTS OF
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
40.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TDRSS SATELLITE
I. TEST CONDITIONS AND PROCEDURE
A. All evaluation tests were performed at Room Ambient (RA) pressure
and temperature (25° C + 2° C), with discharges at the 2-hour rate, and in
accordance with reference (b), unless otherwise specified, and consisted
of the following:
1. Phenolphthalein leak tests (2).
2. Three capacity tests, third at 20 6 C, with internal resistance
measurements during second charge/discharge.
3. Charge retention test, 20° C.
4. Internal short test.
5. Charge efficiency test, 20° C:
6. Overcharge tests, 00 and 35° C.
7. Pressure versus capacity test.
8. Phenolpthalein leak test.
(See Appendix II for summary of test procedure.)
II. CELL IDENTIF ATION AND DESCRIPTION
A. The cells were identified by the manufacturers serial numbers,
catalog numbers and TRW's Part/Material Control Document Number
8EO11-001Z-001 Revision B. The manufacturer's numbers are as follows:
Catalog	 Serial
	42BO40AB03-G1
	 02660303-001 to 003-01
	
42BO40AB03-G2	 02660303-004 and 005-01
The cells were placed in a temporary pack configuration for initial test-
ing (Pack 547X). Each cell was individually restrained and two cells
(S/Ns 004 and 005) had pressure transducers.
B. The 40.0 ampere-hour cell is rectangular with an average weight
and physical dimensions as follows:
WQEC/ C 78-416
Thickness (in.)	 Width (in.)**
Pre-Test Post-Test
Weight (g)* Height (in.) id„ge	 Center	 Center	 ^dge	 Center
1457.0	 6.591	 1.303 1.304	 1.310	 3.406 3.445
* - Does not include pressure transducer cells (2)
** - Cells received having convex sides.
C. The cell containers and covers are made of stainless steel. The
positive and negative terminals are insulated from the cell cover by
ceramic seals and protrude through the cover as solder-type terminals.
III. RESULTS - The following was condensed from Tables I through V1.
A. Measurements of the cell containers, following test, indicated
an average increase of .006 inches in the plate stack thickness.
Q. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
Charge
	
Volts	 PSIA	 ah Out
c/20 for 48 hrs @ 25° C 1.438 39 51.2
c/10 for 24 hrs @ 25° C 1.447 80 48.5
c/10 for 24 hrs @ 20° C 1.467 80 50.1
c/10 for 24 hrs @ 20° C* 1.467 85 44.5
c/40 for 20 hrs @ 20° C** 1.369 7 14.5
c/20 for 60 hrs @ 0° C 1.493 68 47.1
c/10 for 24 hrs @ 35° C 1.401 58 49.4
*Charge retention test
**Charge efficiency test, 20.0 ah input
C. The average internal resistance at the end-of-charge (Cycle 1)
was 3.0 milliohms and during discharge (Cycle 2) it was 2.9 milliohms.
D. Three cells exceeded the voltage requirement of 1.48 volts during
both c/10 charges at 20°C. Their peak voltages were 1.480 to 1.482
volts.
E. All cells exceeded the voltage requirement of 1.52 volts during
the 0° C overcharge test although their end-of-charge voltages were below
1.50 volts. Peak voltages were 1.523 to 1.527 volts.
F. The pressure requirement of 65 psia was exceeded by both pressure
transducer cells during the c/10 charges at 25° C and 20° C and also
during the 0° C overcharge test.
2
L
WQEC/C 78-416
G. The average cell voltage at the end of 1 week open-circuit, during
the charge retention test, was 1.312 volts.
H. The 24-hour average cell voltage following the 16-hour short
period, during the internal short test, was 1.236 volts.
I. The cells, with pressure transducers, reached a pressure of 20
psia before reaching the voltage limit of 1.550 volts during the pressure
versus capacity test. The average ampere-hours in and voltage at this
pressure were 61.5 ah and 1.53" volts respectively. The cells exhibited a
pressure decay of 2 psia during the last 30 minutes of the 1-hour open-
.ircuit stand. Average capacity out was 51.3 ampere-hours.
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TABLE III	 WQEC/C 78-416
INTERNAL. RESISTANCE AND SHORT TEST DATA
9FAD-NADC (SP 1-1/73)
SERIAL
NUMBER
INTERNAL RESISTANCE (MILLIOHMS) INTERNAL SHORT TES.
AFTER 16 AFTER MOM;
HR SHORT	 OCV STANDEND-OF-CHARGE
ONE HOUR AFTER
START-OF-DISCHARGE
TWO HOURS AFTER
START-OF-DISCHARGE
CELT. CELL PRESS
001. 2,9 2,^ z,p .t69 11237
003 3.0 3,0 3,a , tG7 1,735
005 3.0 21? ^ ,ia qS" 1.2 ., E - 2
TABLE IV	 WQEC/C 78-416
CHARGE RETENTION TEST DATA
END-OF-CHARGE 24 HR. OCV
	
I WE"A t OCV END-OF-DISCHARGE
..^...^SERIAL
NUMBER
VOLTS)
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WQEC/C 78-416
APPENDIX I
10
L
WQEC/C 78416
APPENDIX I
CELL DESCRIPTION
Cell History and Description
Five, 40 ah cells were purchased by the GSFC, under Purchase Order Number
S-49693D, from the General Electric Company. These cells were manufactured
at the same time and from the same materials as Engineering Cells (Lot 1)
manufactured for TRW for the TDRSS Program. These cells were manufactured
in accordance with TRW Part/Material Control Document "Battery Cells 40 ah,"
Number 8E011 and General Electric MCD 232A2222AA-80. The General Electric
Catalog Number is 42BO40ABO3. Some of the pertinent cell design features
and manufacturing data are as follows:
Number of plates: 16 Positive
17 Negative
Plate Dimensions: Positive 5.40" x 3.20" x .027"
Negative 5.40 1' x 3.20" x .0315"
Negative Plate is Silver Treated
Loading (Lot 1): ^ositive 
16:17 
gm/^m2
egative	 m/cm
KOH Quantity (Lot 1): 120 cc of 31% KOH
Precharge (Lot 1): 13.4 ah
Separator: Pellon 2505
Interelectrode spacing: .0085" nominal
Flooded cell tests (Lot 1): Average Positive 55.49 ah
Average Negative 92.92 ah
Cell case dimensions: 6.24" x 3.413" x 1.308"
Case thickness: .019"
Height to top of terminals: 6.669" maximum
WQEC/C 78-416
APPENDIX II
12
L
-.4
WQEC/C 78-416
APPENDIX II
I. TEST PROCEDURE
A. Phenolphthalein Leak Tests:
1. This test is a determination of the condition of the welds
and ceramic seals on receipt of the cells and following the last discharge
of the cells (Cycle 8).
2. The cells were initi; , ll, f.hecked with a one-half of one per-
cent phenolphthalein solution app'; .sc:i with a cotton swab and then placed
in a vacuum chamber and exposed to a vacuum of 40 microns of mercury or
less for 24 hours. Upon removal they were rechedked for leaks and then
received a final check following test completion. The requirement is no
red or pink discoloration which indicates a leak.
B. Capacity Tests:
1. The capacity test is a determination of the cells' capacity
at the c/2 discharge rate to 0.75 volt per cell, where c is the manufac-
turer's rated capacity. This type discharge follows all charges of this
evaluation test.
2. The charges for the capacity tests are as follows:
a. c/20, 48 hours, room ambient (RA), cycle 0, with a test
limit of 1.52 volts or pressure of 100 psia;
b. c/10, 24 hours, RA, cycle 1, with a test limit of 1.52
volts or 100 psia pressure and a requirement of maximum voltage (1.48)
or pressure (65 psia);
c. c/10, 24 hours, 20° C, cycle 2, with the same limits and
requirements as the charge of cycle 1.
C. Internal Resistance:
1. Measurements are taken across the cell terminals 0.5 hour
before the end-of-charge (EOC) on cycle 1; and 1 and 2 hours after the
start-of-discharge of cycle 2. These measurements were made with a
Hewlett-Packard milliohmmeter (Model 4328A).
D. Special Charge Retention Test, 20° C:
1. This test is to establish the capacity retention of each cell
following a 7-day open-circuit stand in a charge mode.
13
61--
14QEC/C 78-416
2. The cells are charged at c/10 for 24 hours with the same
limits and requirements as the charge of cycle 1. They then stand on
open-circuit for 7 days, with the requirement that the open-circuit
voltage of each cell, following this period, is within + 5 millivolts
of the average cell voltage. The cells are then discharged and AO
percent capacity out of that obtained in cycle 3 is required.
E. Internal Short Test:
1. This test is a means of detecting slight shorting conditions
which may exist because of imperfections in the insulating materials,
or damage to element in handling or assembly.
2. Following completion of the charge retention test capacity
discharge, the cells are shunted with a 0.5-ohm, 3-watt resistor for
16 hours. At the end of 16 hours the resistors are removed and the
cells stand on open-circuit voltage tiOCV) for 24 hours. A minimum
voltage of 1.15 is required at the end of 24 hours.
F. Charge Efficiency Test, 20° C:
1. This test is a measurement of the cells' charge efficiency
when charged at a low current rate.
2. The cells are charged at c/40 for 20 hours with a test limit
of 1.52 volts or 100 psia pressure. They are then discharged and the
requirement is that the minimum capacity out equals 55 percent of capacity
in during the preceding charge.
G. Overcharge Test 1, 0° C:
1. The purpose of this test is to determine the degree to which
the cells will maintain a balanced voltage, and to determine the cells'
capability to be overcharged without overcharging the negative electrode.
2. The cells are charged at c/20 for 60 hours. The test limits
are cell voltages of 1.56 or greater for a continuous time period of
2 hours or pressures of 100 psia. The requirement is a voltage of 1.520
or a pressure of 65 psia. The cells are then discharged and 85 percent
capacity out of that obtained in cycle 3 is required.
H. Overcharge Test 2, 35° C:
1. This test is a measurement of the cells' capacity at a higher
temperature when compared to its capacity at 20° C. This test also deter-
mines the cells' capability of reaching a point of pressure equilibrium;
oxygen recombination at the negative plate at the same rate it is being
generated at the positive plate.
..0
14
.J
WQEC/C 78-416
2. The cells are charged at c/10 for 24 hours with a test limit
of 1.52 volts or 100 psia pressure and a requirement of 1.45 volts or
65 psia pressure. The cells are then discharged with a requirement that
capacity out equals 55 percent capacity out as obtained in cycle 3.
I. Pressure Versus Capacity Test:
1. The purpose of this test is to determine the capacity to a
pressure and the pressure decay during charge and open-circuit stand
respectively.
2. Each cell is charged at c/2 to either a pressure of 20 psia
or a voltage of 1.550. Recordings are taken on each cell when it reaches
5, 10, 15 and 20 psia pressure. The cells then stand 0CV for 1 hour with
30-minute recordings and then are discharged, shorted out and leak tested.
15
L


Evaluation program for secondary spacecraft cells:  Initial evaluation tests of General Electric Company 40.0 ampere-hour nickel-cadmium spacecraft cells for the tracking data relay satellite system

Evaluation program for secondary spacecraft cells: Initial evaluation tests of General Electric Company 40.0 ampere-hour nickel-cadmium spacecraft cells for the tracking data relay satellite system

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