Evaluation tests of 10 nickel cadmium cells are described. Although pressures were greater than what normally was exhibited by General Electric cells in the past, it is recommended that these cells be placed on life test simulating the predicted Dynamic Explorer flight profiles

Harkness, J. D.

English

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INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
6.0 AMPERE-FLOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
DYNAMIC EXPLORER SATELLITE PROGRAM
prepared for
GODDARD SPACE FLIGHT CENTER
Contract S-57075AG
A
WEAPONS QUALITY ENGINEERING CENT1^ 
NWSC Crane, Indiana
DEPARTMENT OF THE NAVY
NAVAL WEAPONS SUPPORT CENTER
WEAPONS QUALITY ENGINEERING CENTER
CRANE, INDIANA 47522
EVALUATION PROGRAM
FOR
SECONDARY SPACECRAFT CELLS
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
6.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
DYNAMIC EXPLORER SATELLITE PROGRAM
WQEC/C 80-128
	 0 9 APR 1980
1
PREPARED BY
^j) ^	 ,-
J. D. HARKNESS
PREPARED UNDER THE DIRECTION OF
D. E. MAINS, Manager
Satellite & Shipboard Battery Branch
A PROVED BY
MORRIS L. ROB TSON
Manager, Electrochemical Power
Sources Division
Enclosure (1)
WQEC/C 80-128
REPORT BRIEF
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
6.0 AMPERE-HOUR NICKEL- CADMIUM SPACECRAFT CELLS
FOR THE
DYNAMIC EXPLORER SATELLITE PROGRAM
Ref; (a) NASA Purchase Order S-57075AG
(b) Initail Evaluation Test Procedure for Nickel-Cadmium Sealed
Space Cells: NAD 3053-TP324; 10 Apr 1973
I. TEST ASSIGNMENT BRIEF
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 ten cells were provided by the National Aeronautics and
Space Administration, Goddard Space Flight Center (GFSC), to NAVWPNSUPPCEN
Crane for evaluation in the two predicted Dynamic Explorer (DE) Satellite
Flight profiles. The cells were purchased by GSFC, under NASA Purchase
Order Number S-63727B from the General Electric Company. The cells were
manufactured at the same time and from the same materials as the first
lot of cells manufactured for RCA for the DE Program. They were manu-
factured in accordance with "Product Specification Hermetically Sealed
Nickel -Cadmium Battery Cell", RCA PS No. 2295143, Revision A, The General
Electric catalog number is 42BO06AB60. (See Appendix I for deV iled cell
description) The cells were identified by the manufacturer's serial
numbers and RCA's part number 2295143-1. These cells are rated at
6.0 ampere-hours, contain dual, nickel-braze ceramic seals and four cells
have pressure transducers. Testing was funded in accordance with reference (a).
C. Test limits specify those values at which a cell is to be
terminated 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 require-
ment does not constitute a limit for discontinuance from test.
II. SUMMARY OF RESULTS
A. Measurement-, of the cell containers, following test, indicated an
increase of .002 inches in the plate stack thickness of one cell (S/N 160).
B. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
9WQEC/C 80-128
Ctw	 e Volts PSIA ah Out
c/20 for 48 hrs @ 25° C 1.430 32 7.0
c/10 for 24 hrs @ 25° C 1.440 69 6.8
c/10 for 24 hrs @ 20° C 1,448 80 6.4
c/10 for 24 hrs @ 20° C* 1.446 84 5.8
c/40 for 24 hrs @ 20° C** 1.373 3 2.6
c/20 for 60 hrs @ 0° C 1.474 91 6.2
c/10 for 24 hrs @ 35° C 1.407 27 7.2
*Charge retention test.
**Charge efficiency test, 3.0 ah input
C. High pressures were exhibited by the four pressure transducer cells
during their c/10, 24 hour charges at 25°C and 20°C. Three cells
exceeded the requirement of 65 psis at 25°C and all 4 cells exceeded this
requirement during both charges at 2.0°C.
D. During the 0°C overcharge test, two cells were discontinued
from charge when their pressure reached the test limit of 100 psia and
the other two pressure transducer cells exceeded the pressure require-
ment of 65 psia. Peak voltages, for all cells, during charge ranged
from 1.499 to 1.511 volts.
E. The cells delivered 86% of the input capacity during the 20°C
charge efficiency test.
F. The average cell voltage at the end of 1 week open-circuit-
stand, during the charge retention test, was 1,318 volts.
G. The 24-hour average cell voltage following the 16-hour shunt
period, during the internal short test, was 1.248 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 8.6 ah and 1.512 volts respectively. The cells
did not exhibit a pressure decay during the last 30 minutes of the 1-hour
open-circuit-stand period. Average capacity out was 7.2 ampere-hours.
III. RECOMMENDATIONS
A. Although pressures were greater than what normally has been
exhibited by General Electric cells in the past, it is recommended that
these cells be placed on life test simulating the predicted DE flight
profiles.
B. In March 1980, two packs (22D and 22E) began life test. Pack
22D simulates the DE-A flight profile at 25°C and pack 22E simulates
DE-B at 10°C.
ii
WQEC/C 80-128
RESULTS OF
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
6.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
DYNAMIC EXPLORER SATELLITE PROGRAM
I.	 TEST CONDITIONS AND PROCEDURE
A. All evaluation tests were performed at room ambient (RA)
pressure and temperature (25 0 + 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 0 C; with internal
resistance measurements during second charge/discharge.
3. Charge retention test, 20 0 G.
4. Internal short test.
5. Charge efficiency test, 20° C.
6. Overcharge tes •cs, 0° and 35" C.
7. Pressure versus capacity test.
8. Phenolphthalein leak test.
(See ApperO
 ix II for summary of test procedure).
II. CELL IDENTIFICATION AND DESCRIPTION
A. The cells were identified by the manufacturer's serial numbers
(02950333-113 to 161 non-inclusive-LO1), and RCA's part number 2295143-1.
The cells were placed in a temporary pack configuration for initial testing
^
Pack 5590. Each cell was individually restrained and four cells
S/N's 113, 115, 121 and 151) had pressure transducers.
B. The 6.0 ampere-hour cell is rectangular with an average weight
and physical dimensions as follows:
Thickness (in)
Pre-Test	 Post-Test
Weig ht 	 Height (in)
	
Edge	 Center
	
Center	 Width (in)
282.2
	 3.175	 .839	 .839	 .839	 2.146
*Does not include pressure transducer cells (4).
i
WQEC/C 80-128
C. The cell containers and covers are made of stainless steel.
The positive and negative terminals are insulated from the cell cover
by dual, nickel-braze, ceramic-to-metal seals and protrude through the
cover as solder-type terminals.
III. RESULTS - The following was condensed from Tables I through VI.
A. Measurement of the cell containers, following test, indicated an
increase of .002 inches in the plate stack thickness of one cell (S/N 160).
B. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
Ch- arm Volts ASIA ah Out,
c/20 for 48 hrs @ 250 C 1.430 32 7.0
c/10 for 24 hrs @ 25 0 C 1.440 69 6.8
c/10 for 24 hrs @ 200 C 1.448 80 6.4
c/10 for 24 hrs @ 200 C* 1.446 84 5.8
c/40 for 20 hrs @ 200 C** 1.373 3 2.6
c/20 for 60 hrs @ 00 C 1.474 91 6,2
c/10 for 24 hrs @ 35 0 C 1.4.07 27 7.2
*Charge retention test
**Charge efficiency test, 3.0 ah input
C. The average internal resistance at the end-of-charge (Cycle 1)
was 3.6 mill-iohms and at the end-of-discharge (Cycle 2) it was 3.2 milliohms.
D. Three of the 4 cells, having pressure transducers, exceeded the
pressure requirement of 65 psia during the c/10 charge for 24 hours at
25 0
 C. All four cells exceeded this requirement during their c/10 charges,
for 24 hours at 200 C.
E. Two pressure transducer cells were discontinued from charge
during the 0 0 C overcharge test when their pressure reached the test limit
of 100 psia. The other 2 pressure transducer cells exceeded the require-
ment of 65 psia. Peak voltages, for all the cells, during charge ranged
from 1.499 (S/N 155) to 1.511 volts (S/N 113).
F. The cells delivered 86% of the input capacity during the 20 0 C
charge efficiency test.
G. The average cell voltage at the end of 1 week open-circuit-
stand, during the charge retention test, was 1.318 volts.
M. The 24-hour average cell voltage following 'the 16-hour shunt
period, during the internal short test, was 1.248 volts.
I. The cells, with pressure transducers, reached a pressure of 20
psia before reaching the voltage limit at 1.550 volts during the pressure
versus capacity test. The average ampere-hours in and voltage at this
pressure were 8.6 ah and 1.512 volts respectively. The cells did not
exhibit a pressure decay during the last 30 minutes of the 1-hour open-
circuit-stand period. Average capacity out was 7.2 ampere-hours.
2
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WQEC/C 80-I28
APPE14DIX I
CELL DESCRIPTION
WQEC/C 80-128
APPENDIX I
CELL DESCRIPTION
Cell History and Description
Twelve 6AH cells were put° phased by GSFC under Purchase Order Number
S-637276 from the General Electric Company. Four cells were fitted with
SWAG-LOC caps. All cells were manufactured at the same time and from
the same materials as the first lot of cells manufactured for RCA for
the DE program. These cells were manufactured in accordance with
"Product Specification Hermitically Sealed Nickel-Cadmium Battery Cell,"
RCA PS #2295143, Revision A. The General Electric catalog number is
42BO06AB60. Pertinent cell design features and manufacturing data are
as follows:
Number of Plates: 10 positive, 11 negative
Two GE nickel-braze, ceramic-to-metal seal
Plate Dimensions: positive: 2.170" x 1.968" x .027" nominal
negative: 2.170 1" x 1.978 1" x .031 11 nominal
Negative plate is Teflon treated
Plate Loading: positive: 12.19 to 12.89 g/dm2
negative: 15.46 to 16.02 g/dm2
KOH Quantity: 28cc of 31% KOH
Precharge: 2.67 AH
Separator: Pellon 2505
Cell Case (welded) Dimensions: 3.180" x 2.134" x .830"
Case Wall Thickness: .019" + .003
Overall Cell Height Including Terminals: 3.629"
10
WQEC/C 80-128
APPENDIX II
TEST PROCEDURE
11
WQEC/C 80-128
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 initially checked with a one-half of one per-
cent phenolphthalein solution applied 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 rechecked 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 charge c, for the capacity tests are as follows:
a. c/20, 48 hours, room ambien-C (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.
12
EWQEC/C 80-128
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 requ"rument that the open-circuit
voltage of each cell, following this j)' °4!, is within + a millivolts
of the average cell voltage, The cells: ^lre then discharged and 80
percent capacity out of that obtained °i 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 (OCV) 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 :harged 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 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.
13
WQEC/C 80-128
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 cell, are then discharged with a requirement that
capacity out equals 55 pem ent 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 OCV for 1 hour with
30-minute recordings and then are discharged, shorted out and leak tested.
14


Evaluation Program for Secondary Spacecraft Cells: Initial Evaluation Tests of General Electric Company 6.0 Ampere Hour Nickel Cadmium Spacecraft Cells for the Dynamic Explorer Satellite Program

Evaluation Program for Secondary Spacecraft Cells: Initial Evaluation Tests of General Electric Company 6.0 Ampere Hour Nickel Cadmium Spacecraft Cells for the Dynamic Explorer Satellite Program

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