Average end of charge voltages and pressures, and capacity output in ampere hours are presented. Test limits specify those values at which a cell is to be terminated from charge or discharge. Requirements are based on past cell performance data. The requirement does not constitute a limit for discontinuance from testing. The nickel cadmium batteries were screened for internal shorts, low capacity, electrolyte leakage, or inability of any cell to recover its open circuit voltage above 1.150 volts during the internal short test

Hall, S. W.

English

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https://ntrs.nasa.gov/search.jsp?R=19810009008 2020-03-21T15:02:22+00:00Z
RECFIVFO
NAS A STI FACILITY
MISS UEPT. ^.
EVALUATION PROGRAM
FOR
S:CONDARY SPACECRAFT CELLS
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
AC►.O AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TRACKING DATA RELAY SATELLITE SYSTEM
prepared for
GODDARD SPACE FLIGHT CENTER
Contract S-49693B
(NAB" -CR- 1o3924)	 LVALUAriUN PRUGRAM kUw	 Nd1 - 1753)
SLC'uNdAtiY SeACLCh,&FT C,ELLS: iNi'TIAL 	 A03 fNtF AO
EVALUAI IUN TjLilS JF GENERAL ^,LLClhlC CJCIYANY
4U.0 AtIPLLE HOUR h1CKEL CAOMiUd SPACECRAr'r
	 U.,cia_.
Ck.LLS k.)R THE (NdV<il Wedt)U:[^i _)Ue j.ULt :rnt. ^r, L;J/44	 u}577
WEAPONS QUALITY ENGINEERING CENTER
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
40.E AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TRACKING DATA RELAY SATELLITE SYSTEM
	
4
WQEC/C 80-194
	
2 3 JUN wo
PREPARED BY
S. W. HALL
PREPARED UNDER THE DIRECTION OF
D. E. MAINS, Manager
Satellite & Shipboard Battery Branch
AP ROVED BY	 --^ J
I^IS L . ROdERT, SON
WQEC/C 80-194
REPORT BRIEF
INITIAL EVALUATION TESTS
OF
GENERAL ELECTRIC COMPANY
40.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
TDRSS SATELLITE
Ref: (a) NASD, Purchase Order S-496933, Modification Number 17
(b) Initial Evaluation Test Procedure for Nickel-Cadmium Sealed Space
Cells: NAD 3053-TP324
1. 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 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. These cells were manufactured
at the same time and from the same materials as Lot 2 cells, manufactured for
the Tracking Data Relay Satellite System (TDRSS) program. They were manufac-
tured in accordance with TRW Part/Material Control Document "Battery Cells
40 ah", Number 8E0ll and General Electri c MCD 232A2222AA-80. (See Appendix I
for detailed cell description). The cL	 Nere identified by the manufac-
turer's catalog number 42B040AB03. These cells are rated at 40.0 ampere-hours
and contain double ceramic seals. 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 requirement does not constitute a limit
for discontinuance from test,
II. SUMMARY OF RESULTS
A. Measurements of tha cell containers, following test, -indicated an
average increase of .019 inches in the plate stack thickness of only +hose cells
without pressure transducers. Also, the narrow sides of cli;:s cells containers
became convex during testing.
B. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
WQEC/ C 80-194
Charge Volts PSIA ah Out
c/20 for 48 hrs @ 25° C 1.448 29 53.7
c/10 for 24 hrs @ 25° C 1.459 70 52.0
c/10 for 24 hrs @ 20° C 1.467 68 50.0
c/10 for 24 hrs @ 20° C* 1.464 78 45.3
c/40 for 20 hrs @ 20" C** 1.373 4 16.4
c/20 for 60 hrs @ 0° C 1.500 75 50.1
c/10 for 24 hrs @ 35° C 1.398 29 49.6
*Charge retention test
**Charge efficiency test, 20.0 ah input
C. One cell (S/N 14-5) exceeded the voltage requirement of 1.48 volts
during the first c/10 charge at 20° C. Four cells exceeded this requirement
during the second c/10 charge at 20° C.
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 1.51
volts. Peak voltages were 1.539 to 1.545 volts.
E. The pressure requirement of 65 psia was exceeded by one pressure
transducer cell (S/N 146) during the first c/10 charge at 20° C. Both
.pressure transducer cells exceeded this pressure requirement during the c/10
charge at 25° C, the second c/10 charge at 20° C, and during the 0° C over-
charge test.
F. The average cell voltage at the end of one week open-circuit-stand,
during the charge retention test, was 1.316 volts.
G. The 24-hour average cell voltage following the 16-hour short period,
during the internal short test, was 1.240 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 61.2 a,, and 1.548 volts respectively. The cells exhibited a pressure
decay of 4 psia during the last 30 minutes of the 1-hour open-circuit stand.
Average capacity out was 52.0 ampere-hours.
III. RECOMMENDATIONS
A. Manufacturing processes and controls shoule be such to prevent cell
case distortion.
B. It was recommended that these cells be placed on a synchronous
orbit life test.
C. In April 1980, one pack (2328) began synchronous orbit life test
with its first eclipse season.
ii
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 G 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° 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, 0° and 35° C.
7. Pressure versus capacity test.
8. Phenolphthalein leak test.
(See Appendix II for summary of test procedure.)
II. CELL IDENTIFICATION AND DESCRIPTION
A. The cells were identified by the manufacturer's serial numbers,
catalog numbers and TRW's Part/Material Control Document Number 8EO11-001Z-
001 Revision E. The manufacturer's numbers are as follows:
Catalog
	
Serial
42BO40AB03	 02670304 S/N 02-141 to 145
The cells were placed in a temporary pack configuration for initial testing
(Pack 560X). Each cell was individually restrained and two cells (S/Ns 145
and 146) had pressure transducers.
B. The 40.0 ampere-hour cell is rectangular with an average weight and
physical dimensions as*follows:
WQEC/C 80-194
Thickness (in.)
	
Width (n.)*
Pre-Test	 Post-Test
Weight (g)*	 Height (in.)	 Edge	 Center*	 Center*	 Edge	 Center
1.449.8	 6.588	 1.307	 1.311	 1.330	 3.405	 3.433
*Does not include pressure transducer cells (2) which indicated no increase
in plate stack thickness and whose width (narrow side) were not convex
following test.
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 VI.
A. Measurements of the cell containers, following test, indicated an
average increase of .019 inches in the plate stack thickness of only those
cells without pressure transducers. Also, the narrow sides of these cells'
containers became convex during testing.
B. Average end-of-charge voltages and pressures, and capacity output
in ampere-hours (ah) were as follows:
Charge Vilts PSIA ah Out
c/20 for 48 hrs @ 25° C 1.448 29 53.7
c/10 for 24 hrs @ 25° C 1.459 70 52.0
c/10 for 24 hrs @ 20° C 1.467 68 50.0
c/10 for 24 hrs @ 20° C* 1.464 78 45.3
c/40 for 20 hrs @ 20° C** 1.373 4 16.4
c/20 fcr 60 hrs @ 0° C 1.500 75 50.1
c/10 for 24 hrs @ 35° C 1.398 29 49.6
*Charge retention test
**Charge efficiency test, 20.0 ah input
C. The average internal resistance at the end-of-charge (Cycle 1) was
2.5 milli, chms and during discharge (Cycle 2) it was 2.4 milliohms.
D. One cell (S/N 145) exceeded the voltage requirement of 1.48 volts
during the first c/10 charge at 20° C. Four cells exceeded this requirement
during the second c/10 charge at 20° C.
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 1.51
volts. Peak voltages were 1.539 to 1.545 volts.
F. The pressure requirement of 65 psia was exceeded by one pressure
transducer cell (S/N 146) during the first c/10 charge at 20° C. Both pressure
transducer cells exceeded, this pressure requirement during the c/10 charge at
25° C, the second c/10 charge at 20° C, and during the 0° C overcharge test.
2	 ;,	 .
x;
WQEC/C 80-194
G. The average cell voltage at the end of 1 week open-circuit, during
the charge retention test, was 1.316 volts.
H. The 24-hour average cell voltage following the 16-hour short period,
during the internal short test, was 1.240 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 the voltage at this pressure were
61.2 ah and 1.548 volts respectively. The cells exhibited a pressure decay
of 4 psia during the last 30 minutes of the 1-hour open-circuit stand.
Average capacity out was 52.0 ampere-hours.
3
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WQEC/C 80-194
TABLE III
INTERNAL RESISTANCE AND SHORT TEST DATA
(SP 11
INTERNAL RESISTANCE (MILLIOHMS)
	
INTERNAL
!SERIAL E' "16
;NUMBER	
END-OF-CHARGE	
ONE HOUR AFTER
	 TWO HOURS AFTER
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j	 f	 START-OF-DISCHARGE
	 START-OF-DISCHARGE
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TABLE IV
	
WQEC/C 80-194
CHARGE RETENTION TEST DATA
SERIAL
NUMBER
END-OF-CHARGE
°—
24 HR. OCV 1 WEEK OCV END-OF-DISCHARGE
CELL
VOLTS )(VOLTS
AUX
ELECT. PRESS
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CAPAC-
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(AH)
AUX.
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(VOITS)(PSIA)
lq l tq^3 I 1.348 /.314 44.1
/ q2 ! q c,S /-3s?, 1,31(. 4T,I
lqq 1,y , 117,15Z 1,34, qs,l
l^fS lf^6 20 1,3s4 /,317 3 4(,.7 3
1 X110 /,'^62 7G 0 , 41 8 ! 316 7 K5-,3
WQI I• /C 80-194
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WQEC/C 80-194
APPENDIX I
CEL- DESCRIPTION
10
WQEC/ C 80-194
APPENDIX I
CELL DESCRIPTION
Cell History and Description
Five, 40 ah cells were purchased by the GSFC, under Purchase Order Number
S-49693B, from the General Electric Company. These cells were manufactured
at the same time and from the same materials as (Lot 2) cells manufactured
for TRW for the TDRSS Program. These cells were manufactured in accordance
with TRW Part/Material Control Document "Battery Cells 40 ah", Number 8EO11
and General Electric MCD 232A2222AA-80. The General Electric Catalog Number
is 42BO40AB03. This cell lot consists of two plate lots (2A and 2B). 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" x 3.20" x .0315"
Negative Plate is
Loading (Lot 2A):
Loading (Lot 2B):
KOH Quantity (Lot
Precharge (Lot 2)
Silver Treated
Positive 01049
Negative 02013
Positive 01056
Negative 02003
1): 120 cc of
14.4 ah
13.36 gm/dm2
16.46 gm/dm2
13.49 gm/dm2
16.47 gm/dm2
31 % KO H
Separator: Pellon 2505
Interelectrode spacing: .0085" nominal
Flooded cell tests (Lot 2A): Average Positive 55.78 ah
Average Negative 92.74 ah
Flooded cell tests (Lot 2B): Average Positive 55.62 ah
Average Negative 94.64 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 80-194
APPENDIX II
TEST PROCEDURE
12
WQEC/ r, 80-194
APPENDIX II
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 percent
phenolphthalein sol^jtion applied with a cotton swab and then placed in a
vacuum chamber and exposed to a vacuum o f 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 cell's capacity at
the c/2 discharge rate to 0.75 volt per cell, where c is the manufacturer'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 1i,nits and
requirements as the charge of cycle 1.
C.	 Internal Resistance:
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-
discharcce 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.
2. The cells are charged at c/10 for 24 hours witr. the same 11-r is
:.and requirements as the ,u rge of cycle 1. They then stand on open-circuit
for 7 days, with the requ-. rement that the open-circuit voltage of each cell,
following this period, is within T 5 millivolts of the average cell voltage.
'he cells are then discharged and 80 percent capacity out of that obtained
cycle 3 is required.
13
WQEC/C 80-194
E.	 Internal Short Test:
1. This test is a means of detecting slight shorting conditio,is
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 cell's charge efficiency
when charged at a lo ,.^i 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 than discharged and the require-
ment 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 cell's 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 cell's capacity at a higher
temperature when compared to its capacity at 20° C. This test also determines
the cell's 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.
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.
14
WQEC/C 80-194
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.
15


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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