The results of tests to insure that all cells put into the life cycle program are of high quality are reported. The tests consisted of the following: phenolptalein leak tests, internal short test, charge efficiency test, and overcharge tests. The results of tests for 10 cells are tabulated

Harkness, J. D.

English

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https://ntrs.nasa.gov/search.jsp?R=19790007236 2020-03-22T01:33:31+00:00Z
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	 INITIAL F.VAL11ATION TF.S .,N79-15407
IF FAOLE-PICFEP I"1D'ISTHI
'^
	r'.S 9.0 AMPEPF-1icUP ^ 4)_/ 01
	 ^SPACECRAFT CEL
	
b^
':IKF.L-CADMI'ly
	 LS FOR THE HEATC AII i CI: Y AAPPIN(; "!ISSICN SATLLLI T E AND 711E
	 OnclasSTRATU:;PF?Fr,IC (Naval Weapons Support Center, (;3/44 43200
INITIAL EVALUATION TESTS
OF
EAGLE-PICHER INDUSTRIES
9.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT SELLS
FOR THE
HEAT CAPACITY MAPPING MISSION SATELLITE
AND THE
STRATOSPHERIC AEROSOL AND GAS EXPERIMENT SATELLITE
y	 r
prepared for
GODDARD SPACE FUGHT CENTER
Contract S-53742AG
WEAPONS QUALITY ENGINE=RING CENTER
NWSC C -ane, Indiuna
WQEC/C 78-37
REPORT BRIEF
INITIAL EVALUATION TESTS
OF
EAGLE-PICiER INDUSTRIES
9.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
HEAT CAPACITY 14APPING 14ISSION SATELLITE
AND THE
STRATOSPHERIC AEROSOL AND GAS EXPERIMLNT SATELLITE
Ref: (a) NASA Purchase Order S-53742AG
(b) Initial Evaluation Test Procedure for Nickel-Cadmium Sealed
Space Cells: NAD 3053-TP324, 10 Apr 73
TEST ASSIGNMENT BRIEF
A. The purpose of this evaluation test program is t o 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 10 cells were purchased by the National Aeronautics and Space
Administration, Goddard Space Flight Center (GSFC), under NASA contract
NAS 5-55909 from Eagle-Picher Industries. The cells were manufactured by
Eagle-Picher Industries, Joplin, Missouri, according to the Boeing
Specification 268-10408 which is similar to the GSFC Specification 74-15000.
Five cells were purchased from a lot of cells to be used on the Heat Capacity
Mapping i4ission Satel1 ite (I1CM11) and the other 5 cells from the lot of
cells to be used on the Stratospheric Aerosol and gas Experiment	 tellite
(SAGE). The HCMM cells were activated in November 1976 and t.ne ^muE
cells were manufactured in April 1977. The cells were iden ; ified with
the manufacturer's type number RSN-10-3. These cells are rated at 9.0
ampere-hours, contain double ceramic seals, and were fitted with pressure
transducer assemblies. Testing was funded in accordance with reference (a).
C. Test limits specify those values at which a cell is to be terminated
from a particular 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. The HCMM cells exhibited lower voltages and pressti-es, but
delivered higher capacities than the SAGE cells.
i
14QEC/C 78-37
B. The HCMM cells exceeded the voltage requirement of 1.52 volts
during the 0"C overcharge test, but their end-of-charge voltages were
below 1.50 volts.
C. The SAGE cells exceeded the voltage and pressure test limits
during the following charges:
Type Change
	
Number of Cells
	
Test Limit Exceeded
C/10, 24 hrs, @ 25"C 2 Pressure
C/10, 24 hrs, @ 20% 2 Voltage
C/10, 24 hrs, @ 20% 2 Pressure
C/20, 60hrs, @ 0°C 5 Voltage
C/10, 24hrs, @ 35°C 4 Pressure
D. Three SAGE cells delivered less than 55" of the input capacity
requirement during the 20°C charge efficiency test.
E. The 24-hour average cell voltage following a 16-hour short period,
for the HCMM and SAGE cells was 1.249 and 1.226 volts respectively.
F. The cell container-; had a convex contour, in which the thickness
was greater in the center , f' the can than at the edye of the container.
Following test, the thickness at the edge was greater (HCMM cells not
measured) indicating a reduction in the plate stack thickness.
III. RECOMMENDATIONS
A. It was recommended that these cells be placed on life test under
the orbit regimes of the HCMM and SAGE spacecrafts.
B. In May 1977., the HCMM cells (Pack 18H) began life test (1.6 hour
obit, 20"C) and in September 1977 the SAGE cells (Pack 18I) began life
test (1.64 hour obit, 20 0C).
ii
.f
WQEC/C 78-37
RESULTS OF
INITIAL EVALUATION TESTS
OF
EAGLE-PICHER INDUSTRIES, INCORPORATED
9.0 AMPERE-HOUR NICKEL-CADMIUM SPACECRAFT CELLS
FOR THE
HEAT CAPACITY MAPi'ING MISSION SATELLITE
AND THE
STRATOSPHERIC AEROSOL AND GAS EXPERIMENT 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. Phenolphtalein 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 0C.
5. Overcharge tests, Wand 35°C.
7. Phenolphtalein leak test.
(See Appendix I for summary of test procedure.)
II. CELL IDENTIFICATION AND DESCRIPTION
A. The cells were identified by the manufacturer's type number,
RSN-10-3, and serial numbers as follows:
Project
	
Manufacturer's Serial Numbers
HCMM	 233, 2 1 2, 248, 252, 256
SAGE	 290, 311, 334, 345, 352
The cells were placed in pack configurations for initial testing: (Pack
18H (HCMM) and Pack 18I kSAGE). Each cell was equipped with a pressure
transducer.
WQEC/C 78-37
B. The 9.0 ampere-hour cell is retangular with an average weight and
physical dimensions is follows:
Thickness_ inn..)***
Overall	 Pre- est
	 ost-Test***
Wei ht `*	 Height in.	 Minimum	 Maximum	 Maximum Width in.1
570.8*(HCMM)	 3.301	 .898	 .902	 2.990
420.1(SAGE)
	
3.285	 .900	 .906	 .894
	 2.992
* - includes weight of pressure transducer assembly
** - minimum measured at edge of can and maximum at center
*** - SAGE cell data only
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.
(See Appendix II for detailed cell description)
III. RESULTS - The following was condensed from Tables I through U.
A. The cell containers had a convex contour. in which the thickness
was greater in the center of the can than at the edge of the container.
Following test, the thickness at the ed ge was greater (HCMM cells not
measured) indicating a reduction in the plate stack thickness.
B. The SAGE cells exhibited higher average end-of-charge (EOC)
voltages and pressures (PSIA) than the HCMM cells; but exceeded the
voltage and pressure test limits during various charges. The HCMM cells
delivered a higher capacity output in ampere-hours (ah) following these
charges. The following is a listing of these averages:
HCMM Cells SAGE CELLS
Charge Volts PSIA ah Out Volts PSIA ah Out
C/20 for 48 hrs @ 25°C 1.445 28 11.5 1.453 62 10.8
C/10 for 24 hrs @ 25% 1.441 51 11.4 1.461 88 10.7
C/10 for 24 hrs @ 20% 1.459 63 11.2 1.502 66 10.7
C/10 for 24 hrs @ 20°C 1.457 64 10.1 1.495 66 9.9
C/40 fnr 20 hrs @ 20°C* 1.380 4 2.7 1.384 6 2.5
C120 for 60 hrs @ 0°C 1.483 69 10.8 1.616 31 10.4
C/10 for 24 hrs 0 35°C 1.418 70 10.8 1.436 91 10.3
*Charge Efficiency Test, 4.5 ah input
2
WQEC/C 78-37
C. Average Internal Resistance Measurements (milliohms):
Resistance
Measurement Taken	 HCMM	 SAGE
30 min before end-of-charge (Cyl:le 1) 	 3.0	 2.1
1 hr after start-of-discharge (Cycle 2)
	 2.9	 2.5
2 hrs after start-of-discharge (Cycle 2)
	 2.9	 2.5
D. Two SAGE cells exceeded 100 PSIA during the C/10 charge 0 25°C.
E. Four SAGE cells exceeded the test limits (2 on pressure and 2 on
voltage) during the C/10 charges @ 20°C.
F. Tnree SAGE cells delivered less than 55" of the input capacity
requirement durin g, the 20% charge efficiency test.
G. All the SAGE cells exceeded the voltage test limit during the
overcharge test @ 0°C. The HCMM cells exceeded the voltage requirement of
1.52 volts during this test although their end-of-charge voltages were
below 1.50 volts.
H. Fcur SAGE cells exceeded the pressure test limit during the 35°C
overcharge test.
I. The average cell voltage at the end of one week open-circuit, during
the charge retention test was 1.303 and 1.301 volts respectively for the
HCMM and SAGE cells.
J. The 24-hour average cell voltage following a 16-hour short period,
for the HCMM and SAGE cells was 1.249 and 1.226 volts respectively.
3
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TABLE
INTERNAL RESISTANCE AND SHORT TEST DATA
1-NNADC (SP 11/71)____ WQEC/C 78-37
INTERNAL RESISTANCE (MIILIOHMS) INTERNAL SHORT TEST
SERIAL ------- __ _	 ---
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NUMBER
END-OF-CHARGE:
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STPRT-OF . DISCHAKE	 START-OF-OISCHAkGE
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TABLE V
CHARGE RETENTION TEST DATA
WQEC/C 78-37
SERIAL
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WQEC/C 78-37
APPENDIX I
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 #7).
2. The cells were initially checked with a one-half of one
percent 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 'pests:
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 manufact-
urer's rated capacity. Ti-is 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, Cyrfe 1, with a test limit of 1.52
volts or 100 psia pressure and a requirement of maximum voltage (1.48)
or pressure (75 psis).
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 112 hour
before the end-of-charge (EOC) on Cycle 1, 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.
9
WQEC/C 78-37
2. The cells are charged at C/10 for 24 hours with a test limit
of 1.52 volts or 100 psia pressure. 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 i ,iillivolts of the average cell voltage.
The cells are then discharged and 80 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 third 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 the 24 hours.
F.	 Ch, ,,. -fficiency 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 C120 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 Asia. The requirement is a voltage of 1.520
or a pressure of 75 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 determines
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.
10
WQEC/C 18-37
2. The cells are charged C/10 for 24 hours with a test liinit of
1.52 volts or 100 psia pressure and a requirement of 1.45 volts or 75 psia
pressure. The cells are then discharged and 55 percent capacity out of
that obtained in Cycle 3 is required.
WQEC/C 78-37
APPENDIX	 11
HCMM CELL DESIGN
These -ells were activated at Eagle-Picher in November 1976 and have the
following properties:
Lot Number 1	 Positive Plates	 (P-1913) Lot Number 2 Negative 	 (N-1393)
11.2 Ah	 to +	 1.Ov 20.0 Ah to	 -1.Ov
12.11
	
Ali 28.13	 Ali
92 percent efficiency 71	 percent efficiency
Neg/Pos Ratio	 1.79 Neg/Pos Patio	 1.79
Loading 0.69 g/in 2 Loading	 1.15 g/in2
Avg.	 thickness 0.027 -,nch Avg.	 thickr	 s	 0.030	 inch
Number of Plates	 11 Number of Plates 12
Area of a Plate 5.5	 in2
Free Volume of Cell:	 52 cc
Amount of Electrolyte:	 40g or 32 cc of 31	 percent KOH
Separator:	 12 mils	 pellon 2505 non-woven nylon
Cell	 Case Thickness:
	
.022 inch,	 304	 stainless steel
Precharqe:
	
2.4	 to	 2.8 Ali
Excess Negative: 	 8.8 Ah
These cells were subjected to acceptance tests at Eagle-Picher where they
exhibited	 the following results:
ATP 408 Paragraph 4.4,	 35"C (12-3-76)
S/N	 AH Voltage PSIG
233	 8.6 1.399 +14
242	 8.0 1.387 +2.1
248
	
8.1 1.386 +13
252	 7.8 1.385 +21
256	 7.7 1.386 +17
12
WQEC/C 78-37
S/ tI
	
Ail Vol tage PSI G
233	 10.7 1.495 +20
242	 10.7 1.493 +19
248	 10.7 1.4J3 +16
252	 10.7 1.493 +22
256	 10.7 1.494 +22
Following acceptance test at Eagle-Picher the cells were stored at GSFC
in a
	
freezer discharged and shorted.
SAGE CELL DESIGN
These cells were activated at Eagle-Picher in March 1977 and have the
following properties:
Positive	 Plates	 (T-1992) Negative	 (N-1416)
11.0 Ah	 to	 +l.Ov 16.2 Ah	 to	 -l.Ov
12.11	 Ah	 theoretical 25.69 Ah theortical
91	 Percent efficiency 63 percent efficiency
Neg/Pos	 Ratio	 1.47 Neg/Pos	 Ratio	 1.47
Loading 0.69 g/in 2 Loading	 1.04	 9/in2
Avg thickness 0.027 	 inch Avg	 thickness	 .031	 inch
Number of plates	 11 Number of plates 12
Area of a plate 5.54	 in2
Free Volume of Cell:	 52 cc
Amount of Electrolyte:	 40g or 32 cc of 31 percent KOH
Separator:	 12 mils pellon 2505 non-woven nylon
Cell	 Case Thickness:	 .022 inch,	 304	 stainless	 steel
Precharge:	 2.2 to	 2.7 Ah
Excess Negative:	 5.2 Ah
13
r


Initial evaluation tests of Eagle-Picher Industries 9.0 ampere-hour nickel-cadmium spacecraft cells for the heat capacity mapping mission satellite and the stratospheric aerosol and gas experiment satellite

Initial evaluation tests of Eagle-Picher Industries 9.0 ampere-hour nickel-cadmium spacecraft cells for the heat capacity mapping mission satellite and the stratospheric aerosol and gas experiment satellite

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