Munitions Batteries: Basics, Requirements, and Challenges...- ARL: Cindy Lundgren - Welcome and...

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UNCLASSIFIED The Nation’s Premier Laboratory for Land ForcesUNCLASSIFIED The Nation’s Premier Laboratory for Land Forces

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Munitions Batteries:Basics, Requirements, and Challenges

Michael Ding, Frank Krieger, Jeff SwankMunitions Battery TeamU.S. Army Research [email protected] 7, 2016

mailto:[email protected]

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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces

Welcome

Welcome to the Future of Munitions Batteries Workshop!

First Day (7 December 2016)Registration Starts 7:20 AM- ARL: Cindy Lundgren - Welcome and Introduction to CREB 8:00 AM1. Munitions Batteries: Taking Stock 8:20 AM- ARL : Michael Ding - Munitions Batteries: Basics, Requirements, and challenges 8:20 AM- ARL : Michael Ding - Developing Thin-Film Thermal Batteries and Heat Source Materials 8:40 AM- ARL: Jeff Swank - Liquid Reserve Fuze Batteries: Trying to Move Beyond the Status Quo 9:00 AM- SNL: Scott Roberts - Multiphysics modeling of thermal batteries at Sandia 9:20 AM- > Break < 9:40 AM- Rafael: Ofer Raz - Advances in R&D and Production of Thermal Batteries 10:00 AM- Eagle Picher: Dharmesh Bhakta - Battery Technologies for Munitions 10:20 AM- EnerSys: Paul Schisselbauer - Advanced Munitions Batteries 10:40 AM- ATB: Guy Chagnon - Munitions Batteries: Taking Stock 11:00 AMDiscussions (Auditorium; Running microphones at the ready) 11:20 AMLunch 12:00 PM2. DoD Needs and Requirements for Munitions Batteries 1:00 PM- Army-AMRDEC: Patrick Taylor - Spare No Expense: Missiles' Special Needs 1:00 PM- OSD-JMP: Paul Butler - The Munitions Power Maze: OSD, JMP, JFTP, and More 1:20 PM- Army-ARDEC: Tony Pergolizzi - TCG-V and the Newly Identified Munitions Power Gaps 1:40 PM- Navy-Crane: Sam Stuart - Progression of Missile Battery Technology and Where It Is Headed 2:00 PM- > Break < 2:20 PM

3. Potentials of Active Battery Technologies for Munitions Applications 2:40 PM- ARL: Jeff Read - Feasibily of Using Active Batteries for Munitions Applications 2:40 PM- Energizer: Matt Wendling - Active Battery Technologies for Munitions Applications 3:00 PM- MaxPower: Steve Shantz - Organic-Based R/T Liquid Reserve Technologies 3:20 PM- Army-ARDEC: Karen Amabile - (2) Power Requirements for Munitions: Present and Futu 3:40 PMDiscussions (Auditorium; Running microphones at the ready) 4:00 PMGet-Together Dinner (Olive Garden, 14650 Baltimore Ave, Laurel, MD 20707; 301-284-0826) 7:30 PM

Second Day (8 December 2016)4. Non-Conventional Thinking and Technologies for Munitions Power 8:00 AM- Army-ARL: Bruce Geil - Inside the Box: An Outside the Box Look at Power Requirements for New Concepts 8:00 AM- Army-ARDEC: Guisseppe Di Benedetto - Nanomaterials and Additive Manufacturing for Munitions Power Sources 8:20 AM- SNL: Chris Apblett - Thin Film Thermal Battery Development for High Rate Applications 8:40 AM- Missouri U of Sci and Tech: Nick Leventis - Aerogel-Wise: Making Novel Heat Source Materials for Thermal Batteries 9:00 AM- OmniTek: Jay Rastegar - Hooked on Munitions Power: Mini-Inertial Igniters, Piezo-Energy-Harvesters, and More 9:20 AM- > Break < 9:40 AMDiscussions (Continuation of this Session; Running microphones at the ready) 10:00 AMEnd of Workshop 12:00 PM

Munitions Batteries: batteries for gun-fired munitions, rockets, missiles, bombs, mines, and other exploding devices that are used for one-shot, non-maintainable, always-ready applications, roles that have traditionally been filled by reserve batteries.

Purpose: to bring together scientists, technologists, program managers, system designers, and users from government agencies,research labs, private companies, universities, and program offices to understand, exchange information on, and discuss the present, the past, and the future of munitions batteries to bring about a new vision and new pathways for munitions battery technologies going forward.

Style: informative, interactive, inter-disciplinary, synergetic, non-conventional, and forward-looking.

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Requirements for Munitions Batteries

• Core requirements for munitions and missiles batteries:

• Long shelf life (> 20 years)

• Charge stability (retention)

• Materials stability (limited long-term deterioration)

• Device stability (packaging)

• High G/spin conditions (50 kG/300 rps)

• Wide temperature range (-54 to 71 °C)

• High reliability (99+%)

• More requirements

• Faster rise

• Higher energy and power densities in smaller volumes for smart munitions

• More flexible geometries (form-factor and conformal)

• Lower cost

• Better manufacturability

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The Unique Munitions Batteries

Electrolyte

Impact

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MOFA Cutaway Illustration

Endplate

Case

Cell Cup

Cell Stack

Positive Pin(GTM Seal) Terminal

Plate

(+)(-)Spring

Interlock Pin(2 Places)

Cutter

Drive DiskReservoir

Spacer

Ball Seal

Ground Pin(Case Ground)

Electrolyte

Cell Cup BottomT.P. Insulator

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Thermal Battery Basics

s.s. electrodeAnode

ElectrolyteCathode

Pyrotechnicheat pellet

Source: Guidotti, Masset, J. Power Sources,161 (2) 1443-1449

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Pros/Cons of Traditional Mechanisms


Long shelf life (> 20 years)

Charge stability (retention)

Materials stability (limited long-term deterioration)

o Device stability (packaging)

o High G/spin conditions (50 kG/300 rps)

Wide temperature range (-54 to 71 °C)

High reliability (99+%)


Faster rise

Higher energy and power densities in smaller volumes for smart munitions

More flexible geometries (form-factor and conformal)

Lower cost

Better manufacturability

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Munitions Power Candidate Matrix

Satisfied Inherently unsuitable Unknown but potentially suitable

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Example: 40-Year-Old Thermals Still Work

CaCrO4/LiCl-KCl/Ca

Temperature (oC)

Number Tested

Number Meeting 1 sec Activation

Time

Number Meeting 18 sec Discharge

Life

Number Meeting 30 sec Discharge

Life

-54 12 12 10 1

25 10 10 10 10

74 11* 11 10 6

Total 33 33 30 17

Output voltage: 350 +/- 17.5 volts, not to exceed 380 voltsCurrent: 110 mAActivation time: 1 second (to reach 332.5 volts)Discharge life: 18 and 30 seconds (before dropping below 332.5 volts)

Test Results of 33 Thermal Batteries Aged 40 Years

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Needs and Challenges

• Needs for the future munitions power devices

• Reduce production cost

• Raise energy and power densities (complexity ↓ packaging ↓)

• Shorten rise time

• Increase spatial adaptability (geometric flexibility)

• Improve manufacturability

• Challenges for the potential replacing technologies

• Prolonged shelf life (> 20 years)

• Adequate long-term charge retention

• Highly chemically stable components (storage temperature)

• Wide temperature rang (storage and operation)

• Short rise time (passivation problem)

• High reliability

• High G/spin tolerance

• Sustained financial support and management focus

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Questions?

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UNCLASSIFIED The Nation’s Premier Laboratory for Land ForcesUNCLASSIFIED The Nation’s Premier Laboratory for Land Forces

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Developing New Heat Source Materials and Thin-Film Thermal Batteries

Michael Ding, Frank Krieger, Jeff SwankMunitions Battery TeamU.S. Army Research [email protected] 7, 2016

ARDEC Team, Picatinny Arsenal, NJSandia Team, Albuquerque, NMNick Leventis, MST, Rolla, MOOSD-JMP (Chris Janow)

mailto:[email protected]

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New Heat Source Materials

Heat paper: Zr-BaCrO4 powder mixture supported by an inorganic fiber Pressed pellets: pressed Fe-KClO4 powder mixture (Fe in excess) Fe-aerogel-based pyrotechnic materials as heat source

Motivation and rationale A schematic flow-chart for materials preparation Some examples of initiation and burning of such samples

NanoFoil as heat source material Materials preparation by physical sputtering Motivation and rationale Nano-structure and initiation and propagation of exothermic reaction Other tests and properties for thermal battery applications

Summary

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Mechanisms of heat source materials

NanoFoil T. B. heat source – more recent:

Al and Ni metals alternately nano-layered into foilsAl + Ni → (Al,Ni) + ∆H

Fe-particle T.B. heat source – traditional:

Fe (particulate) and KClO4 particles pressed into pellets4 Fe + KClO4 → 4 FeO + KCl + ∆H

Fe-aerogel T.B. heat source – most recent:

Fe (porous) and LiClO4 particulate deposits in the pores:4 Fe + LiClO4 → 4 FeO + LiCl + ∆H

10 µm 25 µm

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Fe-aerogel: motivations and merits

Inexpensive to make with aerogel-based preparation routes

Monolithic, thus imparting the end material with sufficient

mechanical strength and electrical conductivity

Tailorable properties via structural control (micro/nano)

Improved materials utilization

Fe-aerogel T.B. heat source – most recent:

Fe (porous) and LiClO4 particulate deposits in the pores:4 Fe + LiClO4 → 4 FeO + LiCl + ∆H

10 µm 25 µm

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Energizing aerogel Fe0 with LiClO4

PBO-FeOx-200

800 oC, Ar

Fe0/C

FeOx PBO CFe0LiClO4

Pyrotechnic composites

sat. LiClO4/acetone

Fe0/C Fe2O3/Fe0

600 oC, Air 1200 oC, H2

Fe0

Fe2O3

Fe0 (denser, coarser, stronger)

Consolidation for desired mechanical and

electrical properties

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Ignition and burning of an energetic composite

The Fe aerogel was sintered at 1200 °C.

The aerogel shrunk in size but still maintained a porosity greater than 60%.

The Fe-aerogel material was infiltrated with solution of LiClO4 and then dried.

The resulting material was initiated successfully and maintained its mechanical integrity before, during, and after the initiation and subsequent burning reaction.

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Fe-aerogel: motivations and merits

Metallic, with inherent mechanical strength and electrical conductivity

Gas-less

Tailorable properties via structural control (bilayer thickness)

Flexible form factor

Conducive to continuous production

Expensive and rigid

NanoFoil T. B. heat source – more recent:

Al and Ni metals alternately nano-layered into foilsAl + Ni → (Al,Ni) + ∆H

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NanoFoil as New Heat Source

Reactionzone

thermaldiffusionat

omic

diffu

sion

reacted foil

AlNi

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NanoFoil: Flame Propagation

Filmreacting

Filmreacted

Flame propagation speed: 9 m/s NanoFoil can be readily ignited edgewise Flame propagates considerably faster in

NanoFoil than in heat paper

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NanoFoil: Peak TemperatureMeasurement and Control

43

2

3

2

1

0

200

400

600

800

1000

1200Peak temperature / °C

Number of NanoFoil discs

No. B

uffe

r D.

0

100

200

300

400

500

600

700

800

900

1000

1100

-5 5 15 25 35 45 55 65Time, t / s

Tem

pera

ture

, θ /

°C

3-2-3, 200 lb, no microtherm3-2-3, 200 lb, microtherm2-2-2, 200 lb, microtherm2-3-2, 200 lb, microtherm2-4-2, 200 lb, microtherm2-4-2, 100 lb, microtherm1-4-1, 200 lb, microtherm1-2-1, 200 lb, microtherm3-3-3, 200 lb, microtherm3-4-3, 200 lb, microtherm

Peak temperature is effectively controlled by stainless steel buffer discs

Peak temperature increases with NanoFoil disc number and decreases with buffer discs

Peak temperature is dependent more on buffer disc number than NanoFoil

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Summary of Heat Source Work

NanoFoil as heat source material Proven effective in both traditional and thin-film thermal batteries Inherently better mechanical and conductive properties Rapid flame propagation leading to short rise time Gasless reaction Expensive, rigid, and excessive skin temperature.

Fe-aerogel-based pyrotechnic materials as heat source Inherently better mechanical and conductive properties Less expensive (potentially cheap) Offering many ways to desired microstructures Highly tailorable for targeted physical and pyrotechnic properties Demonstrated desired pyrotechnic behavior in initiation and burning Promising but requiring further work

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Why Thin-Film Thermal Battery?


Long shelf life (> 20 years)

Charge stability (retention)

Materials stability (limited long-term deterioration)

o Device stability (packaging)

o High G/spin conditions (50 kG/300 rps)

Wide temperature range (-54 to 71 °C)

High reliability (99+%)


Faster rise

Higher energy and power densities in smaller volumes for smart munitions

More flexible geometries (form-factor and conformal)

Lower cost

Better manufacturability

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Prototyping NanoFoil-Heated Thin-Film Thermal Battery

Program background and acknowledgement

Thermal battery, NanoFoil, and other thin-film components

Some experiments leading to the battery prototype

o Regulation of skin-temperature on NanoFoil by buffer layers

o Effective positioning of fuse strip

o Heat-sink effects and their mitigation

Construction of the prototype NanoFoil-heated thin-film thermal battery

Test results of the prototype battery

o Discharge profile, runtime, and resistance

o Rise time

o Gas analysis (no gas at all)

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The program resulted from combining and synergizing the efforts by ARL-ARDEC of using NanoFoil as the new heat source material for thermal battery, and those by SNL of developing thin-film anode/electrolyte and cathode components for thermal battery.

SNL’s Advanced Power Sources Group is our major collaborator, providing coated anode/electrolyte and cathode/current collector

Financial support from OSD and JMP

Chris Janow (retired) of JMP and ARDEC for program formulation and support

Many people at Picatinny Arsenal, ARDEC

Program Backgroundand acknowledgements

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Prototype Thermal Battery— NanoFoil Skin-Temperature

Time, t / s0 1 2 3 4 5 6 7 8 9 10

Tem

pera

ture

, θ /

°C

0

100

200

300

400

500

600

700

800

900

2345

Buffer layer thickness / mil

Buffer layer thickness, τ / mil

1 2 3 4 5 6

Pea

k Te

mpe

ratu

re, θ

/ °C

600

650

700

750

800

850

900

Nichromematch wire

TC

Heat paper fuse strip

8.0V 1.4A

AgilentE3649A

Agilent34970A

606.5

Time, t / s0 10 20 30 40 50 60

Vol

tage

, E /

V

0

2

4

6

8

10

12

14

16

18

Cur

rent

, I /

mA

0

50

100

150

200

250

300

350

400

VoltageCurrent

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Other Related Experiments— Fuse-Strip Positioning

Runtime, t / ms0 100 200 300 400 500 600

Vol

tage

, E /

V

0

1

2

3

4

5

6

7

8

9

Tem

pera

ture

, θ /

°C

-100

0

100

200

300

400

Match, longBattery, longTop TC, longBottom TC, long Match, shortBattery, shortTop TC, shortBottom TC, short

• Proper positioning of a fuse-strip in relation to match-wire can significantly shorten rise time because of its much slower burn-rate than that of NanoFoil.

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Experimental Setup for Stack Discharge and Characterization

CathodeElectrolyteAnodeMicrothermHeat paperNanoFoilBuffer

CathodeElectrolyteAnodeMicrothermHeat paperNanoFoilBuffer

Agilent34970A

606.5Agilent34970A

606.5

NichromewireNichromewire

Maccor4300

Maccor4300

TCTCTCTC

Fuse stripFuse strip

8.0V 1.4A

AgilentE3649A

8.0V 1.4A

AgilentE3649A

Nat InsPCI-6251M

Nat InsPCI-6251M

Nat InsPCI-6251M

• Experimental setup for the discharge and the electrical and thermal characterization of NanoFoil-heated thin-film thermal battery stacks. The stack in the figure consists of two (2) thermal cells.

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Other Related Experiments— Heat-Sink Effects

Time, t / s0 10 20 30 40 50 60

Res

ista

nce,

R /

0

5

10

15

20

25

30

End-heatingNo end-heating

Cur

rent

, I /

mA

0

50

100

150

200

250

300

350

400

Vol

tage

, E /

V

0

2

4

6

8

10

12

14

16

18

20

Current, end-heatingVoltage, end-heatingVoltage, no end-heating

Time, t / s0 5 10 15 20 25 30 35 40 45 50

Tem

pera

ture

, /

°C0

100

200

300

Res

ista

nce,

R /

0.0

0.2

0.4

0.6

0.8

1.0

Top TC, end-heatingResistance, end-heatingTop TC, no end heatingResistance, no end-heating

Vol

tage

, E /

V

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

Cur

rent

, I /m

A

0

50

100

150

200

250

300

Voltage, end-heatingCurrent, end-heatingVoltage, no end-heating

12-cell 1-cell

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Prototype NanoFoil-Heated TFTB

Layer Materials Thickness /milThermal insulation Microtherm 90 (uncompressed)Match wire NichromeThermal insulation Microtherm 90 (uncompressed)Heat source NanoFoil 150 µmHeat buffer Stainless steel 2Thermal insulation Microtherm 90 (uncompressed)Positive electrode Stainless steel 3Heat buffer Stainless steel 5Heat source NanoFoil 150 µmHeat buffer Stainless steel 5Cathode substrate Not listed Not listed Cathode Not listed Not listed Separator Not listed Not listed Anode/substrate Not listed Not listedHeat buffer Stainless steel 5Heat source NanoFoil 150 µmHeat buffer Stainless steel 5Negative electrode Stainless steel 3Thermal insulation Microtherm 90 (uncompressed)Heat buffer Stainless steel 2Heat source NanoFoil 150 µmHeat buffer Stainless steel 2Thermal insulation Microtherm 90 (uncompressed)

* The portion in blue repeats 12 times.

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NanoFoil-Heated Thin-Film Thermal Battery: Performance and Rise Time

Time, t / ms0 50 100 150 200 250 300 350 400

Vol

tage

, E /

V

0

2

4

6

8

10

12

MatchBattery

Time, t / s0 10 20 30 40 50 60

Res

ista

nce,

R /

Ω

0

5

10

15

20

25

30

Vol

tage

, E /

V

0

2

4

6

8

10

12

14

16

18

Cur

rent

, I /

mA

0

50

100

150

200

250

300

350

400

VoltageCurrent

Pressed-pellet: 500 msCurrent: 100 ms

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Samples Total Pressure / torr H2 O2 N2 CO CH4 CO2

First 100.7 80.6 0.0 0.0 17.2 2.2 0.0

Second 100.2 68.6 6.8 6.3 14.0 4.3 0.0

Typical in pptb ~500

Prototype Thermal Battery— Gas Reduction

• Total pressure of gases inside traditional pressed-pellet thermal batteries can easily reach close to a thousand Torr during operation.

Summary for Prototyping an All-Thin-Film Thermal Battery Prototyped a 12-Cell NanoFoil-heated thin-film thermal battery The prototype battery initiated and performed well Rise time shortened within 100 milliseconds Internal pressure was negligible Demonstrated the viability of all-thin-film thermal batteries

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Questions?

Munitions Batteries: Basics, Requirements, and Challenges...- ARL: Cindy Lundgren - Welcome and...

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