Munitions Batteries: Basics, Requirements, and Challenges

Transcription

1 Munitions Batteries: Basics, Requirements, and Challenges Michael Ding, Frank Krieger, Jeff Swank Munitions Battery Team U.S. Army Research Laboratory December 7, 2016

2 Welcome Welcome to the Future of Munitions Batteries Workshop! 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. First Day (7 December 2016) Registration Starts 7:20 AM - ARL: Cindy Lundgren - Welcome and Introduction to CREB 8:00 AM 1. 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 AM 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 PM Discussions (Auditorium; Running microphones at the ready) Get-Together Dinner (Olive Garden, Baltimore Ave, Laurel, MD 20707; ) - 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 Discussions (Auditorium; Running microphones at the ready) 11:20 AM for Munitions Power Sources 8:20 AM Lunch 12:00 PM - SNL: Chris Apblett - Thin Film Thermal Battery Development for High Rate Applications 8:40 AM 2. DoD Needs and Requirements for Munitions Batteries 1:00 PM - Missouri U of Sci and Tech: Nick Leventis - Aerogel-Wise: Making Novel Heat Source - Army-AMRDEC: Patrick Taylor - Spare No Expense: Missiles' Special Needs 1:00 PM Materials for Thermal Batteries 9:00 AM - OSD-JMP: Paul Butler - The Munitions Power Maze: OSD, JMP, JFTP, and More 1:20 PM - OmniTek: Jay Rastegar - Hooked on Munitions Power: Mini-Inertial Igniters, - Army-ARDEC: Tony Pergolizzi - TCG-V and the Newly Identified Munitions Power Gaps 1:40 PM Piezo-Energy-Harvesters, and More 9:20 AM - Navy-Crane: Sam Stuart - Progression of Missile Battery Technology - > Break < 9:40 AM and Where It Is Headed 2:00 PM Discussions (Continuation of this Session; Running microphones at the ready) 10:00 AM - > Break < 2:20 PM End of Workshop 12:00 PM 4:00 PM 7:30 PM Second Day (8 December 2016) 4. Non-Conventional Thinking and Technologies for Munitions Power 8:00 AM

3 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

4 The Unique Munitions Batteries Impact Electrolyte

5 MOFA Cutaway Illustration Endplate Drive Disk Ball Seal Reservoir Case Cell Cup Spacer Cell Stack Electrolyte T.P. Insulator Cutter Cell Cup Bottom Positive Pin (GTM Seal) (+) Spring Terminal Plate (-) Interlock Pin (2 Places) Ground Pin (Case Ground)

6 Thermal Battery Basics s.s. electrode Anode Electrolyte Cathode Pyrotechnic heat pellet Source: Guidotti, Masset, J. Power Sources,161 (2)

7 Pros/Cons of Traditional Mechanisms Core requirements for munitions and missiles batteries: Long shelf life (> 20 years) o Charge stability (retention) Materials stability (limited long-term deterioration) o 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

8 Munitions Power Candidate Matrix Satisfied Inherently unsuitable Unknown but potentially suitable

9 Example: 40-Year-Old Thermals Still Work CaCrO 4 /LiCl-KCl/Ca Test Results of 33 Thermal Batteries Aged 40 Years Temperature ( o C) Number Tested Number Meeting 1 sec Activation Time Number Meeting 18 sec Discharge Life Number Meeting 30 sec Discharge Life * Total Output voltage: Current: Activation time: Discharge life: 350 +/ volts, not to exceed 380 volts 110 ma 1 second (to reach volts) 18 and 30 seconds (before dropping below volts)

10 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

11 Questions?

12 Developing New Heat Source Materials and Thin-Film Thermal Batteries Michael Ding, Frank Krieger, Jeff Swank Munitions Battery Team U.S. Army Research Laboratory December 7, 2016 ARDEC Team, Picatinny Arsenal, NJ Sandia Team, Albuquerque, NM Nick Leventis, MST, Rolla, MO OSD-JMP (Chris Janow)

13 New Heat Source Materials Heat paper: Zr-BaCrO 4 powder mixture supported by an inorganic fiber Pressed pellets: pressed Fe-KClO 4 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

14 Mechanisms of heat source materials Fe-particle T.B. heat source traditional: Fe (particulate) and KClO 4 particles pressed into pellets 4 Fe + KClO 4 4 FeO + KCl + H Fe-aerogel T.B. heat source most recent: Fe (porous) and LiClO 4 particulate deposits in the pores: 4 Fe + LiClO 4 4 FeO + LiCl + H NanoFoil T. B. heat source more recent: Al and Ni metals alternately nano-layered into foils Al + Ni (Al,Ni) + H 10 µm 25 µm

15 Fe-aerogel: motivations and merits Fe-aerogel T.B. heat source most recent: Fe (porous) and LiClO 4 particulate deposits in the pores: 4 Fe + LiClO 4 4 FeO + LiCl + H 10 µm 25 µm 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

16 Energizing aerogel Fe 0 with LiClO o C, Ar PBO-FeOx-200 Fe 0 /C 600 o C, Air 1200 o C, H 2 Fe 0 /C Fe 2 O 3 /Fe 0 Fe 0 Consolidation for desired mechanical and electrical properties sat. LiClO 4 /acetone Fe 0 (denser, coarser, stronger) Pyrotechnic composites FeOx PBO Fe0 C Fe 2 O 3 LiClO 4

17 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 LiClO 4 and then dried. The resulting material was initiated successfully and maintained its mechanical integrity before, during, and after the initiation and subsequent burning reaction.

18 Fe-aerogel: motivations and merits NanoFoil T. B. heat source more recent: Al and Ni metals alternately nano-layered into foils Al + Ni (Al,Ni) + H 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

19 NanoFoil as New Heat Source atomic diffusion thermal diffusion Reaction zone reacted foil Al Ni

20 NanoFoil: Flame Propagation Film reacting Flame propagation speed: 9 m/s NanoFoil can be readily ignited edgewise Flame propagates considerably faster in NanoFoil than in heat paper Film reacted

21 NanoFoil: Peak Temperature Measurement and Control Temperature, θ / C , 200 lb, no microtherm 3-2-3, 200 lb, microtherm 2-2-2, 200 lb, microtherm 2-3-2, 200 lb, microtherm 2-4-2, 200 lb, microtherm 2-4-2, 100 lb, microtherm 1-4-1, 200 lb, microtherm 1-2-1, 200 lb, microtherm 3-3-3, 200 lb, microtherm 3-4-3, 200 lb, microtherm Time, t / s Peak temperature / C Number of NanoFoil discs No. Buffer D. 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

22 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

23 Why Thin-Film Thermal Battery? Core requirements for munitions and missiles batteries: Long shelf life (> 20 years) o Charge stability (retention) Materials stability (limited long-term deterioration) o 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

24 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)

25 Program Background and acknowledgements 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

26 Prototype Thermal Battery NanoFoil Skin-Temperature Temperature, θ / C Buffer layer thickness / mil Peak Temperature, θ / C Buffer layer thickness, τ / mil Time, t / s Heat paper fuse strip Nichrome match wire TC Voltage, E / V Voltage Current Current, I / ma V 1.4A Agilent E3649A Agilent 34970A Time, t / s

27 Other Related Experiments Fuse-Strip Positioning Voltage, E / V Match, long Battery, long Top TC, long Bottom TC, long Match, short Battery, short Top TC, short Bottom TC, short Temperature, θ / C Runtime, t / ms 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.

28 Experimental Setup for Stack Discharge and Characterization Cathode Electrolyte Anode Microtherm Heat paper NanoFoil Buffer Nichrome wire Fuse strip 8.0V 1.4A Agilent E3649A TC Nat Ins PCI-6251M TC Agilent 34970A Maccor 4300 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.

29 Other Related Experiments Heat-Sink Effects Voltage, E / V Current, end-heating Voltage, end-heating Voltage, no end-heating Current, I / ma Voltage, E / V Voltage, end-heating Current, end-heating Voltage, no end-heating Current, I /m A Resistance, R / End-heating No end-heating Temperature, / C Top TC, end-heating Resistance, end-heating Top TC, no end heating Resistance, no end-heating Resistance, R / Time, t / s Time, t / s 12-cell 1-cell

30 Prototype NanoFoil-Heated TFTB Layer Materials Thickness /mil Thermal insulation Microtherm 90 (uncompressed) Match wire Nichrome Thermal insulation Microtherm 90 (uncompressed) Heat source NanoFoil 150 µm Heat buffer Stainless steel 2 Thermal insulation Microtherm 90 (uncompressed) Positive electrode Stainless steel 3 Heat buffer Stainless steel 5 Heat source NanoFoil 150 µm Heat buffer Stainless steel 5 Cathode substrate Not listed Not listed Cathode Not listed Not listed Separator Not listed Not listed Anode/substrate Not listed Not listed Heat buffer Stainless steel 5 Heat source NanoFoil 150 µm Heat buffer Stainless steel 5 Negative electrode Stainless steel 3 Thermal insulation Microtherm 90 (uncompressed) Heat buffer Stainless steel 2 Heat source NanoFoil 150 µm Heat buffer Stainless steel 2 Thermal insulation Microtherm 90 (uncompressed) * The portion in blue repeats 12 times.

31 NanoFoil-Heated Thin-Film Thermal Battery: Performance and Rise Time Voltage, E / V Voltage Current Current, I / ma Voltage, E / V Match Battery Resistance, R / Ω Time, t / ms Pressed-pellet: 500 ms Current: 100 ms Time, t / s

32 Prototype Thermal Battery Gas Reduction 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 Samples Total Pressure / torr H 2 O 2 N 2 CO CH 4 CO 2 First Second Typical in pptb ~500 Total pressure of gases inside traditional pressed-pellet thermal batteries can easily reach close to a thousand Torr during operation.

33 Questions?