Validation test of 125 Ah advanced design IPV nickel-hydrogenflight cells

An update of validation test results confirming the advanced design nickel-hydrogen cell is presented. An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed for storing and delivering energy for long-term, low-earth-orbit (LEO) spacecraft missions. The new features of this design are: the use of 26% rather than 31% potassium hydroxide (KOH) electrolyte; a patented catalyzed wall wick; serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while maintaining physical contact with the wall wick for electrolyte management; and a floating rather than a fixed stack to accommodate nickel electrode expansion. The resulting improvements include extended cycle life and enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. Six 125-Ah flight cells based on this design are in the process of being evaluated in a LEO cycle life test     

Status of the Air Force nickel hydrogen low earth orbit life test

The US Air Force NiH₂ LEO (low earth orbit) life test consists of 200 cells undergoing real-time LEO cycling, pulse discharge testing, and storage testing. To date, three of the program's four objectives have been met: NiH₂ performance in LEO applications has been demonstrated. A significant number of cells have completed more than 20,000 cycles at 40% DOD. A database for cells of both 3.5 in. and 4.5 in. diameter has been generated. There have been no indications of any performance problems related to scaling up in terms of cell size. Initial data on the pulse discharge performance of a small number of cells has been demonstrated. Concerning the goal of achieving 20,000 cycles at 60% DOD, the data are mixed. Overall, it appears highly unlikely that cell designs such as those currently in the US Air Force test can achieve 20,000 cycles at 60%     

某Ⅰ级涡轮盘低循环疲劳寿命试验研究

为了确定某Ⅰ级涡轮盘的技术寿命,根据该盘的标准循环载荷谱,对该盘进行了应力分析,确定在标准循环时该盘中心孔与径向销孔相交处为考核部位。为模拟标准循环时该盘在其考核部位的应力谱,专门设计了该Ⅰ级涡轮盘的试验转子及试验参数,在轮盘低循环疲劳试验器上,对该Ⅰ级涡轮盘的一个旧盘进行了高温低循环疲劳试验。试验结果表明：该旧盘低循环疲劳试验至第６０４７ 次循环时,有５ 个销孔考核部位出现了裂纹。断口分析表明：该旧盘剩余的试验低循环疲劳失效寿命为６０４７ 周     

The Hy-StorTM battery

The Hy-Stor^TM Battery is a rechargeable battery being developed for electric vehicles and other large battery applications. The battery combines the high energy storage capability of metal hydride alloys with the high cycle life and discharge rate capabilities of nickel-hydrogen cells. It is a hybrid battery concept that offers potential performance, economic and safety advantages over other large battery technologies. Very recent developments indicate that much smaller batteries can also be produced to meet the needs of the portable computer and other portable electronic device markets. Initial tests demonstrated the ability of a metal hydride storage system to achieve high cycle life when absorbing hydrogen that was saturated with battery electrolyte solution and then passed through a purifier. Based on positive test results, a patent for the Hy-Stor battery was applied for and granted     

Life expectancy of a 24-V, 15-Ah sealed lead-acid aircraft battery

This paper presents the results of cycle life testing F24-V, 15-Ah sealed lead-acid batteries intended for use the B-1B aircraft. Test samples were procured from two different manufacturers and subjected to cycle testing at 33% and 100% depth-of-discharge (DOD). The cycle life at 33% DOD ranged from 500 to 750 cycles. The cycle life at 100% DOD ranged from 160 to 260 cycles     

A nickel/hydrogen battery for PV systems

The nickel-hydrogen battery, developed in the early nineteen-seventies as an energy-storage subsystem for commercial communication satellites, is discussed. The advantages offered by nickel-hydrogen batteries, including long life, low maintenance and high reliability, make it very attractive for terrestrial applications such as stand-alone photovoltaic systems. The major drawback to the wider use of the nickel-hydrogen battery is its high initial cost. A 7-kWh battery has been on test since January 1988 using a flat-plate photovoltaic array for charging. The cell, battery design and test methods are briefly described, and the results of cycling and solar tests are presented. It is concluded that the battery is well suited for remote solar applications     

Evaluation of nickel-hydrogen battery cells for space-based radar

A study conducted in 1991 on nickel-hydrogen (NiH₂) battery cells, to assess their use for space-based radar satellites, is discussed. Current NiH₂ and related programs were investigated. Cell performance data were assessed, focusing on pulsed-load operation, cell design factors, and life expectancy. A need for pulsed-load testing of candidate cells, especially to characterize their effective series resistance, dynamic impedance, and possible degradations, was identified. A NiH₂ cell test program was planned, and test preparations started in mid-1992     

Bipolar nickel-metal hydride batteries for aerospace applications

Electro Energy Inc. (EEI) is developing high power, long life, bipolar nickel-metal hydride batteries for aerospace applications. Bipolar nickel-metal hydride designs allow for high energy and high power designs with a 25 percent reduction in both weight and volume as compared to prismatic and/or cylindrical Ni-MH designs. Utilizing a sealed wafer cell design EEI has demonstrated a 1.2 kW/kg power capability. Prototype designs have achieved 70 Wh/kg. Designs studies show 80 Wh/kg are achievable with EEI's state-of-the-art technology. The sealed wafer cell is the building block for EEI's high power and high voltage bipolar batteries making the assembly easy and significantly lower in cost. Satellite and aircraft batteries are being developed which provide high power and long life. Sealed cells now show excellent rate capability and life. Cells tested in a low earth orbit (LEO) cycle have reached 9000 cycles and continue on test. High power, bipolar battery designs are ideal in applications where using conventional aerospace battery technology would require excessive capacity; weight and volume, thereby reducing usable payload on the vehicle     

面向导航增强的低轨卫星钟差确定及预报方法研究

低轨导航增强是未来导航发展的重要趋势,而高精度低轨卫星钟差是实现低轨导航增强的必要条件。基于Sentinel-6A卫星,对低轨卫星钟差特性进行了分析,给出了钟差确定方法及影响因素,介绍了顾及钟差特性的低轨卫星钟差预报方法。实验表明,低轨卫星钟差含有多个周期项,给低轨卫星建模和预报带来了困难。与使用运动学定轨模型相比,基于简化动力学的定轨模型可显著提升低轨卫星钟差精度;当基于运动学模型确定低轨卫星钟差时,相较于使用GPS单系统数据,多GNSS观测数据可提升低轨卫星钟差精度。研究表明,基于GPS和Galileo观测的Sentinel-6A卫星钟差精度相较于GPS单系统钟差精度改善了36%,同时,所使用的GNSS产品精度与低轨卫星钟差精度密切相关。利用顾及卫星钟差特性的低轨卫星钟差预报方法,当预报时长小于1 min,低轨卫星钟差预报精度（预报与解算值之差的RMSE）在0.1 ns之内,当预报时长小于5 min,预报精度在0.3 ns之内,随着预报时长的增长,预报精度显著下降。     

Five-year update: nickel hydrogen industry survey

A 1984 survey of the nickel hydrogen (NiH₂) battery industry is updated. Late 1980s and early 1990s issues are identified, and usage and testing results of the survey are summarized. NiH₂ is the system of choice for new geosynchronous-earth-orbit (GEO) satellites and is being seriously considered for low-earth-orbit (LEO) applications. In five years, the annual cell production rate has doubled from approximately 1000 to 2000 cells. A number of cells under test have exceeded 20000 cycles at 40% DOD in LEO regimes, while other cells have achieved over 35 seasons in accelerated GEO regimes. The LEO database clearly indicates that NiH₂ performance is at least as good as the best conventional nickel-cadmium performance demonstrated under test     

Hubble Space Telescope at twelve years of age

The Hubble Space Telescope was deployed from the Space Shuttle Discovery into a 380-mile high Earth orbit on April 25, 1990. It subsequently made outstanding astronomical discoveries with its 8-foot (2.4-meter) telescope and other scientific instruments. Critical to the successful observations was continuous availability of power from its solar arrays during sunlit periods, and from nickel-hydrogen batteries when the satellite was in the Earth's shadow. The adopted nickel-hydrogen batteries were carefully selected and tested to confirm their depth-of-discharge and operating temperature that delivered the longest life in charge/discharge cycling service. These batteries had a design life of 7 years. At 12 years after launch the Hubble batteries have delivered more charge/discharge cycles than any other batteries in low-Earth orbit. However, the Hubble batteries have been subjected to many unexpected stresses, and peculiar reductions in battery capacity have been observed. Battery replacement requires a costly trip to the Hubble Space Telescope by astronauts, so the remaining useful life of the batteries must be predicted. Already in four servicing missions, astronauts have replaced or modified optics, solar arrays, a power control unit, and various science packages. A fifth servicing mission is scheduled in 2004. This paper discusses battery charging hardware and software controls, history of battery events in Hubble, cell performance model and spare battery tests, and capacity walkdown.     

中低纬地区混合LEO星座增强GNSS UPPP收敛性能评估

针对全球卫星导航系统(GNSS)精密单点定位(PPP)收敛时间过长的问题,提出了利用低轨卫星(LEO)几何结构变化快的优势,增强GNSS非差非组合PPP(UPPP)的收敛性能。选取中低纬度地区28个能接收GPS、GALILEO和BDS3信号的测站观测数据,比较了极轨和混合LEO星座的增强效果。结果表明：混合LEO星座增强GPS、GALILEO和BDS组合系统时,各测站收敛时间减少60%～80%,70%的测站收敛速度优于极轨星座。当混合LEO星座增强单BDS时,CL和GCL组合系统的收敛时间相当,ENU方向定位误差变化基本一致。收敛时间从10～20 min下降至3 min以内,原因是混合LEO增强BDS定位时,大大改善了卫星的空间结构。     

基于LTSA融合降维法的滚动轴承可靠性评估方法

为了保障滚动轴承在给定工况下安全平稳地运行,提出了一种基于局部切空间排列（LTSA）和威布尔比例故障率模型（WPHM）的滚动轴承可靠性评估方法。该方法提取滚动轴承整个寿命周期的时域、频域、时频域及统计等不同分析域上的特征指标,从中筛选出包含滚动轴承运行状态的特征指标,构建出高维多域特征集;利用局部切空间排列算法对高维多域特征集进行融合降维,得到可全面反映滚动轴承性能退化趋势的综合特征指标作为WPHM的响应协变量进行可靠性评估。通过滚动轴承的寿命试验,得到该试验轴承的寿命为491 min。该方法能够得出轴承在489 min左右失效,寿命误差小于1%,故验证了该方法可以对滚动轴承的运行可靠性进行有效地评估。      

2024-T3铝合金孔板高低周复合疲劳试验研究

对2034-T3铝合金孔板试件进行了高低周复合疲劳性能试验,研究高低周循环次数比对复合疲劳寿命的影响,建立了高低周循环次数和应力幅比与高低周复合疲劳寿命之间的关系式,并对现有损伤累积模型的适用性进行了分析讨论。试验和分析结果表明：随着高低周循环次数增大,复合疲劳寿命有显著的降低,复合疲劳寿命与高低周循环次数比呈对数线性关系。现有的累积损伤准则对试验结果的预测偏于危险,非线性累积损伤准则优于线性累积损伤准则。     

涡轮叶片复合疲劳特性曲线及其规律的试验

为了解高周振动载荷对于涡轮叶片高温疲劳性能的影响,对某型涡轮叶片进行高低周复合疲劳试验.试验结果表明,在低周载荷基础上叠加高频振动载荷,显著缩短了叶片的疲劳寿命;复合疲劳的分散性很大,且不存在疲劳极限,当叶片高周循环次数超过107时,继续试验叶片仍会发生断裂;在双对数坐标下,叶片的振动应力与其高周循环寿命成线性关系,即复合疲劳特性曲线(应力-寿命曲线、概率-应力-寿命曲线)服从双对数线性规律,进一步研究发现该规律对于高温合金材料的复合疲劳特性曲线具有普遍性.      

2.5维机织复合材料的纬向力学性能试验

通过室温(20℃)及高温(180℃)静态拉伸及拉 拉疲劳试验,获得了25维树脂基机织复合材料在不同温度下的力学性能及拉 拉疲劳寿命。基于宏观试验,探讨了材料在静载及拉 拉疲劳载荷作用下的破坏模式和失效机理,对比了材料在疲劳载荷作用后的剩余强度与静强度的关系,之后分析了温度对材料静态力学性能及疲劳寿命的影响。结果表明:在20~180℃温度范围内材料的纬向模量对温度不敏感,但纬向强度及疲劳寿命随温度的升高而显著下降。在高温高应力水平（高于80%静强度）下材料的纬向疲劳寿命非常短(小于104次循环),但当应力水平仅下降2%后,材料的纬向疲劳寿命趋于106次循环。另外,高温下材料的剩余强度大于高温静强度。      

多轴随机载荷下的疲劳寿命估算方法

提出了一种多轴随机载荷下的疲劳寿命预测方法.通过雨流计数法对各平面上的剪应变进行循环计数,以统计出的剪应变循环作为多轴疲劳损伤的主要控制参数,将各剪应变循环历程内对应的最大正应力和正应变变程作为多轴疲劳损伤的第二控制参数.根据多轴疲劳寿命模型计算出各平面上的损伤,以最大损伤平面作为多轴随机疲劳的临界平面,通过该临界平面上的损伤计算出多轴随机载荷下的疲劳寿命.采用SNCM630钢,304不锈钢和S45C钢3种金属材料的多轴随机疲劳试验数据对提出的寿命预测方法进行评估和验证.结果表明:疲劳寿命预测结果大都分布在试验结果的2倍分散带之内.     

面向适航要求的涡轮发动机限寿件概率失效风险评估方法

为了满足适航规章关于民用航空涡轮发动机限寿件的要求,通过综合分区概率统计、应力-强度干涉理论、线弹性断裂力学等方法建立了限寿件失效的概率风险评估数学模型,确定了模型的数值解法,开发了计算程序,并结合咨询通告中所提供的校准算例完成了模型的验证工作.评估结果表明,寿命期内不进行无损探伤检查和在10000循环进行一次检查的限寿件示例失效风险分别为1.45×10-9次/飞行循环和1.0×10-9次/飞行循环,完全符合校准算例,表明了评估方法能够反映适航规章关于限寿件失效风险分析的要求.      

基于整机试车的涡轮叶片高低循环复合疲劳试验技术

针对航空发动机涡轮叶片同时承受高循环载荷和低循环载荷的特征,以小推力涡喷发动机为研究对象,搭建了基于引电器的涡轮叶片动应力测量系统,利用数值模拟和试验测试结合的方法,实现了高度为30mm的涡轮叶片在40000r/min转速、950℃环境温度条件下的动应力测量,并以此为基础发展了整机高低循环复合疲劳试验方法,开展了高压涡轮叶片高低复合疲劳整机试验。研究结果表明,该型发动机转速在34920r/min时,叶片高循环振动应力达到112.7MPa,带来了涡轮叶片的高循环疲劳损伤且是引起涡轮叶片产生裂纹的主要因素,低循环疲劳载荷是导致裂纹扩展的主要因素,两者综合作用会显著影响涡轮叶片寿命。      

某型钛铝合金航空发动机叶片高温高周振动疲劳实验

以某型钛铝合金航空发动机叶片为研究对象,针对该型叶片高温高周振动疲劳实验时遇到的高温疲劳应力监测、高频激励等问题进行了实验方法研究。采用闭环控制最大应力的方法解决了高温疲劳应力的监测,通过夹具放大设计实现了高频激励,利用辐射加热和电磁振动台完成了温度载荷和振动载荷的综合施加。运用所述的高温高周振动疲劳实验方法,对该型叶片进行了寿命实验。实验的高温疲劳应力控制精度优于±2%,得到该型叶片可靠度为50%的中值疲劳极限是444 MPa,并有效获得了其寿命曲线。该实验方法适合航空发动机叶片高温高周振动疲劳实验,并可为其他航空发动机零部件高温高周疲劳实验提供参考。