AS 6413 and slash sheets /1 & /2 hold the main information for testing of battery packaging. This document holds further information and expansion of philosophy, clarification etc. surrounding the testing and industry needs.

G-27 Lithium Battery Packaging Performance

SAE TOMORROW TODAY - The Hidden Role of Battery Vents in EV Safety and Adoption

135196/12/2025

One failure can reshape public trust in EVs overnight. That's why every detail matters--and why collaboration across the entire EV ecosystem is critical. Even small components like battery pack vents play an outsized role in preventing thermal runaway events, explosions, and fires. The SAE Battery Pack Venting Committee understands this challenge and answered the call with the new SAE J3325(TM) Technical Information Report a guide to designing, testing, and integrating battery vents that perform when it matters most. To dive deeper, we spoke with Dr. Michael Harenbrock, Principal Expert of Electric Mobility at MANN+HUMMEL GmbH, and chair of the SAE Battery Pack Venting Committee about how SAE J3325 is helping engineers enhance EV battery safety--and how their work evolves to keep pace with emerging ventilation technologies and trends. Want to help shape the future of EV safety? Join an SAE Committee today! Contact Standards Specialist Dante Rahdar at dante.rahdar@sae.org. We'd love to

Hineman, Marcie

Dynamic Drop Testing of eVTOL Energy Storage Systems Part 1: Drop Test Data Summary

F-0081-2025-0042

5/20/2025

Researchers at the National Aeronautics and Space Administration (NASA) have conducted a series of module-level tests on electric Vertical Take-off and Landing (eVTOL) Energy Storage Systems (ESS) for the generation of dynamic impact data to support standards developments. The tests were conducted on zero-state-of-charge Electric Power Systems (EPS) Electric Propulsion Ion Core (EPIC) modules at the National Institute for Aviation Research (NIAR), utilizing the NIAR outdoor drop test setup and personnel. Four total tests were conducted. For each test, the module was dropped at a specific orientation from a height of 50 feet while connected to a guided trolley in order to assess the effects of a 50-foot drop test on the ESS. The test velocities ranged between 46.9 and 52.8 ft/s with impact angles ranging between a flat, zero-degree impact and 18 degrees. Data were recorded in the form of temperatures, cell-level voltage, module level acceleration and digital image correlation from the

Littell, Justin, Gardner, Nathaniel, Ellafrits, Shay

Experimental Evidence to Influence Design of Novel Low Lubrication Method for Rotorcraft Secondary Lubrication Systems

F-0081-2025-0279

5/20/2025

This paper presents experimental research aimed at developing novel low lubrication methods for rotorcraft and jet engines, focusing on sustaining minimal lubrication to prevent catastrophic bearing failure during loss of lubrication (LoL) events or to increase fuel consumption performance on once-through, fuel-oil bearing lubrication engines. Utilizing two high-speed bearing test rigs simulating low and high thrust class engine conditions, the study establishes lower bounds for oil flow rates necessary to maintain thermal stability and prevent thermal runaway in hybrid ball bearings. These findings inform the design of the Zulu Pod (ZPod), a passively driven, self-contained oil delivery system that uses engine compressor bleed air to precisely meter lubricant flow. Engine test stand results demonstrate that replacing traditional fuel-oil lubrication with the ZPod system reduces thrust specific fuel consumption (TSFC) by an average of 7%, with up to 11% savings, without compromising

Boersma, Pieter, Currier, Todd, Ferrante, Jason, Rosenthal, Julius

Basic Science and Art of Aircraft Wreckage Reconstruction

R-4804/23/2025

Basic Science and Art of Aircraft Wreckage Reconstruction is a unique title which addresses important aspects of investigating crashes, who does this kind of work, and how a healthy attitude and open mind are required to properly perform investigations. It also discusses what to expect from the on-scene part of the investigation, and the fundamental approaches to common types of wreckage reconstruction. Written by Don Knutson, a veteran of this industry, Basic Science and Art of Aircraft Wreckage Reconstruction is intended for the practitioner, student, or those who are simply curious about how aircraft wreckage is reconstructed. Full references are provided in the various chapters for additional reading and research. Many examples of aircraft crash scenarios and circumstances are presented in a "generic" form but relate to actual investigations, which should prove as a useful investigative resource whether you are an apprentice or an experience professional with a government aviation

Knutson, Donald F.

Effect of Ceramifiable Silicone Rubber Composite based Thermal Insulators in Battery Packs

2024-26-03511/16/2024

Silicone and rubber composite, often called Ceramifiable Silicone Rubber (CSR) has proven to show excellent mechanical and thermal properties. CSR materials have been mainly used in industrial applications like electrical insulating cables, decorations, and fire-proof materials. The mechanical and ceramifiable properties of CSR can be altered by changing the silicone rubber matrix and by adding the right additives or fillers. In this work, we prove the potential of CSR composites as thermal insulating materials in battery packs. Specifically, we explore the usage of CSR inside the battery pack to improve safety during thermal events. We also characterize the material properties before and after exposing the CSR composite to elevated temperatures and flame. Finally, we investigate the effectiveness of the CSR composite sheet in preventing or delaying cell-to-cell thermal propagation during a thermal runaway event inside the battery pack. Our experiments show that the CSR composite sheet

Nambisan T M, Praveen Kumar, H, Manjunatha, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan

Adaptive derating algorithm for EV application based-Li-Ion battery for safe and healthy operation

2024-26-01081/16/2024

Battery packs used in Electric Vehicles (EVs) pose significant safety risks and can incur additional costs and downtime when facing extreme conditions such as thermal and undervoltage hard cut-off. This article emphasizes the importance of implementing thermal and voltage based derating techniques to ensure the safe operation of battery packs. Thermal derating controls the maximum allowed battery current to prevent thermal runaway along with maintaining the health of the cells. While voltage derating prevents cut-off at low SOC regions by managing the cell voltage operating range through real time calculation of DCIR based voltage drop. By adopting these methods, battery packs can operate more safely and reliably in various environment conditions, which is essential in many applications. The article introduces the adaptive derating index, which utilizes State of Health (SoH) and real-time measurements of battery parameters such as temperature, voltage drop, and current to adjust the

Gautam, Ashish, SJ, Janarthanan, Badiger, Kartik, Soni, Lokesh

A Comparison of Wire Bonding vs. Spot Welding vs. Soldering in the Prevention of Thermal Runaway in a Battery Pack

2024-26-01091/16/2024

EVs are a fast-growing market and appear as a promising option against the high emission of gasoline and diesel vehicles. The growth in the EV market has been decent and a regular buyer is still skeptical due to fire incidents occurring with EVs. Complex electronics, improper thermal management, mechanical abuse, improper cell grading activities and control in production, lack of testing in a production plant, and of course, uneven degradation of cells can be one of the reasons this promising technology is facing thermal runaway and in turn, the wrath of the government and public alike. One of the reasons thermal runaway can be triggered after a cell catches fire is because a part of heat travels via busbars to the neighboring cells, as the busbars can conduct heat faster than the air. For the heat that is conducted, it is easily understandable that we need to break the electrical, as well as thermal conduction connection to the neighboring cells. This paper presents a comparison of

Pawar, Aniruddha, Khan, Faiz, Shah, Harsh, Malani, Shekhar

Simulation Based Validation of Battery Structural Integrity for Mechanical Abuse as per AIS 156

2024-26-02421/16/2024

Battery is one of the safety critical systems in EV. As the number of EVs increases, battery safety becomes an important task to avoid any mishap during its use, as even small accidents may slow down the adaptation of EVs. Automotive environment being one of the harshest operating environments, it is important to ensure both mechanical and electrical safety of the battery pack. Li-Ion batteries are most popular among traction batteries, due to their high energy density, long life, and fast charging capabilities. But mechanical damage, overtemperature, short-circuit, etc. may lead to battery thermal runaway, causing a major accident. Mechanical abuse of battery can be one of the reasons that may lead to the damages mentioned above, eventually causing thermal runaway in batteries. That’s why all major battery safety standards have requirements for vibration and mechanical shock tests. In this paper, we will be developing a methodology to evaluate the structural integrity of a battery

Dandge, Sunil, Mahamuni, Ameya, Sevda, Gaurav, H, Rajesh, Kumar, Ravindra, Mahajan, Rahul

A Review on Fire Prevention and Suppression Solutions for EV Battery Packs

2024-26-00121/16/2024

The lithium-ion batteries are susceptible to fires or explosions due to their extremely volatile nature. The energy-dense batteries, such as LiNi_0.8 Mn_0.1 Co_0.1 O_2/Graphite (NMC811) battery that meets the consumer range demands, are most vulnerable under thermal events. A wide number of solutions are being explored to suppress or prevent battery fires. The solutions range from integrating active cooling techniques, passive heat dissipation using heat carrier pads, thermal insulating materials to prevent thermal propagation, safety vents to remove ejecta, and protection circuitries with advanced battery management system. In this paper, we review various safety solutions employed in battery packs for preventing or suppressing potential fire during any thermal runaway event. The identified safety solutions also feature distinctive methods such as usage of hydrogel agents, aerosol fire suppressants and design features. Among the reviewed countermeasures, we provide a detailed analysis

H, Manjunatha, Nambisan T M, Praveen Kumar, R, Pavan, P, Hari Prasad Reddy, G M, Bharath, Kulkarni, Mukund Aravind, Sundaram, Saravanan

Predicting the Onset of Vent Valve Opening in 18650 Cell During Thermal Runaway

2022-28-041711/9/2022

Oven exposure testing is a standard benchmark that Li-ion cells must pass to get approval for sale by the regulating bodies. These tests are designed to ensure the safety of battery user. However, these tests can be costly and time consuming. The development of simulation capabilities, which can replace the physical test to a certain extent helps both battery manufacturers and OEMs not only in the cost cutting but also to optimize the critical parameters which can directly influence the safety criterions. In this paper, a numerical model of 18650 Li-ion cell in an oven test condition is developed to study the thermal runaway, cell venting, internal pressure, and gas flow dynamics behavior using ANSYS FLUENT commercial software. k-ϵ Reynolds-Averaged Navier-Stokes model is used to describe the turbulent flow out of the cells. Thermal abuse reactions are described using by a four-equation lumped reaction model which considers the reaction kinetics of Solid Electrolyte Interface (SEI

U, Reghunath, Gudi, Abhay, Bonala, Sastry

Study of Various Battery Thermal Management Systems & its Benefits

2022-28-041411/9/2022

Electric Vehicle is the need of hour as the excessive usage of IC Engine driven Vehicles has depleted the ozone layer to a significant level. With new technology into the market, challenges come hand in hand because of Electric Vehicle. In comparison to IC Vehicle, areas of thermal management or the number of components for which thermal management needs to be done is higher and rather complex. As the thermal management system is the second highest energy consuming source after the powertrain of the electric vehicle, an efficient and reliable design becomes inevitable to ensure last mile driving range. Thermal Management of the Electric Vehicle has been identified as one of the critical parameters in defining the life, durability, range of the vehicle and the safety of its occupants. One of the major concerns in the development of lithium-ion battery packs for EVs is thermal management. The temperature of all cells must be strictly maintained within a few degrees C across the entire

Anandan, Ram

Theoretical Analysis of the Thermal Resistance Network for Battery Thermal Management

2022-01-508710/12/2022

Battery thermal management for electric vehicles have gained significance over recent years, especially for the present lithium-ion batteries. However, high operating temperature and uneven temperature distribution inside the battery cell can significantly reduce capacity and lifetime. The temperature difference between the battery cells needs to be minimized to avoid premature aging of specific cells exposed to a higher temperature. The most common way to dissipate heat from the battery cells is to use air or liquid cooling. Air cooling is less complex than liquid cooling, but the extremely high ambient temperature dramatically limits the usage of air cooling. This paper developed a thermal connector that could be repeatedly assembled and disassembled between the battery cell. The thermal connector can effectively dissipate the heat into the refrigeration cycle while providing constant thermal resistance among the battery cells, which can be as lower as 0.115°C/W. Heat transfer

Lian, Yubo, Liu, Jianjian, Liao, Yinsheng, Xu, Haolun

3D FEA Thermal Modeling with Experimentally Measured Temperature Gradient Function from Large Format Ultra-Fast Charging Battery Module used in EVs

2022-01-08433/29/2022

In an electric vehicle (EV), due to a number of single cells connected either in series or parallel, generates a large amount of heat because of electrochemical reactions and physical changes, and that would result in the battery degradation (performance and capacity) and thermal runaway issues, and hence demands for an efficient battery thermal management system (BTMS). In this paper, an efficient BTMS is designed and developed for a large format Lithium-ion battery module using a liquid cooling technique. Experiments are conducted on 31Ah NMC/Graphite battery cell which is sandwiched by foams and heat sinks on both sides. A battery module is also developed with three batteries connected in parallel and four cold plates. A total twenty T-type thermocouples are used for this experimental work to measure thermal characteristics including the cell and foam surface temperature, heat flux distribution, and the heat generation from batteries under 2.5C and 3.5C constant power loss tests

Zhao, Ziyu, Panchal, Satyam, Kollmeyer, Phillip, Emadi, Ali, Gross, Oliver, Dronzkowski, David

Investigation on the impact of high-temperature calendar and cyclic ageing on battery overcharge performance

2022-01-08723/29/2022

With the degradation of lithium-ion batteries, the battery safety performance changes, which further influences the safe working window. In this paper, pouch ternary lithium-ion battery with a rated capacity of 4.2 Ah is used as the research object to investigate the impact of high-temperature calendar and cyclic aging on the tolerance performance. The overcharge-to-thermal-runaway test is performed on the fresh cell and aged cell (90% SOH). the inflection point of voltage for aged cell appears earlier than that of fresh cell, while the voltage corresponding to the inflection point is the same for them, which means that the voltage at which lithium plating occurs is the same. However, the voltage plateau and the crest voltage before thermal runaway of aged cell is significantly higher than that of fresh cell. Besides, for the thermal runaway triggering, ohmic heat, reversible heat, and side reaction heat all make contribution, among them, the side reaction heat plays a dominant role

Zhang, Guangxu, Chen, Siqi, Zhu, Jiangong, Dai, Haifeng, Wei, Xuezhe

Comparison of Representative Wet and Dry Fire Suppressants to Retard Fire Propagation in Lithium-Ion Modules initiated by Overcharge Abuse

2022-01-08603/29/2022

The batteries tested during this work were common batteries used in existing automotive applications, and they included a nickel manganese cobalt (NMC) battery from a Chevrolet Bolt, a lithium manganese oxide (LMO) battery from a Chevrolet Volt, and a lithium iron phosphate (LFP) battery in a hybrid transit bus. The battery abuse and emissions tests were designed to intentionally drive the three different battery chemistries into thermal runaway while measuring battery temperatures, battery voltages, gaseous emissions, and feedback from volatile organic compound (VOC) sensors. Overcharge tests simulated a failure in the devices responsible for ensuring the battery remained within safe operating limits during charging. Overcharging a battery can cause lithium plating and other exothermic reactions that will lead to thermal runaway. During the testing, VOC sensors were used to determine what, if any, amount of forewarning they may provide in the event the battery enters thermal runaway

Surampudi, Bapiraju, Jones, Kevin, Shuvodeep Bhattacharyya , Bhattacharyya

Development of a New Flammability Test Method: Enabling Material-Level Evaluation of Polymeric Materials for Electric Vehicle Battery Enclosures

2022-01-08463/29/2022

The drive for reducing the weight and cost of battery systems for electric vehicles has led to continued interest in metal-to-plastic substitution and mixed-material designs for battery enclosures. However, the extreme performance requirements, such as thermal runaway mitigation, pose a challenge for plastic materials to meet. In an effort to design a cost-effective, lightweight next-generation battery enclosure while meeting the latest requirements, the Materials Development Department at the Hyundai-Kia America Technical Center has screened material performance of several plastic types. A new thermal runaway test set-up was developed with support from Underwriters Laboratory (UL), to create a scaled-down test representative of a full battery assembly in real-world conditions. The objective of this development was to provide a comprehensive matrix of test data that can inform material selection and design of next-generation battery enclosures based on performance requirements and

Nummy, Amanda

Novel Nanocrystalline Silver Alloy Coatings to Boost Performance of EV High Voltage Interconnects and Charging Interfaces

2022-01-08743/29/2022

Electric vehicle performance needs challenge connector designers and powertrain engineers with new paradigms for performance under more rigorous operational conditions. Traditional connector design protocols direct the engineer to silver plating for the contact interface, but these coatings have a maximum interface temperature of 170 C (ambient temperature plus T-rise). To avoid thermal runaway, engineers have to derate the ampacity of powertrain connections, which reduces available energy delivery as the temperature increases. This is especially true during transient power events like regenerative braking and acceleration. The soft nature of silver coatings make them well suited for power delivery and low contact resistance, but requires an engineering trade-off for wear durability. This is especially problematic for charging connectors which require tens of thousands of mating cycles before failure. In this work, we demonstrate the performance enhancements that can be achieved using

Griffiths, Peteris, HILTY, Robert, Chan, Lisa, Cahalen, John

Comparative thermal runaway behavior analysis of high-nickel lithium-ion batteries with different specifications

2022-01-08623/29/2022

High-nickel lithium-ion batteries extend the driving mileage of electric vehicles (EVs) to 600km without much cost increment. However, thermal accidents commonly occur due to their poor thermal stability, such as thermal runaway. To address the issue, a comprehensive analysis of the thermal runaway behavior of high-nickel lithium-ion batteries with different specifications is conducted. The thermal runaway process is divided into five stages based on self-heating generation, voltage drop, safety valve rupture, and thermal runaway triggering for the three tested cells. The three tested cells demonstrate similar behaviors during each stage of the thermal runaway process. However, there are still apparent differences between their characteristics. Four aspects of characteristic temperature, the relationship between sudden voltage drop and characteristic temperatures, temperature recovery, and thermodynamics, are discussed. Although Cell 01 has the highest T1, its T2 is the lowest. In

Chen, Siqi, Wei, Xuezhe, Zhang, Guangxu, Wang, Xueyuan, Zhu, Jiangong

Identifying key aspects of thermal runaway modelling for lithium-ion battery cells

2022-01-08703/29/2022

Electrification and hybridization of powerplants in the transportation sector is one of the most important changes in the last few decades. Lithium-ion batteries are the main energy storage systems, but despite the maturity of this technology, it has certain contains compared to traditional internal combustion engines in the day-to-day usage. As the operating conditions of the batteries are pushed to the limits to overcome certain disadvantages relative to other conventional systems like charge and discharge times or vehicle autonomy, new concerns and safety limitations must be considered. High power rates and cooling deficiencies can produce excessive operating temperatures within the cells, leading to problems with degradation or even unchain chemical reactions that can end in thermal runaway, one of the most worrying failure modes attaining electric platforms nowadays. One of the main challenges in the ordeal of designing the system considering these effects is the crossed

Garcia, Antonio, Monsalve-Serrano, Javier, Sari, Rafael, Fogué Robles, Álvaro

A Comparative Study of Lithium-Ion Cathode Chemistry Correlations with Emissions Initiated by Nail Penetration Abuse in the Presence of an Immersive Coolant

2022-01-08473/29/2022

The batteries tested during this work were common batteries used in existing automotive applications, and they included a nickel manganese cobalt (NMC) battery from a Chevrolet Bolt, a lithium manganese oxide (LMO) battery from a Chevrolet Volt, and a lithium iron phosphate (LFP) battery in a hybrid transit bus. The battery abuse and emissions tests were designed to intentionally drive the three different battery chemistries into thermal runaway while measuring battery temperatures, battery voltages, gaseous emissions, and feedback from volatile organic compound (VOC) sensors. A conductive nail was used to pierce the battery cell separator membrane which provided direct electrical contact between the positive and negative electrodes. The electrical contact between the electrodes acted as a low resistance path for a significant amount of current to pass between the electrodes which caused heat generation leading to thermal runaway of a single cell inside a module. During this testing

Surampudi, Bapiraju, Jones, Kevin

Battery Heat Load Estimation and modeling its Thermal management using Air Conditioning System of an Electric Vehicle

2021-28-023110/1/2021

The performance of lithium-ion batteries and its service life depends on its operating temperature. Operating the battery above 45 °C degrades the performance of the battery and reduces its service life. The high-temperature operation also leads to thermal runaway. So there is a need to monitor the operating temperature and voltage output of the battery using a battery thermal management system to ensure its safety. Battery Thermal Management System (BTMS) is a part of the battery management system. The effectiveness of the battery thermal management system depends on the battery pack design, battery chemistry, vehicle operating characteristics and ambient conditions. In this work, a refrigerant-based BTMS is modeled using MATLAB Simulink. Refrigerant R134a used in the air conditioning system of an Electric Vehicle is used as an evaporative cooling medium to cool the batteries. The battery pack is submerged in the pool of refrigerant for cooling and to control the battery temperature

Kaliaperumal, MuthuKrishnan

Failure of Li-Ion 18650 Cylindrical Cells Subjected to Mechanical Loading and Computational Model Development

2021-26-03189/22/2021

To enhance the crashworthiness of electric vehicles, designing the optimized and safer battery pack is very essential. The deformed battery cell can result in catastrophic events like thermal runaway and thus it becomes crucial to study the mechanical response of battery cell. The goal of the research is to experimentally investigate the effect of mechanical deformation on Lithium ion battery cell. The paper thoroughly studies the phenomenon of short circuiting at the time of failure. Various experiments are carried on 18650 cylindrical cells (NCA chemistry) under custom designed fume hood. The setup captures the failure modes of battery pack cell. The loading conditions have been designed considering the very possible physical conditions during crash event. The study has been done for radial compression, semicircular indentation, hemispherical indentation, flat circular indentation and case of three point bending. A detailed computation model is developed in Hypermesh to study the

Aphale, Siddharth, H, Rajesh, Dandge, Sunil, Mahajan, Rahul, Nandurdikar, Vijay, Murugkar, Milind

Comparison of different thermal management strategies in tropical conditions for Li ion batteries and the effect of using Phase change materials (PCM)

2021-26-01409/22/2021

The automobile sector is moving towards electrification as a replacement for the conventional IC Engine as the power source of vehicles. In electric vehicles, Li-ion battery is the widely used energy source for traction and is a major differentiator among various sub components that affect vehicle performance, safety and efficiency. The life of the battery pack is affected by different stress factors like SoC (state of charge), DoD (depth of discharge), C-rates (charge and discharge currents) and battery temperature. Out of the mentioned stress factors, the life of batteries is most influenced by the temperature excursion seen by the li-ion cells in the battery pack. There are various thermal management strategies available to keep the temperature under control like air cooling , chilled liquid cooling and hybrid cooling systems. The benefit of using Phase Change Materials (PCM) in case of hybrid cooling systems in mitigating thermal runaway propagation within the battery pack and the

Kumar, Tirukoti Mohan, C, Vijay Ram

A Review on Thermal Management in electric vehicle battery system by liquid cooling

2021-28-01459/15/2021

With the advent of sophisticated technologies and complexity of electronics and mechanical system for mobility applications, the challenges for better heat management is paramount. The challenge is largely driven by integration of most innovative auto subsystems and their demand of being tightly packed into a lower volume, mass and relatively higher power consumptions compared to the older version. One of the examples is the thermal management in electric vehicle battery system. Electric Vehicles has been on the front burner as an aftermath of the recent announcement of the Government to make India an all-electric passenger vehicle market by 2030. The mirage of having electric vehicles on the roads is now transforming to a pleasant but perplexed reality as it comes with plethora of technical and feasibility challenges. According to current design the Lithium-ion batteries are the single most important component of an electric vehicle, comprising 40% of total production cost which is

Sahoo, Pranati

Battery Thermal Management Simulation - 1D+1D Electrochemical Battery and 3D Module Modeling on Vehicle System Level

2021-01-07574/6/2021

Approaching engineering limits for the thermal design of battery modules requires virtual prototyping and appropriate models with respect to physical depth and computational effort. A multi-scale and multi-domain model describes the electrochemical behavior of a single battery unit cell in 1D+1D at the level of intra-cell phenomena, and it applies a 3D thermal model at module level. Both models are connected within a common vehicle simulation platform. The models are discussed with special emphasis on battery degradation such as solid electrolyte interphase layer formation, decomposition and lithium plating. The performance of the electrochemical model is assessed by discharge cycles and repeated charge/discharge simulations. The thermal module model is compared to CFD reference data and studied with respect to its grid sensitivity. The temperature evolution of a module is simulated for enabled and disabled degradation equations revealing a very high impact of the degradation equations

Wurzenberger, Johann C., Jelovic, Mario, Šimundić, Mate, Mele, Igor, Katrasnik, Tomaz

NAWA aims for 5-minute EV charge

21AUTP03_023/1/2021

A new nano-based carbon electrode is key to reducing electric-vehicle charging time. A French nanomaterials company has developed a technology that it claims can significantly increase the storage efficiency of electric vehicle batteries. NAWA Technologies' Ultra-Fast Carbon Electrode (UFCE) is a key to bringing EV battery-charging time into parity with gasoline-refueling time, while improving battery life-cycle performance by a factor of up to five, according to company founder and CTO, Pascal Boulanger. In an interview with SAE's Automotive Engineering, Pascal Boulanger said the UFCE technology can help deliver 1,000-km (620-mi) operating range for mass-market EVs, with a time of five minutes for an 80% charge. “The uniqueness of the technology is its 3D structure and use of vertically aligned carbon nanotubes [VACNT],” he noted. Each nanotube is formed from a graphene sheet that is rolled in a cylindrical shape. The tubes have “the same aspect ratio [between diameter and length] as

Birch, Stuart

STATIC TESTING of EV components

20AUTP09_049/1/2020

Firing nails into your latest Li-ion battery pack is but one of many regimens in the comprehensive testing of new electric vehicles. The market for electric vehicles (EVs) continues to grow. To offset the immense weight of their batteries, a heightened focus has been put on lightweighting, which has brought many new materials and components into the global automotive supply chain. These components and assemblies, including polymer films used for Li-ion battery cell separators and the packs they ultimately form, require development and production quality testing to verify their mechanical properties. One of the methodologies, static mechanical testing, is commonly performed by universal testing machines operated within manufacturing and research labs. Put simply, universal testing machines are designed to hold a test specimen and subject it to tensile (pull) or compression (push) forces by moving the machine's crosshead up or down. Transducers, such as a load cell, capture valuable data

Caesar, Dan

Battery Management Systems for Rechargeable Lithium Batteries Used in Aerospace Standards

AIR6897 (Current)

8/20/2020

This AIR provides basic background information and guidance for design and development of BMS architectures to be used in RLBs for aerospace applications. This guidance applies to batteries that are considered “installed” equipment and are intended to be part of the original or supplemental type certification or military airframe qualification.

AE-7D Aircraft Energy Storage and Charging Committee

Portable Emergency Lighting Systems for Flight Crew Members

ARP1798B (Current)

7/14/2020

The purpose of this SAE Aerospace Recommended Practice (ARP) is to recommend general design and performance characteristics for hand-held portable, emergency lighting systems (note: the portable portion of this system that contains the lamp and reflector will be identified throughout the remainder of this document simply as a “flashlight”) intended for use by crew members of commercial aircraft during any emergency situation, within or outside of the aircraft cabin, where emergency lighting is required.

A-20C Interior Lighting

Portable Emergency Lighting Systems for Flight Crew Members

ARP1798B-TEST-REC (Historical)7/14/2020

A-20C Interior Lighting

Designing Battery Packs for Harsh Environment Mission-Critical Devices

TBMG-370946/1/2020

Designing Battery Packs for Harsh Environment Mission-Critical Devices

20AERP06_016/1/2020

Many portable military electronic devices are used in extreme environments and are designed to comply with the MIL-STD-810 environmental test specification. The device and battery pack need to survive high or cold temperatures, shock or vibration, or even submersion underwater. Typical devices include handheld radios, laptops and personal protection equipment. Battery packs in these devices serve a critical role, as in most cases, they are the sole source of power. The energy density in these packs is typically as high as possible, given the space available, to maximize device run times. This intensifies the need to control and protect the stored energy where a failure could result in catastrophic events such as thermal runaway. This article presents design considerations and techniques for designing and manufacturing a battery pack that operates in extreme temperatures, absorbs shock and vibration, and maintains a watertight seal.

Adhesives, Sealants, and Heat Transfer Materials in Battery Systems: A Primer on Materials, Applications, and End-Use Performance Requirements

J3178_202005 (Current)

5/5/2020

This SAE Information Report introduces key concepts and properties of adhesives, sealants, and HTMs and the roles they serve in present-day battery systems applications. The basic chemistry and properties of the three types of materials are summarized along with important health and environmental information. Relevant material dispense methodologies and equipment for material dispensing is reviewed. A series of representative battery applications examples employing adhesives, sealants, and HTMs is also provided with particular attention given to end-use performance.

Battery Systems Adhesives, Sealants and Heat Transfer Matl's