Fatigue Life Modeling of Composite Bonded Joints in Rotorcraft Structures

Not Available We propose a thermal spray process to deposit thin-film cathodes and anodes on rugged substrates to replace the thick, fragile, pressed pellets currently used in thermal batteries. Plasma- spraying is an innovative alternative to slurry techniques to manufacture such thin-film electrodes. We have previous experience demonstrating that the plasma-spray approach works with lithiated-cathode materials and works at high temperature, two aspects of interest in this application. Specifically, we have plasma-sprayed: (1) Lithium-compatible cathode materials (LiCoO2) for batteries, and (2) Selective emitter materials (rare-earth oxides) which retain the correct crystal structure and operate at high temperature up to 1700 K. The plasma-spray process is readily transitioned to the production environment; our existing plasma-spray equipment is the same equipment as used in production facilities. We propose to deposit cathode and anode materials in Phase I and to characterize their morphologies to demonstrate that the thermal spray process is a feasible approach to manufacturing thin components for thermal batteries. We will also develop a preliminary battery design, estimate performance benefits, and estimate production costs. Optional activities include testing sample cells. In Phase II we will complete the battery design and build working prototypes.