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Title: National Center of Excellence for Energy Storage Technology 168.10

This report documents the performance of the Ohio State University (OSU) and Edison Welding Institute (EWI) in the period from 10/1/2010 to 12/31/2012. The objective of the project is to establish a Center of Excellence that leverages the strengths of the partners to establish a unique capability to develop and transfer energy storage industries to establish a unique capability in the development and transfer of energy storage system technology through a fundamental understanding of battery electrical and thermal performance, damage and aging mechanisms, and through the development of reliable, high-speed processes for joining substrates in battery cell, module and pack assemblies with low manufacturing variability. During this period, the OSU activity focused on procuring the equipment, materials and supplies necessary to conduct the experiments planned in the statement of project objectives. In detail, multiple laboratory setups were developed to enable for characterizing the open-circuit potential of cathode and anode materials for Li-ion batteries, perform experiments on calorimetry, and finally built multiple cell and module battery cyclers to be able to perform aging campaign on a wide variety of automotive grade battery cells and small modules. This suite of equipment feeds directly into the development, calibration of battery models ranging frommore » first principle electrochemical models to electro-thermal equivalent circuit models suitable for use in control and xEV vehicle simulations. In addition, it allows to develop and calibrate ‘aging’ models for Li-ion batteries that enable the development of diagnostics and prognostics tools to characterize and predict battery degradation from automotive usage under a wide array of environmental and usage scenarios. The objective of the EWI work scope is to develop improved processes for making metal-tometal joints in advanced battery cells and packs. It will focus on developing generic techniques for making functional (electrically conductive and mechanically robust) metal-to-metal joints between thin substrates. Joints with multiple layers and bimetallic constituents will be investigated. During the current period of performance, EWI has defined the test matrix to evaluate the application of different welding technologies (laser welding, ultrasonic welding, resistance welding) to specific components of battery cells and modules, such as foils-to-tabs, tabs-to-tabs, and tabs-to-bus bars. The test matrix also includes a range of substrates (aluminum 1145 and 1100, copper 110 and nickel 200 as substrates). Furthermore, a set of procedures was defined to perform mechanical and electrical testing of the samples, including metallography, and non-destructive evaluations. Both on the OSU and EWI, this project enabled to leverage very significant industrial collaborations with a wide array of companies ranging from battery manufacturers and pack integrator all the ways to Tier 1 automotive suppliers and OEMs during the period of exercise of the project, and in the future for years to come.« less
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Resource Type:
Technical Report
Research Org:
The Ohio State University
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Country of Publication:
United States