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The Swedish Armed Forces are investigating high-risk applications where lithium-ion batteries (LIB) can replace traditional lead-acid batteries. Understanding the potential safety risks and evaluating a battery's instability is crucial for military applications. This report aimed to identify critical safety parameters (temperature, potential, and impedance) in commercial batteries with NMC and LFP electrode chemistries, and to investigate how surrounding cells are affected when a battery suffers from thermal runaway (TR) in a battery module developed by FOI. Accelerated rate calorimetry (ARC) experiments on NMC-based Samsung SDI INR21700-40T and INR21700-50E and LFP-based A123 Systems ANR26650m1-B batteries were conducted to identify critical onset conditions of TR. ARC experiments were conducted with continuous electrochemical impedance spectroscopy (EIS) measurements to correlate thermal behavior with electrochemical changes in the cell impedance and voltage. The NMC-based batteries showed a distinct endothermic reaction between 116 °C and 121 °C, an onset temperature of exothermic self-heating at around 120 °C, which progressed to an explosive decomposition at about 170 °C and resulted in an adiabatic temperature rise of 250 °C to 290 °C. A significant increase in the cell’s impedance at around 100 °C indicated that the current interrupt device (CID) was triggered due to gas formation and critical pressure build-up within the cell. The LFP-based battery demonstrated improved thermal stability during ARC measurements and did not suffer from TR when heated to 300 °C. Thermal runaway propagation experiments were conducted in a battery module developed by FOI. The identified onset temperatures and electrochemical markers were then used to evaluate the stability of the module cells. Cell temperature increases between 16 °C and 48 °C was observed in cells directly adjacent to the trigger cell. Cells further from the trigger cell experienced uniform temperature increases of between 8 °C and 30 °C. EIS measurements of the module cells revealed no significant changes in their impedance spectra. The insulating polymer wrap around each cell was found to be crucial in preventing TR propagation. TR propagated from cell-to-cell in the module when the insulating wraps were removed, and cells were in direct contact with the thermally conductive heat sink. / Försvarsmakten undersöker högriskapplikationer där litiumjonbatterier kan ersätta traditionella blysyrabatterier. Att förstå säkerhetsrisker och utvärdera ett batteris instabilitet är särskilt viktigt för militära tillämpningar. Denna rapport syftar till att identifiera kritiska säkerhetsparametrar (temperatur, spänning och impedans) för kommersiella batterier med NMC- och LFP-elektrodkemier samt undersöka hur omkringliggande celler påverkas när ett batteri termiskt rusar (TR) i en batterimodul utvecklad av FOI. ARC-experiment genomfördes på NMC-baserad Samsung SDI INR21700-40T och INR21700-50E och A123 Systems ANR26650m1-B batterier för att karakterisera förloppet av termisk rusning (TR). ARC-experiment utfördes med kontinuerliga elektrokemisk impedansspektroskopi (EIS) för att korrelera termiskt beteende med elektrokemiska förändringar i cellimpedansen och spänningen. Det NMC-baserade batterierna uppvisade en tydlig endotermisk reaktion mellan 116 °C och 121 °C, exotermiska reaktioner påbörjades vid 120 °C och ledde till explosiv termisk rusning vid cirka 170 °C, vilket gav upphov till en adiabatisk temperaturökning på 250 °C till 290 °C. En signifikant ökning av cellens impedans vid cirka 100 °C indikerade att den inre säkerhetsventilen utlöstes på grund av gasbildning och kritisk tryckuppbyggnad i cellen. Det LFP-baserade batteriet visade förbättrad termisk stabilitet under ARC-mätningar och drabbades inte av TR vid uppvärmning till 300 °C. Termiska rusningsförsök genomfördes på en batterimodul utvecklad av FOI. De identifierade starttemperaturerna och elektrokemiska markörerna användes för att utvärdera modulcellernas stabilitet. Celltemperaturökningar mellan 16 °C och 48 °C observerades i celler direkt intill triggcellen. Celler längre från triggcellen upplevde likformiga temperaturökningar mellan 8 °C och 30 °C. EIS-mätningar av modulcellerna avslöjade inga signifikanta förändringar i deras impedansspektra. Det isolerande polymeromslaget runt varje cell var avgörande för att förhindra propagering av termisk rusning i modulen. Termisk rusning propagerade från cell till cell i modulen när de isolerande omslagen togs bort och cellerna var i direkt kontakt med den värmeledande kylflänsen.

Environmental stresses arising from temperature and moisture changes, and/or other aggressive fluid ingressions can degrade the mechanical properties of the adhesive, as well as the integrity of an adhesive interface with a substrate. Therefore such disruptions can significantly reduce the lifetime and durability of an adhesive joint.1-4 In this research, the durability of certain epoxy adhesive joints and coatings were characterized using a fracture mechanics approach and also by constant frequency impedance spectroscopy. The shaft-loaded blister test (SLBT) was utilized to measure the strain energy release rate (G) or adhesive fracture energy of a pressure sensitive adhesive tape. In this study, support for the value of the SLBT fracture mechanics approach was obtained. The SLBT was then used to investigate the effects of relative humidity on a model epoxy bonded to silicon oxide. Lastly, the effects of water and temperature on the adhesion of a commercial filled epoxy bonded to silicon oxide was characterized and interpreted. A novel impedance sensor for investigating adhesion was developed in a collaborative effort between Virginia Tech and Hewlett-Packard. Utilizing the technique of constant frequency impedance spectroscopy, the distribution and transport of fluids at the interface of adhesive joints was measured. A broad spectrum of adhesives was tested. In addition, the effects of hygroscopic cycling on the durability of adhesive coatings were measured for the commercial filled epoxy using the device. Lastly, recommended modifications of the experimental set-up with the new sensor are proposed to improve the technique. / Ph. D.

På senare år har efterfrågan på stålmaterial av låg vikt ökat, speciellt inom transportsektorn. Genom att addera Al till stål sänks densiteten vilket gör att FeAl-legeringar är ett lovande material för fordonskonstruktion. Vätskekorrosionsegenskaper undersöktes av 3D – printade FeAl prover som innehöll 0 – 10 vikt% Al och 0,1 vikt% Zr för att bestämma hur korrosionsegenskaperna förändrades med avseende på Al – innehållet. Korrosionsresistansen var i stor utsträckning beroende av huruvida en passiv film av Al2O3 bildades på ytan eller ej. Korrosionshastigheten bestämdes genom EIS – och PDP – analyser utförda i 3,5 vikt% NaCl-lösning samt genom viktförlusttester i 1 M HCl respektive 0,5 M H2SO4. Vidare karaktäriserades proverna genom XRF, XRD, EDS, SEM och optisk mikroskopi vilket bland annat visade på att samtliga prover var enfassystem samt att den kemiska sammansättningen var enligt förväntan. Vidare indikerade optisk mikroskopi och SEM att ett högre Al – innehåll resulterar i att proverna blir mer porösa. Elektrokemiska tester antyder att ett Al – innehåll om 10 vikt% förbättrade korrosionsresistansen. Detta antyder möjligen, men kan inte definitivt fastslås från de utförda experimenten, att det krävs 10 vikt% Al för att en passiv film som täcker hela materialytan ska bildas. Korrosionshastigheten var 7 – 10 gånger högre vid viktförlusttest jämfört med elektrokemiska test. Detta förklaras genom att den skyddande passiva filmen bröts ned under de sura förhållanden som viktförlusttesten utfördes i medan den passiva Al2O3 filmen kunde bestå i de pH – neutrala förhållanden som elektrokemiska test utfördes vid. Detta speglar att bildandet och stabiliteten av Al2O3-filmen är vitalt för att sänka korrosionshastigheten. / In recent years the demand for lightweight ferritic steels has increased, particularly for transport applications. The addition of Al lowers the density, hence making FeAl alloys promising materials for such constructions. Aqueous corrosion properties of 3D – printed FeAl samples ranging from 0 – 10 wt% Al and containing 0.1 wt% Zr were investigated to determine how the Al content affects the corrosion resistance. The corrosion rate was found to greatly depend on the formation and stability of a protective passive film of Al2O3 forming on the material surface. A corrosion rate was obtained via EIS and PDP in 3.5 wt% NaCl as well as via weight loss testing in 1 M HCl and 0.5 M H2SO4. Additionally, XRF, XRD, EDS, SEM and optical microscopy tests were carried out to characterize the samples. XRF and EDS confirmed that the elemental composition of the samples was as expected and XRD indicated that all samples were single phase systems. Furthermore, optical microscopy and SEM indicated that higher Al content makes the samples more porous. Electrochemical testing indicated that addition of 10 wt% Al greatly improves the corrosion properties suggesting that it may require 10 wt% Al to form a passive film that covers the whole surface, although this cannot be said for certain from these experiments. Moreover, the corrosion rate was 7 – 70 times lower during electrochemical testing compared to weight loss testing, in which the passive film breaks down due to the acidic conditions. This emphasizes that the stability of the Al2O3 film is vital for slowing down the corrosion rate of FeAl alloys.

The environmentally unsafe by-products (CO2, H2S, NOx and SO2 for example) of using carbon-based fuels for energy generation have paved the way for research on cleaner, renewable and possibly cheaper alternative energy production methods. Hydrogen gas, which is considered as an energy carrier, can be applied in a fuel cell setup for the production of electrical energy. Although various methods of hydrogen production are available, sulphur-based thermochemical processes (such as the Hybrid Sulfur Process (HyS)) are favoured as alternative options for large scale application. The SO2 electrolyser is applied in producing H2 gas and H2SO4 by electrochemically converting SO2 gas and water. This study focused firstly on the evaluation of the performance of the SO2 electrolyser for the production of hydrogen and sulphuric acid, using commercially available PFSA (perfluorosulfonic acid) (Nafion®) as benchmark by evaluating i) various operating parameters (such as cell temperature and membrane thickness), ii) the influence of MEA (membrane electrode assembly) manufacturing parameters (hot pressing time and pressure) and iii) the effect of H2S as a contaminant. Subsequently, the suitability of novel PBI polyaromatic blend membranes was evaluated for application in an SO2 electrolyser. The parametric study revealed that, depending on the desired operating voltage and acid concentration, the optimisation of the operating conditions was critical. An increased cell temperature promoted both cell voltage and acid concentration while the use of thin membranes resulted in a reduced voltage and acid concentration. While an increased catalyst loading resulted in increased cell efficiency, such increase would result in an increase in manufacturing costs. Using electrochemical impedance spectroscopy at the optimised operating conditions, the MEA manufacturing process was optimised with respect to hot press pressure and time, while the effect of selected operating conditions was used to evaluate the charge transfer resistance, ohmic resistance and mass transport limitations. Results showed that the optimal hot pressing conditions were 125 kg.cm-2 and 50 kg.cm-2 for 5 minutes when using 25 and 10 cm2 active areas, respectively. The charge transfer resistance and mass transport were mostly influenced by the hot pressing procedure, while the ohmic resistance varied most with temperature. Applying the SO2 electrolyser in an alternative environment to the HyS thermochemical cycle, the effect of H2S on the SO2 electrolyser anode was investigated for the possible use of SO2 electrolysis to remove SO2 from mining off-gas which could contain H2S. Polarisation curves, EIS and CO stripping were used to evaluate the transient voltage response of various H2S levels (ppm) on cell efficiency. EIS confirmed that the charge transfer resistance increased as the H2S competed with the SO2 for active catalyst sites. Mass transport limitations were observed at high H2S levels (80 ppm) while the ECSA (electrochemical surface area obtained by CO stripping) showed a significant reduction of active catalyst sites due to the presence of H2S. Pure SO2 reduced the effective active area by 89% (which is desired in this case) while the presence of 80 ppm H2S reduced the active catalyst area to 85%. The suitability of PBI-based blend membranes in the SO2 electrolyser was evaluated by using chemical stability tests and electrochemical MEA characterisation. F6PBI was used as the PBI-containing base excess polymer which was blended with either partially fluorinated aromatic polyether (sFS001), poly(2,6-dimethylbromide-1,4-phenylene oxide (PPOBr) or poly(tetrafluorostyrene-4-phosphonic acid) (PWN) in various ratios. Some of the blend membranes also contained a cross-linking agent which was specifically added in an attempt to reduce swelling and promote cross-linking within the polymer matrix. The chemical stability of the blended membranes was confirmed by using weight and swelling changes, TGA-FTIR and TGA-MS. All membranes tested showed low to no chemical degradation when exposed to 80 wt% H2SO4 at 80°C for 120 h. Once the MEA doping procedure had been optimised, electrochemical characterisation of the PBI MEAs, including polarisation curves, voltage stepping and long term operation (> 24 h) was used to evaluate the MEAs. Although performance degradation was observed for the PBI membranes during voltage stepping, it was shown that this characterisation technique could be applied with relative ease, producing valuable insights into MEA stability. Since it is expected that the SO2 electrolyser will be operated under static conditions (cell temperature, pressure and current density) in an industrial setting (HyS cycle or for SO2 removal), a long term study was included. Operating the SO2 electrolyser under constant current density of 0.1 A cm-2 confirmed that PBI-based polyaromatic membranes were suitable, if not preferred, for the SO2 environment, showing stable performance for 170 hours. This work evaluated the performance of commercial materials while further adding insights into both characterisation techniques for chemical stability of polymer materials and electrochemical methods for MEA evaluation to current published literature. In addition to the characterisation techniques this study also provides ample support for the use of PBI-based materials in the SO2 electrolyser. / PhD (Chemistry), North-West University, Potchefstroom Campus, 2015

The environmentally unsafe by-products (CO2, H2S, NOx and SO2 for example) of using carbon-based fuels for energy generation have paved the way for research on cleaner, renewable and possibly cheaper alternative energy production methods. Hydrogen gas, which is considered as an energy carrier, can be applied in a fuel cell setup for the production of electrical energy. Although various methods of hydrogen production are available, sulphur-based thermochemical processes (such as the Hybrid Sulfur Process (HyS)) are favoured as alternative options for large scale application. The SO2 electrolyser is applied in producing H2 gas and H2SO4 by electrochemically converting SO2 gas and water. This study focused firstly on the evaluation of the performance of the SO2 electrolyser for the production of hydrogen and sulphuric acid, using commercially available PFSA (perfluorosulfonic acid) (Nafion®) as benchmark by evaluating i) various operating parameters (such as cell temperature and membrane thickness), ii) the influence of MEA (membrane electrode assembly) manufacturing parameters (hot pressing time and pressure) and iii) the effect of H2S as a contaminant. Subsequently, the suitability of novel PBI polyaromatic blend membranes was evaluated for application in an SO2 electrolyser. The parametric study revealed that, depending on the desired operating voltage and acid concentration, the optimisation of the operating conditions was critical. An increased cell temperature promoted both cell voltage and acid concentration while the use of thin membranes resulted in a reduced voltage and acid concentration. While an increased catalyst loading resulted in increased cell efficiency, such increase would result in an increase in manufacturing costs. Using electrochemical impedance spectroscopy at the optimised operating conditions, the MEA manufacturing process was optimised with respect to hot press pressure and time, while the effect of selected operating conditions was used to evaluate the charge transfer resistance, ohmic resistance and mass transport limitations. Results showed that the optimal hot pressing conditions were 125 kg.cm-2 and 50 kg.cm-2 for 5 minutes when using 25 and 10 cm2 active areas, respectively. The charge transfer resistance and mass transport were mostly influenced by the hot pressing procedure, while the ohmic resistance varied most with temperature. Applying the SO2 electrolyser in an alternative environment to the HyS thermochemical cycle, the effect of H2S on the SO2 electrolyser anode was investigated for the possible use of SO2 electrolysis to remove SO2 from mining off-gas which could contain H2S. Polarisation curves, EIS and CO stripping were used to evaluate the transient voltage response of various H2S levels (ppm) on cell efficiency. EIS confirmed that the charge transfer resistance increased as the H2S competed with the SO2 for active catalyst sites. Mass transport limitations were observed at high H2S levels (80 ppm) while the ECSA (electrochemical surface area obtained by CO stripping) showed a significant reduction of active catalyst sites due to the presence of H2S. Pure SO2 reduced the effective active area by 89% (which is desired in this case) while the presence of 80 ppm H2S reduced the active catalyst area to 85%. The suitability of PBI-based blend membranes in the SO2 electrolyser was evaluated by using chemical stability tests and electrochemical MEA characterisation. F6PBI was used as the PBI-containing base excess polymer which was blended with either partially fluorinated aromatic polyether (sFS001), poly(2,6-dimethylbromide-1,4-phenylene oxide (PPOBr) or poly(tetrafluorostyrene-4-phosphonic acid) (PWN) in various ratios. Some of the blend membranes also contained a cross-linking agent which was specifically added in an attempt to reduce swelling and promote cross-linking within the polymer matrix. The chemical stability of the blended membranes was confirmed by using weight and swelling changes, TGA-FTIR and TGA-MS. All membranes tested showed low to no chemical degradation when exposed to 80 wt% H2SO4 at 80°C for 120 h. Once the MEA doping procedure had been optimised, electrochemical characterisation of the PBI MEAs, including polarisation curves, voltage stepping and long term operation (> 24 h) was used to evaluate the MEAs. Although performance degradation was observed for the PBI membranes during voltage stepping, it was shown that this characterisation technique could be applied with relative ease, producing valuable insights into MEA stability. Since it is expected that the SO2 electrolyser will be operated under static conditions (cell temperature, pressure and current density) in an industrial setting (HyS cycle or for SO2 removal), a long term study was included. Operating the SO2 electrolyser under constant current density of 0.1 A cm-2 confirmed that PBI-based polyaromatic membranes were suitable, if not preferred, for the SO2 environment, showing stable performance for 170 hours. This work evaluated the performance of commercial materials while further adding insights into both characterisation techniques for chemical stability of polymer materials and electrochemical methods for MEA evaluation to current published literature. In addition to the characterisation techniques this study also provides ample support for the use of PBI-based materials in the SO2 electrolyser. / PhD (Chemistry), North-West University, Potchefstroom Campus, 2015

Ion sensing represents a grand research challenge. It finds a vast variety of applications in, e.g., gas sensing for domestic gases and ion detection in electrolytes for chemical-biological-medical monitoring. Semiconductor genome sequencing exemplifies a revolutionary application of the latter. For such sensing applications, the signal mostly spans in the low frequency regime. Therefore, low-frequency noise (LFN) present in the same frequency domain places a limit on the minimum detectable variation of the sensing signal and constitutes a major research and development objective of ion sensing devices. This thesis focuses on understanding LFN in ion sensing based on both experimental and theoretical studies. The thesis starts with demonstrating a novel device concept, i.e., ion-gated bipolar amplifier (IGBA), aiming at boosting the signal for mitigating the interference by external noise. An IGBA device consists of a modified ion-sensitive field-effect transistors (ISFET) intimately integrated with a bipolar junction transistor as the internal current amplifier with an achieved internal amplification of 70. The efficacy of IGBA in suppressing the external interference is clearly demonstrated by comparing its noise performance to that of the ISFET counterpart. Among the various noise sources of an ISFET, the solid/liquid interfacial noise is poorly studied. A differential microelectrode cell is developed for characterizing this noise component by employing potentiometry and electrochemical impedance spectroscopy. With the cell, the measured noise of the TiN/electrolyte interface is found to be of thermal nature. The interfacial noise is further found to be comparable or larger than that of the state-of-the-art MOSFETs. Therefore, its influence cannot be overlooked for design of future ion sensors. To understand the solid/liquid interfacial noise, an electrochemical impedance model is developed based on the dynamic site-binding reactions of surface hydrogen ions with surface OH groups. The model incorporates both thermodynamic and kinetic properties of the binding reactions. By considering the distributed nature of the reaction energy barriers, the model can interpret the interfacial impedance with a constant-phase-element behavior. Since the model directly correlates the interfacial noise to the properties of the sensing surface, the dependencies of noise on the reaction rate constants and binding site density are systematically investigated.