New Areas of Automotive NDE: Li-ion Batteries and ...New Areas of Automotive NDE: Li-ion Batteries...
Transcript of New Areas of Automotive NDE: Li-ion Batteries and ...New Areas of Automotive NDE: Li-ion Batteries...
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New Areas of Automotive NDE: Li-ion Batteries and Composite Materials
Leonid C. Lev General Motors R&D March 1, 2012 Houston, TX
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Future of Automotive Transportation
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Future of Automotive Manufacturing
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Future of Automotive Powertrain Technology: Chevy Volt
“The 2011 Chevrolet Volt is in the vanguard of the auto industry’s shift from the petroleum-based model…to the electrified model. With its new Voltec propulsion system, GM…brings a unique approach...” [SAE, 2011]
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Voltec Powertrain
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The hart of Voltec powertrain: Li-ion Battery
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Voltec Battery Design
Battery Management System
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Automotive Li-ion Battery “Cell”
Courtesy MIT TechReview
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Battery Assembly: Stacking Operation
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Assembled Battery Pack
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Installation of Interconnects
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Ultrasonic Welding Is Used for Battery Assembly
Photo courtesy of EWI
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Voltec Battery Joints
Four parts (three cell tabs and a common bus) per joint, three interfaces, dissimilar metals: aluminum and copper. Each battery = 200 welds, multiple automated welding stations, high production rate. Each interface has to be good!
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Active and Passive Flash Thermography NDE Shearographic NDE with Vibration Excitation
Automated “pick test”; Good in finding concealed defects; can detect the extend of weld fused area
High-precision electrical resistance NDE: Tests functionality of the weld and its strength A large number of welds can be measured quickly (~0.2 sec per measurement) and conveniently with one fixture
Novel NDE Techniques Developed In-House
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Flash Thermography NDE
Copper Common Bus
Cell tabs
Energy Signal to the IR camera:
temperature T as a function of time t: T=f(t)
Energy (flash
light, etc.) IR
camera
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Thermal model
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.010
20
40
60
80
100
120
T
t
t0=5ms q=5E7 j/m2
Thickness: 1mm Material: Copper
Temperature
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.01-10
0
10
20
30
40
50
60
70
80
T
t
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How to detect the fused area
Spot SP1
Spot SP2
Spot SP3
Time, sec
Temperature, degC
The temperature rise is more rapid in the fused area.
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Results of differentiation with regard to time
dC
-1
0
1
2
0 .250 .500 .750 1 .250 .500 .750 2
dC
-1
0
1
0 .250 .500 .750 1 .250 .500 .750 2
dC
-1
0
1
0 .250 .500 .750 1 .250 .500 .750 2
-0.4dC
1.7dC
0
1SP01SP02SP03
AR01
Time, sec
Time, sec Time, sec
dT/dt
dT/dt
dT/dt
Post-processing: differentiating with respect to time in each point (pixel) to find total fused area.
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Weld strength correlates with the size of the “nugget” …unless the joint fails elsewhere
0.00
200.00
400.00
600.00
800.00
1000.00
1200.00
1400.00
1600.00
1800.00
2000.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00
Stre
ngth
of t
he ta
b in
shea
r, N
Area of all three welded nuggets, mm^2
Shear Strength v nugget size
Series1
Shear strength of nuggets
~28.2N/mm^2 = 28.2MPa
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What is a shearographic camera?
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Formation of a shearographic pattern
Non-sheared beams
Two superimposed images are formed: a sheared image(s) of the object and the superimposed image of the fringes containing
information about surface strains.
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Shearography-based NDE with vibration excitation
When vibration is applied to an assembly, a pattern of (elastic) strains forms around the weld
Pattern of strains ε (generally, a 3D field, becomes 2D on the surface)
A schematic of a spot weld, loaded with loads L
L
ε
x
ε
x
Image recognition is used to detect weld defects. FEM model is used to determine the size of the fused area from the strain pattern (“inverse problem”).
Size of the weld nugget
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Sample with three welds, illuminated by a laser
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Good weld. Excitation frequency is 9.3KHz
3 good welds.
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Defective weld. Excitation frequency is 2.5KHz
No weld nugget
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Defective weld. Excitation frequency is 5KHz
Partial weld
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High-precision electrical resistance NDE
1: −∝
=
=
RSThereforeALR
AS u
ρ
σ
Strength S
Resistance R
S~R-1
Electrical Resistance R and Strength S of a Weld: •area A •Resistivity ρ •Interface “length” L •Interface ultimate strength σu
Electrical current I
A
L
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The real weld is more complicated…
a1 c1 b1
a3 a2
b3 b2
Common bus
c2 c3
3 2
1
Electrical current I
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Correlation: Strength v Resistance
Strength testing of welded samples
S = 16.766R-0.289
0
100
200
300
400
500
600
700
800
0.0E+00 1.0E-05 2.0E-05 3.0E-05 4.0E-05
Stre
ngth
, N
Resistance, Ohms
Shear strength v El. resist., Al welds
Tearing through the weld
S = 0.2334R-0.169
0
0.5
1
1.5
2
2.5
3
3.5
4
0.0E+00 2.0E-06 4.0E-06 6.0E-06 8.0E-06 1.0E-05 1.2E-05 1.4E-05
Stre
ngth
, S3U
, kN
Resistance, R3u, ohms
Strength S v El. Resist., Cu welds
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Method Advantages Disadvantages
Thermography The only method to measure the size of the fused area of multi-ply welds Non-contact
Requires high-power energy input needs protection on production floor.
Shearography Measures the true extent of a fused area; may uncover concealed defects
Requires: •high-resolution shearographic cameras •sophisticated image analysis and software
Precision Electrical Resistance NDE
Measures the main functional parameter of the weld. Can monitor welds throughout the battery life.
Requires contact fixture; needs a reliable contact with joints
Comparison of the developed NDE methods
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Traditional NDE areas: NDE of safety-critical lightweight automotive components NDE of welding and joining NDE of adhesive joints NDE of spot welds (in selective applications)
New NDE applications: NDE of Li-ion batteries and cells, in production and throughout the life Inexpensive NDE methods for composite materials NDE of joints of dissimilar materials, composites Life monitoring of composite structures.
Production process control
Automotive NDE Needs
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THANK YOU FOR YOUR ATTENTION!
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BACKUP SLIDES
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Traditional NDE areas: NDE of safety-critical lightweight automotive components NDE of welding and joining, particular of dissimilar materials and composites NDE of adhesive joints
New NDE applications: NDE of Li-ion batteries and cells, in production and throughout the life Inexpensive NDE methods for composite materials
Infrared, shearography, vibro-thermography, x-ray, CT, ultrasonic, eddy current; combination, new NDE techniques
Life monitoring of composite structures. Fluorescent dyes/penetrants Electrical methods
Process control in production
Automotive NDE Needs
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High-precision electrical resistance NDE
I
I
I The electrical resistance of the weld depends on how the current is applied.
1: −∝
=
=
RSThereforeALR
AS u
ρ
σ
Strength
R
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Explanation of lower power
S = a*R-0.351
S = R-1
S=const
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0 10 20 30 40
combination of inverse and const
Inverse dependence
A constant
Power (combination of inverse and const)
Power (Inverse dependence)
Expon. (A constant)
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The signal can be digitized (made 0 or 1) and counted
Done with Matlab Each pixel is a square with dimensions (approximately):
100µ X 100µ, with area A=10-2 mm2
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The entire module can fit in the field of view of IR camera… …but heat can be applied one joint at a time