Testing that Reaches the World

Battery Technologies for Military Applications

There is a constant demand for technology development for batteries that are used in military applications.  The operating environments and field requirements typically foster new generations of battery technologies that weigh less and are more powerful than traditional lead-acid batteries.  These technology advances offer more advantages to military forces.

The US Department of Defense (DOD) Industrial Base Policy includes a strategy to ensure our Warfighters have the lithium-ion powered capabilities vital to achieving the objectives in the National Defense Strategy, including unmanned systems, directed energy capabilities, tactical vehicle electrification, dismounted warfighter communications, and distributed operations.

Laboratory tested and field-proven batteries deliver exceptional reliability and performance for military applications, from infantry communications, base camps and weapon systems to torpedoes, UAVs/UUVs, naval ships, aircraft and military vehicles.

Rugged and durable batteries are necessary to power electronic devices that soldiers carry to communicate, move, and even shoot while on a mission. It is not uncommon for a soldier to carry up to 20 pounds of batteries.  There are many different types of chemistries for batteries in the market but depending on the application, one type of chemistry can work better than the other:

 Primary vs. Secondary Batteries - The US military classifies batteries as either primary or secondary.

Attributes of Primary Batteries for Military Applications include:

• Non-rechargeable batteries that are used until depleted and then disposed of are classified as primary.
• High energy density since there are no design compromises necessary to accommodate recharging.
• Long shelf life (e.g., 5–10 years) designed to have very low self-discharge rates.
• Work within a wide temperature range, are self-contained, and do not depend on external chargers.
• There is a limited production base for them; they can be hazardous if mishandled and their disposal is regulated.
• Cost can continually increase as they need to replace after one complete discharge.

Rechargeable batteries are termed Secondary Batteries in the military.

• Higher energy density, higher capacity, and longer cycle life than primary batteries.
• More cost-effective and less dependent on a supply system than primary batteries because of their multiple-use capability.
• Low internal resistance, meaning they can produce high current on demand.
• Reliant on external charging devices
• Lifecycle is affected by external factors such as cycling, storage temperature, and state of charge
• Shelf life is limited by a higher self-discharge rate than primary batteries.
• The most common rechargeable batteries used in military applications come in three chemistries:
  • Nickel-Cadmium (NiCd),
  • Nickel-Metal Hydride (NiMH),
  • Lithium-Ion (Li-ion), Lithium-Iron Phosphate (LFP), and Lithium-polymer (Li-poly).

Battery Testing for the Military and Defense Industry

Clark Testing is dedicated to ensuring the performance, reliability, and safety of batteries to meet US military standards which are the benchmark quality standards for all industries. Batteries that meet US military specification ensures high standard products for military applications because they are reliable, safe, efficient and can hold large amount of energy.  Testing applications for batteries and battery packs for US military include:

• Load Testing: Simulates a full load to measure the battery’s performance under actual operating conditions.
• Voltage Testing: Measures the voltage levels to identify weak or failing cells.
• Impedance Testing: Assesses internal resistance to predict battery life and potential failures.
• Charge-Discharge Testing: Batteries undergo repeated charge-discharge cycle test to determine the number of cycles the battery can endure while maintaining specified performance levels.
• Capacity Testing: Batteries are tested to determine their actual capacity compared to their rated capacity ensuring that the batteries meet the required energy storage specifications.
• Short Circuit Testing: Batteries are subjected to short circuit conditions to evaluate their safety features and the ability to withstand internal faults without prompting failures.
• Dielectric Testing:  Dielectric testing known as high potential test, hipot test, or insulation test applies a high level of voltage to the insulation barrier and measure the reaction.
• Isolation Testing:  Isolation testing ensures batteries are free from unwanted electrical connections that could lead to short circuits particularly in high-voltage applications.
• Overcharge Testing:  Overcharge testing is vital, particularly for Lithium-Ion batteries, for ensuring the safe use in consumer electronics, electric vehicles, eMobility, industrial, military and other applications.
• Seismic Testing: Simulates the operating environment ensuring the battery generator, battery back-up or UPS system will operate despite the effects of an earthquake.
• Vibration Testing: Batteries are subjected to a vibration profile emulating the vibration cycle in the field of operation.
• Mechanical Shock Testing: Batteries are subjected to mechanical shocks to verify the structural integrity of the battery housing and its components.
• Destructive/Abuse Testing:  Batteries are subjected to thermal runaway, drop test, penetration test and crush test to assess how batteries react to harsh conditions
• Electromagnetic Compatibility (EMC/EMI) Testing: Batteries are tested for electromagnetic emissions and interference to ensure they do not interfere with other electrical and electronic systems.
• Thermal Cycling: Batteries undergo heating and cooling cycles simulating the thermal stress determining the reaction to standard and critical operating conditions.
• Material & Chemical Analysis:  Clark provides a complete profile of the elemental analysis and chemical properties of the base raw materials and battery cell.

Our team of experienced engineers utilizes calibrated instrumentation with unparalleled expertise to conduct a this comprehensive range of tests on space batteries. From vacuum chamber testing to radiation exposure simulations, our test plans are meticulously crafted to meet the extreme conditions encountered in space. Whether you're developing batteries for satellite propulsion systems, rovers, or deep space missions, our testing services provide invaluable insights to optimize your space battery solutions for maximum efficiency and longevity in the harsh environment of outer space.