title: Low-hazard metallography of moisture-sensitive electrochemical cells.
abstract: A low-hazard approach is presented to prepare metallographic cross-sections of moisture-sensitive battery components. The approach is tailored for evaluation of thermal (molten salt) batteries composed of thin pressed-powder pellets, but has general applicability to other battery electrochemistries. Solution-cast polystyrene is used to encapsulate cells before embedding in epoxy. Nonaqueous grinding and polishing are performed in an industrial dry room to increase throughput. Lapping oil is used as a lubricant throughout grinding. Hexane is used as the solvent throughout processing; occupational exposure levels are well below the limits. Light optical and scanning electron microscopy on cross-sections are used to analyse a thermal battery cell. Spatially resolved X-ray diffraction on oblique angle cut cells complement the metallographic analysis.
authors.affiliation: Power Sources Technology Group, Sandia National Laboratories, USA. dewesol@sandia.gov
authors.forename: D E
authors.initials: DE
authors.lastname: Wesolowski
authors.forename: M A
authors.initials: MA
authors.lastname: Rodriguez
authors.forename: B B
authors.initials: BB
authors.lastname: McKenzie
authors.forename: H W
authors.initials: HW
authors.lastname: Papenguth
mesh_terms: D003035:Cobalt; D004563:Electrochemistry / Q000295:instrumentation*; D004566:Electrodes; D004853:Epoxy Resins; D006586:Hexanes; D008094:Lithium / Q000737:chemistry; D008853:Microscopy / Q000379:methods*; D008855:Microscopy, Electron, Scanning; D016273:Occupational Exposure / Q000517:prevention & control*; D011137:Polystyrenes; D012825:Silicon; D014867:Water; D014961:X-Ray Diffraction / Q000379:methods*
chemical_list: D004853:Epoxy Resins; D006586:Hexanes; D011137:Polystyrenes; D014867:Water; D003035:Cobalt; D008094:Lithium; C027875:cobaltous sulfide; D012825:Silicon