Finite element analysis study on the thermomechanical stability of thermal compression bonding (TCB) joints in tubular sodium sulfur cells

A typical large capacity sodium sulfur (NaS) battery is operated at 300-350 °C with 20-50 °C thermal fluctuations during its charging and discharging. In addition, for maintenance purposes, the cell experiences larger temperature changes down to the intermediate or room temperatures. Such temperature changes can cause mechanical failure of heterogeneous joints such as thermal compression bonding (TCB) joints, which is one of the most critical issues in developing NaS batteries. The present study seeks to build a computational finite element analysis (FEA) model to predict the thermomechanical responses of NaS batteries to the attack induced by the temperature changes. Specifically, the thermomechanical stress accumulation at TCB joints of a tubular cell has been explored during its booting-and-shutdown cycles. Static temperature profiles and simplified friction conditions in the cathode wall were assumed for the model. Using the developed model, the stress components that dominantly contribute the stress accumulation at the joint were identified, and the effects of TCB geometries and container material types on the thermal stress accumulation at the TCB joints were carefully examined. It turns out that the stress accumulation at the bonding interface would be critical for the failure at the TCB joints.