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High temperature materials in spacecraft propulsion devices and electrical power generation systems utilized because of their electronic work functions, thermoelectric properties and corrosion resistance to alkali metals
Despite their relatively low efficiency, thermoelectric generators are used in a limited number of industrial applications where they are preferred to other energy conversion devices because of their high reliability, low maintenance and long life, in particular when considering harsh environments.
A class of proposed thermionic cooling devices would incorporate precise arrays of metal nanowires as electron emitters. The proposed devices could be highly miniaturized, enabling removal of heat from locations, very close to electronic devices, that have previously been inaccessible for heat-removal purposes. The resulting enhancement of removal of heat would enable operation of the devices at higher power levels and higher clock speeds. Moreover, the mass, complexity, and bulk of electronic circuitry incorporating these highly miniaturized cooling devices could be considerably reduced, relative to otherwise equivalent circuitry cooled by conventional electromechanical, thermoelectric, and fluidic means. In thermionic cooling, one exploits the fact that because only the highest-energy electrons are thermionically emitted, collecting those electrons to prevent their return to the emitting electrode results in the net removal of heat from that electrode. Collection is effected by applying an appropriate positive bias potential to another electrode placed near the emitting electrode. The concept underlying the proposal is that the thermionic-emission current and, hence, the cooling effect attainable by use of an array of nanowires could be significantly greater than that attainable by use of a single emitting electrode or other electron- emitting surface. The wires in an array according to the proposal would protrude perpendicularly from a planar surface and their heights would be made uniform to within a sub-nanometer level of precision
Variable-temperature probe for electron spectroscopy requires no cryogenic liquids or resistance heating elements. Device consists of heat sink, probe tip, and nickel-plated copper body which resists oxidation and transfers heat efficiently between tip and heat sink.
A thermocouple which may be rolled as a tape until needed and a method of making it are described. Thermoelectrically different metals are applied to a strip of electrically nonconductive material in longitudinally overlapping relationship. Apertures may be provided along the tape in overlapping region at predetermined intervals. An adhesive material is applied to the side of the tape opposite the thermoelectric metals either before or after the thermoelectric metals are deposited. The tape may be cut or torn to form a thermocouple device which is ready for application to a body whose temperature is to be monitored or measured.
The most common methods to prepare semiconductors are based on use of melts or vapor phase. A tendency to use thin film structures in modern semiconducting devices brought a variety of technologies based on vapor phase deposition. The preparation of chemical compounds and solid solutions from a melt begins with melting the elemental constituents together. Melt technology and techniques are discussed.
It is well known that power generation efficiency improves when materials with appropriate properties are combined either in a cascaded or segmented fashion across a temperature gradient. Past methods for determining materials used in segmentation weremainly concerned with materials that have the highest figure of merit in the temperature range. However, the example of SiGe segmented with Bi2Te3 and/or various skutterudites shows a marked decline in device efficiency even though SiGe has the highest figure of merit in the temperature range. The origin of the incompatibility of SiGe with other thermoelectric materials leads to a general definition of compatibility and intrinsic efficiency. The compatibility factor derived as = (Jl+zr - 1) a~ is a function of only intrinsic material properties and temperature, which is represented by a ratio of current to conduction heat. For maximum efficiency the compatibility factor should not change with temperature both within a single material, and in the segmented leg as a whole. This leads to a measure of compatibility not only between segments, but also within a segment. General temperature trends show that materials are more self compatible at higher temperatures, and segmentation is more difficult across a larger -T. The compatibility factor can be used as a quantitative guide for deciding whether a material is better suited for segmentation orcascading. Analysis of compatibility factors and intrinsic efficiency for optimal segmentation are discussed, with intent to predict optimal material properties, temperature interfaces, and/or currentheat ratios.
A novel method to prepare an advanced thermoelectric material has hierarchical structures embedded with nanometer-sized voids which are key to enhancement of the thermoelectric performance. Solution-based thin film deposition technique enables preparation of stable film of thermoelectric material and void generator (voigen). A subsequent thermal process creates hierarchical nanovoid structure inside the thermoelectric material. Potential application areas of this advanced thermoelectric material with nanovoid structure are commercial applications (electronics cooling), medical and scientific applications (biological analysis device, medical imaging systems), telecommunications, and defense and military applications (night vision equipments).
Solid state energy harvesting using waste heat available in gas turbine engine, offers potential for power generation to meet growing power needs of aircraft. Thermoelectric material advances offer new opportunities. Weight-optimized integrated turbine engine structure incorporating energy conversion devices.
Overview: Solid state energy harvesting using waste heat available in gas turbine engine offers potential for power generation to meet growing power needs of aircraft; Thermoelectric material advances offer new opportunities; Weight-optimized integrated turbine engine structure incorporating energy conversion devices.
The Thermal Energy Conversion Technologies Group at the Jet Propulsion Laboratory has been pursuing the development of thermopiles capable of higher temperature operation in support of terrestrial and space sensing applications in extreme environments. The next-generation sensor technology would rely on filled skutterudite (SKD) compounds, the same materials currently being considered for use in the enhanced Multi-Mission Radioisotope Thermoelectric Generator (eMMRTG). We report on the design, development and fabrication of SKD-based prototype thermopile devices. The beginning-of-life (BOL) experimental and predicted performance of the SKD-based prototype thermopile in terms of electrical resistance, output voltage, current, power output and efficiency in the 423 to 723 K operating temperature range is reported and discussed.
Advanced thermoelectric microdevices integrated into thermal management packages and low power, electrical source systems are of interest for a variety of space and terrestrial applications. By shrinking the size of the thermoelements, or legs, of these devices, it becomes possible to handle much higher heat fluxes, as well as operate at much lower currents and higher voltages that are more compatible with electronic components. The miniaturization of state-of-the-art thermoelectric module technology based on Bi2Te3 alloys is limited due to mechanical and manufacturing constraints for both leg dimensions (100-200 gm thick minimum) and the number of legs (100-200 legs maximum). We are investigating the development of novel microdevices combining high thermal conductivity substrate materials such as diamond, thin film metallization and patterning technology, and electrochemical deposition of thick thermoelectric films. It is anticipated that thermoelectric microcoolers with thousands of thermocouples and capable of pumping more than 200 W/sq cm over a 30 to 60 K temperature difference can be fabricated. In this paper, we report on our progress in developing an electrochemical deposition process for obtaining 10-50 microns thick films of Bi2Te3 and its solid solutions. Results presented here indicate that good quality n-type Bi2Te3, n-type Bi2Te(2.95)Se(0.05) and p-type Bi(0.5)Sb(1.5)Te3 thick films can be deposited by this technique. Some details about the fabrication of the miniature thermoelements are also described.
The Voyager spacecraft is subject to radiation from external natural space, from radioisotope thermoelectric generators and heater units, and from the internal environment where penetrating electrons generate surface ionization effects in semiconductor devices. Methods for radiation hardening and tests for radiation sensitivity are described. Results of characterization testing and sample screening of over 200 semiconductor devices in a radiation environment are summarized.
The design of an unmanned Martian polar exploration system is presented. The system elements include subsystems for transportation of material from earth to Mars, study of the Martian north pole, power generation, and communications. Early next century, three Atlas 2AS launch vehicles will be used to insert three Earth-Mars transfer vehicles, or buses, into a low-energy transfer orbit. Capture at Mars will be accomplished by aerobraking into a circular orbit. Each bus contains four landers and a communications satellite. Six of the twelve total landers will be deployed at 60 deg intervals along 80 deg N, and the remaining six landers at 5 deg intervals along 30 deg E from 65 deg N to 90 deg N by a combination of retrorockets and parachutes. The three communications satellites will be deployed at altitudes of 500 km in circular polar orbits that are 120 deg out of phase. These placements maximize the polar coverage of the science and communications subsystems. Each lander contains scientific equipment, two microrovers, power supplies, communications equipment, and a science computer. The lander scientific equipment includes a microweather station, seismometer, thermal probe, x-ray spectrometer, camera, and sounding rockets. One rover, designed for short-range (less than 2 km) excursions from the lander, includes a mass spectrometer for mineral analysis, an auger/borescope system for depth profiling, a deployable thermal probe, and charge coupled device cameras for terrain visualization/navigation. The second rover, designed for longer-range (2-5 km) excursions from the lander, includes radar sounding/mapping equipment, a seismometer, and laser ranging devices. Power for all subsystems is supplied by a combination of solar cells, Ni-H batteries, and radioisotope thermoelectric generators. Communications are sequenced from rovers, sounding rockets, and remote sensors to the lander, then to the satellites, through the Deep Space Network to and from earth.
A new fabrication method for nanovoids-imbedded bismuth telluride (Bi--Te) material with low dimensional (quantum-dots, quantum-wires, or quantum-wells) structure was conceived during the development of advanced thermoelectric (TE) materials. Bismuth telluride is currently the best-known candidate material for solid-state TE cooling devices because it possesses the highest TE figure of merit at room temperature. The innovative process described here allows nanometer-scale voids to be incorporated in Bi--Te material. The final nanovoid structure such as void size, size distribution, void location, etc. can be also controlled under various process conditions.
The Thermal Energy Conversion Branch (5490) leads the way in designing, conducting, and implementing research for the newest thermal systems used in space applications at the NASA Glenn Research Center. Specifically some of the most advanced technologies developed in this branch can be broken down into four main areas: Dynamic Power Systems, Primary Solar Concentrators, Secondary Solar Concentrators, and Thermal Management. Work was performed in the Dynamic Power Systems area, specifically the Stirling Engine subdivision. Today, the main focus of the 5490 branch is free-piston Stirling cycle converters, Brayton cycle nuclear reactors, and heat rejection systems for long duration mission spacecraft. All space exploring devices need electricity to operate. In most space applications, heat energy from radioisotopes is converted to electrical power. The Radioisotope Thermoelectric Generator (RTG) already supplies electricity for missions such as the Cassini Spacecraft. The focus of today's Stirling research at GRC is aimed at creating an engine that can replace the RTG. The primary appeal of the Stirling engine is its high system efficiency. Because it is so efficient, the Stirling engine will significantly reduce the plutonium fuel mission requirements compared to the RTG. Stirling is also being considered for missions such as the lunar/Mars bases and rovers. This project has focused largely on Stirling Engines of all types, particularly the fluidyne liquid piston engine. The fluidyne was developed by Colin D. West. This engine uses the same concepts found in any type of Stirling engine, with the exception of missing mechanical components. All the working components are fluid. One goal was to develop and demonstrate a working Stirling Fluidyne Engine at the 2nd Annual International Energy Conversion Engineering Conference in Providence, Rhode Island.
Modular thermoelectric cells are easily packaged in various arrays to form power supplies and have desirable voltage and current output characteristics. The cells employ two pairs of thermoelectric elements, each pair being connected in parallel between two sets of aluminum plates. They can be used as solar energy conversion devices.
Future manned and unmanned space missions will require reliable, high efficiency energy conversion systems. For a manned Mars mission, power levels in the range of 10 to 100 kWe will be needed. The Alkali Metal Thermoelectric Converter (AMTEC) is a direct energy conversion technology with the potential to meet these needs. The AMTEC is a thermally regenerative electrochemical device that derives its operation from the sodium ion conducting properties of beta-alumina solid electrolyte (BASE). To date, an efficiency of 19%, area power density of 1 W/sq cm, and a lifetime of 10,000 hours at high temperature were demonstrated in laboratory devices. Systems studies show that projected AMTEC systems equal or surpass the performance of other static or dynamic systems in applications of 1 kWe-1 MWe. Thus, the laboratory experiments and applications studies conducted to date have shown that the AMTEC posseses great potential. In order to bring this technology to the stage where prototype units can be built and operated, several technical issues must be addressed. These include the need for long life, high power electrodes, minimization of radiative parasitic losses, and high temperature seals. In summary, the evidence shows that if AMTEC is developed, it can play a significant role in future space power applications.