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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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The present state-of-the-art is described for the development of solar power generators in far out synchronous orbit for power generation. Concepts of geosynchronous solar power satellites are discussed including photovoltaic arrays for power satellites, solar-thermal power satellites, and power transmission to earth.
Photovoltaic arrays that convert solar energy into electrical energy can become a cost effective bulk energy generation alternative, provided that an adequate supply of low cost materials is available. One of the key requirements for economic photovoltaic cells is reasonably priced silicon. At present, the photovoltaic industry is dependent upon polycrystalline silicon refined by the Siemens process primarily for integrated circuits, power devices, and discrete semiconductor devices. This dependency is expected to continue until the DOE sponsored low cost silicon refining technology developments have matured to the point where they are in commercial use. The photovoltaic industry can then develop its own source of supply. Silicon material availability and market pricing projections through 1988 are updated based on data collected early in 1984. The silicon refining industry plans to meet the increasing demands of the semiconductor device and photovoltaic product industries are overviewed. In addition, the DOE sponsored technology research for producing low cost polycrystalline silicon, probabilistic cost analysis for the two most promising production processes for achieving the DOE cost goals, and the impacts of the DOE photovoltaics program silicon refining research upon the commercial polycrystalline silicon refining industry are addressed.
A high-performance, ultralight, photovoltaic concentrator array is being developed for space power. The stretched lens array (SLA) uses stretched-membrane, silicone Fresnel lenses to concentrate sunlight onto triple-junction photovoltaic cells. The cells are mounted to a composite radiator structure. The entire solar array wing, including lenses, photovoltaic cell flex circuits, composite panels, hinges, yoke, wiring harness, and deployment mechanisms, has a mass density of 1.6 kg/sq.m. NASA Glenn has measured 27.4% net SLA panel efficiency, or 375 W/sq.m. power density, at room temperature. At GEO operating cell temperature (80 C), this power density will be 300 W/sq.m., resulting in more than 180 W/kg specific power at the full wing level. SLA is a direct ultralight descendent of the successful SCARLET array on NASA's Deep Space 1 spacecraft. This paper describes the evolution from SCARLET to SLA, summarizes the SLA's key features, and provides performance and mass data for this new concentrator array.
Equipment developed for the manufacture of over 100 kg of silicon ingot from one crucible by rechanging from another crucible is described. Attempts were made to eliminate the cost of raising the furnace temperature to 250 C above the melting point of silicon by using an RF coil to melt polycrystalline silicon rod as a means of rechanging the crucible. Microprocessor control of the straight growth process was developed and domonstrated for both 4 inch and 6 inch diameter. Both meltdown and melt stabilization processes were achieved using operator prompting through the microprocessor. The use of the RF work coil in poly rod melting as a heat sink in the accelerated growth process was unsuccessful. The total design concept for fabrication and interfacing of the total cold crucible system was completed.
Use of high-power solar arrays, at power levels ranging from approximately 500 KW to several megawatts, has been proposed for a solar-electric propulsion (SEP) demonstration mission, using a photovoltaic array to provide energy to a high-power xenon-fueled engine. One of the proposed applications of the high-power SEP technology is a mission to rendezvous with an asteroid and move it into lunar orbit for human exploration, the Asteroid Retrieval mission. The Solar Electric Propulsion project is dedicated to developing critical technologies to enable trips to further away destinations such as Mars or asteroids. NASA needs to reduce the cost of these ambitious exploration missions. High power and high efficiency SEP systems will require much less propellant to meet those requirements.
The flat-plate solar cell array program which increases the service lifetime of the photovoltaic modules used for terrestrial energy applications is discussed. The current-voltage response characteristics of the solar cells encapsulated in the modules degrade with service time and this degradation places a limitation on the useful lifetime of the modules. The most desirable flat-plate array system involves solar cells consisting of highly polarizable materials with similar electrochemical potentials where the cells are encapsulated in polymers in which ionic concentrations and mobilities are negligibly small. Another possible mechanism limiting the service lifetime of the photovoltaic modules is the gradual loss of the electrical insulation characteristics of the polymer pottant due to water absorption or due to polymer degradation from light or heat effects. The mechanical properties of various polymer pottant materials and of electrochemical corrosion mechanisms in solar cell material are as follows: (1) electrical and ionic resistivity; (2) water absorption kinetics and water solubility limits; and (3) corrosion characterization of various metallization systems used in solar cell construction.
As flexible thin film photovoltaic (FTFPV) cell technology is developed for space applications, integration into a viable solar array structure that optimizes the attributes of this cell technology is critical. An advanced version of ABLE'sS UltraFlex solar array platform represents a near-term, low-risk approach to demonstrating outstanding array performance with the implementation of FTFPV technology. Recent studies indicate that an advanced UltraFlex solar array populated with 15% efficient thin film cells can achieve over 200 W/kg EOL. An overview on the status of hardware development and the future potential of this technology is presented.
In support of NASA's Artemis program with the goal of a sustained human-lunar presence, there is a need for very large (>100kW) and high-voltage-capable solar arrays, estimated to cost over $150M. Perovskite-based thin-film photovoltaics offer substantial advantages over state-of-the-art solar arrays from the perspective of manufacturing large arrays. Many of the challenges perovskite solar cells experience in terrestrial operations, e.g degradation caused by moisture and oxygen exposure, are not applicable in long-term space applications. The future of implementing perovskite photovoltaics in space is promising, further so is manufacturing these solar cells in space. Here we provide an overview of NASA Glenn Research Center's progress towards validating perovskite solar cells for operation in space and we illuminate innovation opportunities to which the greater community can contribute so that we may realize in-space manufacturing of perovskite photovoltaics.
A summary is given of Air Force solar concentrator projects beginning with the Rockwell International study program in 1977. The Satellite Materials Hardening Programs (SMATH) explored and developed techniques for hardening planar solar cell array power systems to the combined nuclear and laser radiation threat environments. A portion of program dollars was devoted to developing a preliminary design for a hardened solar concentrator. The results of the Survivable Concentrating Photovoltaic Array (SCOPA) program, and the design, fabrication and flight qualification of a hardened concentrator panel are discussed.
A technology review committee from NASA, the U.S. Department of Energy (DOE), and the Air Force Research Lab, was formed to assess solar cell and array technologies required for future NASA science missions.
In the foreseeable future, an expedition may be undertaken to explore the planet Mars. Some of the power source options being considered for such a mission are photovoltaics, regenerative fuel cells and nuclear reactors. In addition to electrical power requirements, environmental conditions en route to Mars, in the planetary orbit and on the Martian surface must be simulated and studied in order to anticipate and solve potential problems. Space power systems components such as photovoltaic arrays, radiators, and solar concentrators may be vulnerable to degradation in the Martian environment. Natural characteristics of Mars which may pose a threat to surface power systems include high velocity winds, dust, ultraviolet radiation, large daily variation in temperature, reaction to components of the soil, atmosphere and atmospheric condensates as well as synergistic combinations. Most of the current knowledge of the characteristics of the Martian atmosphere and soil composition was obtained from the Viking 1 and 2 missions in 1976. A theoretical study is presented which was used to assess the effects of the Martian atmospheric conditions on the power systems components. A computer program written at NASA-Lewis for combustion research that uses a free energy minimization technique was used to calculate chemical equilibrium for assigned thermodynamic states of temperature and pressure. The power system component materials selected for this study include: silicon dioxide, silicon, carbon, copper, and titanium. Combinations of environments and materials considered include: (1) Mars atmosphere with power surface material, (2) Mars atmosphere and dust component with power surface material, and (3) Mars atmosphere and hydrogen peroxide or superoxide or superoxide with power system material. The chemical equilibrium calculations were performed at a composition ratio (oxidant to reactant) of 100. The temperature for the silicon dioxide material and silicon, which simulate photovoltaic cells, were 300 and 400 K; for carbon, copper and titanium, which simulate radiator surfaces, 300, 500, and 1000 K. All of the systems were evaluated at pressures of 700, 800, and 900 Pa, which stimulate the Martian atmosphere.
The present work describes the principal goals for the main effort of NASA's research and development of solar photovoltaic cells and arrays. These are (1) to reduce array costs from $270/watt to $90/watt (no change in volume) or to $41/watt (high volume production), (2) raise power density from 66 watts/kg to 110 watts/kg, and (3) minimize dynamic interaction problems. The first two goals can be accomplished by increased cell efficiency, reduced cell thickness, the development of a multiple ribbon growth process, and automation of cell production. To minimize dynamic interaction between array and spacecraft, module flexibility will be increased.
The advantages of manufacturing solar cells for use in space on the moon rather than on Earth are discussed. It is shown how solar cells manufactured on the moon could significantly reduce the cost of transportation of power systems to space destinations, including the moon, Mars, earth orbit, and transfer orbits. Silicon is abundant on the moon, and refining processes are demonstrated which do not depend on extensive use of reactants imported from Earth. Because of the lower requirements for refined silicon, the amorphous silicon process is preferred, despite lower efficiencies. Calculations show that the specific power of amorphous silicon cells can be adequate for most uses.
Solar electric propulsion (SEP) is an alternative to chemical and nuclear powered propulsion systems for both piloted and unpiloted Mars transport vehicles. Photovoltaic solar cell and array technologies were evaluated as components of SEP power systems. Of the systems considered, the SEP power system composed of multijunction solar cells in an ENTECH domed fresnel concentrator array had the least array mass and area. Trip times to Mars optimized for minimum propellant mass were calculated. Additionally, a preliminary vehicle concept was designed.
The photovoltaic (PV) module on the International Space Station (ISS) has been operating since November 2000 and supporting electric power demands of the ISS and its crew of three. The PV module contains photovoltaic arrays that convert solar energy to electrical power and an integrated equipment assembly (IEA) that houses electrical hardware and batteries for electric power regulation and storage. Each PV module contains two independent power channels for fault tolerance. Each power channel contains three batteries in parallel to meet its performance requirements and for fault tolerance. Each battery consists of 76 Ni-Hydrogen (Ni-H2) cells in series. These 76 cells are contained in two orbital replaceable units (ORU) that are connected in series. On-orbit data are monitored and trended to ensure that all hardware is operating normally. Review of on-orbit data showed that while five batteries are operating very well, one is showing signs of mismatched ORUs. The cell pressure in the two ORUs differs by an amount that exceeds the recommended range. The reason for this abnormal behavior may be that the two ORUs have different use history. An assessment was performed and it was determined that capacity of this battery would be limited by the lower pressure ORU. Steps are being taken to reduce this pressure differential before battery capacity drops to the point of affecting its ability to meet performance requirements. As a first step, a battery reinitialization procedure was developed to reduce this pressure differential. The procedure was successfully carried out on-orbit and the pressure differential was reduced to the recommended range. This paper describes the battery performance and the consequences of mismatched ORUs that make a battery. The paper also describes the reinitialization procedure, how it was performed on orbit, and battery performance after the reinitialization. On-orbit data monitoring and trending is an ongoing activity and it will continue as ISS assembly progresses.
The NASA Lunar Orbital Platform-Gateway (LOP-G), a vital component of NASA’s Artemis program, will serve as a multi-purpose outpost orbiting the Moon. A foundational component of LOP-G is the Power and Propulsion Element (PPE). The PPE is a high-power, +60-kilowatt solar electric propulsion spacecraft that will provide power, high-rate communications, attitude control, and orbital transfer capabilities for the Gateway. The solar array system will utilize 4-junction photovoltaic cell technology on a flexible substrate (roll-out solar array or ROSA) in combination with multiple diode assemblies to combine the power of the solar array strings. NASA’s Marshall Space Flight Center, together with the PPE developer, Maxar, are in the midst of completing a rigorous combined environments test campaign of 3 solar array coupons and 1 array blocking diode board coupon. The campaign includes Ultra-Violet Radiation, Charged Particle Radiation, Ion Erosion, Thermal Cycles, and Electrostatic Discharge tests. The environments are applied in 3 separate incremental stages reflecting the various mission phases: 460 days of Earth-to-Lunar Transit, with much of that time through the Van Allen Belts, 5-years in Lunar Near-Rectilinear Halo Orbit (NRHO) at the Moon, and finally 15-years in Lunar NRHO, which represents the end of the design life. This paper will report on the state of the testing for each coupon, and brief look at the array performance, including some unexpected sensitivities of array blocking diodes.
It is pointed out that significant redirection has occurred in the U.S. Department of Energy (DOE) Photovoltaics Program, and thus in the Flat-Plate Solar Array Project (FSA), since the 3rd European Communities Conference. The Silicon Materials Task has now the objective to sponsor theoretical and experimental research on silicon material refinement technology suitable for photovoltaic flat-plate solar arrays. With respect to the hydrochlorination reaction, a process proof of concept was completed through definition of reaction kinetics, catalyst, and reaction characteristics. In connection with the dichlorosilane chemical vapor desposition process, a preliminary design was completed of an experimental process system development unit with a capacity of 100 to 200 MT/yr of Si.Attention is also given to the silicon-sheet formation research area, environmental isolation research, the cell and module formation task, the engineering sciences area, and the module performance and failure analysis area.
Solar cells and arrays as power supply systems for space missions - photovoltaic specialists conference