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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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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

Metallic Thermal Protection System Technology Development: Concepts, Requirements and Assessment Overview

A technology development program was conducted to evolve an earlier metallic thermal protection system (TPS) panel design, with the goals of: improving operations features, increasing adaptability (ease of attaching to a variety of tank shapes and structural concepts), and reducing weight. The resulting Adaptable Robust Metallic Operable Reusable (ARMOR) TPS system incorporates a high degree of design flexibility (allowing weight and operability to be traded and balanced) and can also be easily integrated with a large variety of tank shapes, airframe structural arrangements and airframe structure/material concepts. An initial attempt has been made to establish a set of performance based TPS design requirements. A set of general (FARtype) requirements have been proposed, focusing on defining categories that must be included for a comprehensive design. Load cases required for TPS design must reflect the full flight envelope, including a comprehensive set of limit loads, However, including additional loads. such as ascent abort trajectories, as ultimate load cases, and on-orbit debris/micro-meteoroid hypervelocity impact, as one of the discrete -source -damage load cases, will have a significant impact on system design and resulting performance, reliability and operability. Although these load cases have not been established, they are of paramount importance for reusable vehicles, and until properly included, all sizing results and assessments of reliability and operability must be considered optimistic at a minimum.

Dorsey, John T.↗
NASA NTRS1981

Stuffed MO layer as a diffusion barrier in metallizations for high temperature electronics

Auger electron spectroscopy was employed to characterize the diffusion barrier properties of molybdenum in the CrSi2/Mo/Au metallization system. The barrier action of Mo was demonstrated to persist even after 2000 hours annealing time at 300 C in a nitrogen ambient. At 340 C annealing temperature, however, rapid interdiffusion was observed to have occurred between the various metal layers after only 261 hours. The presence of controlled amounts of oxygen in the Mo layer is believed to be responsible for suppressing the short circuit interdiffusion between the thin film layers. Above 340 C, its is believed that the increase in the oxygen mobility led to deterioration of its stuffing action, resulting in the rapid interdiffusion of the thin film layers along grain boundaries.

Boah, J. K.↗
NASA NTRS1979

Development of Low Cost Contacts to Silicon Solar Cells

Different electroless plating systems were evaluated in conjunction with copper electroplating. All tests involved simultaneous deposition of front and back contacts using a standard cell materials. Cells with good adhesion and good curve fill factors were obtained using a palladium-chromium-copper metallization system. The final copper contact system was evaluated to determine if the copper would migrate at elevated temperatures. The copper migrated at elevated temperatures causing cell output degradation.

Iles, P. A.↗
DOE OSTI2021

Nonlocal and nonadiabatic Pauli potential for time-dependent orbital-free density functional theory

Time-dependent orbital-free density functional theory is an efficient ab initio method for calculating the electronic dynamics of large systems. In comparison to standard time-dependent density functional theory, it computes only a single electronic state regardless of system size, but it requires an additional time-dependent Pauli potential term. Herein we propose a nonadiabatic and nonlocal Pauli potential whose main ingredients are the time-dependent particle and current densities. Our calculations of the optical spectra of metallic and semiconductor clusters indicate that nonlocal and nonadiabatic time-dependent orbital-free density functional theory performs accurately for metallic systems and semiquantitatively for semiconductors. This paper opens the door to wide applicability of time-dependent orbital-free density functional theory for nonequilibrium electron and electron-nuclear dynamics of complex materials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1983

Laser assisted deposition

Applications of laser-based processing techniques to solar cell metallization are discussed. Laser-assisted thermal or photolytic maskless deposition from organometallic vapors or solutions may provide a viable alternative to photovoltaic metallization systems currently in use. High power, defocused excimer lasers may be used in conjunction with masks as an alternative to direct laser writing to provide higher throughput. Repeated pulsing with excimer lasers may eliminate the need for secondary plating techniques for metal film buildup. A comparison between the thermal and photochemical deposition processes is made.

Dutta, S.↗
NASA NTRS1977

Cyclic and low temperature effects on microcircuits

Cyclic temperature and low temperature operating life tests, and pre-/post-life device evaluations were used to determine the degrading effects of thermal environments on microcircuit reliability. Low power transistor-transistor-logic gates and linear devices were included in each test group. Device metallization systems included aluminum metallization/aluminum wire, aluminum metallization/gold wire, and gold metallization/gold wire. Fewer than 2% electrical failures were observed during the cyclic and low temperature life tests and the post-life evaluations revealed approximately 2% bond pull failures. Reconstruction of aluminum die metallization was observed in all devices and the severity of the reconstruction appeared to be directly related to the magnitude of the temperature excursion. All types of bonds except the gold/gold bonds were weakened by exposure to repeated cyclic temperature stress.

Weissflug, V. A.↗
NASA NTRS1982

Investigation of reliability attributes and accelerated stress factors on terrestrial solar cells

The accelerated stress test results obtained on all terrestrial solar cells since the inception of the program are summarized. Tested cells were grouped according to the method used to form the conductive metallization layer: solder dipped, vacuum deposited, screen printed, and copper plated. Although metallization systems within each group were quite similar, they differed in numerous details according to the procedures employed by each manufacturer. Test results were summarized for all cells according to both electrical degradation and catastrophic mechanical changes. These results indicated a variability within each metallization category which was dependent on the manufacturer. Only one manufacturer was represented in the copper plated category and, although these showed no signs of detrimental copper diffusion during high temperature testing, their metallization was removed easily during high humidity pressure cooker testing. Preliminary testing of encapsulated cells showed no major differences between encapsulated and unencapsulated cells when subjected to accelerated testing.

Lathrop, J. W.↗
NASA NTRS1992

The influence of chromium on structure and mechanical properties of B2 nickel aluminide alloys

Major obstacles to the use of NiAl-based alloys and composites are low ductility and toughness. These shortcomings result in part from a lack of sufficient slip systems to accommodate plastic deformation of polycrystalline material (von Mises Criterion). It has been reported that minor additions of chromium to polycrystalline NiAl cause the predominant slip system to shift from the usual. If true, then a major step toward increasing ductility in this compound may be realized. The purpose of the present study was to verify this phenomenon, characterize it with respect to chromium level and Ni to Al ratio, and correlate any change in slip system with microstructure and mechanical properties. Compression and tensile specimens were prepared from alloys containing 0 to 5 percent chromium and 45 to 55 percent aluminum. Following about one percent strain, transmission electron microscopy foils were produced and the slip systems determined using the g x b = 0 invisibility criterion. Contrary to previous results, chromium was found to have no effect on the preferred slip system of any of the alloys studied. Possible reasons for the inconsistency of the current results with previous work are considered. Composition-structure-property relationships are discerned for the alloys, and good correlation are demonstrated in terms of conventional strengthening models for metallic systems.

Cotton, James Dean↗
NASA NTRS1979

Phase Two of the Array Automated Assembly Task for the Low Cost Solar Array Project

Various top contact metal systems were studied. Only Ti Pd Cu approaches baseline (Ti Pd Ag) quality, but this system shows a lack of long term stability. Aluminum back surface field structures were fabricated and thicknesses of p superscript + material of up to 7.0 microns were achieved with open circuit voltages of 0.59V. A general purpose ultrasonic welder was purchased and tests using various metal foils are under way. During fabrication of the demonstration module, several cells became cracked. Due to redundancy of interconnections, the module was not open circuited but the efficiency was reduced to 8.8%. The broken cell was interconnected with a strap across the back and the efficiency was increased to 11.5%. A cost analysis was made and the results indicate a selling price of $0.56/watt peak (in 1986 with 1975 dollars).

Campbell, R. B.↗
DOE OSTI2020

Optimization of Dry Storage Canister Cutting Operations - 20534

A recent project investigated the optimal cutting method for the opening of a welded dry storage/shielded canister (DSC) or dual purpose canister (DPC) containing Used Nuclear Fuel (UNF). Due to the lack of a disposal path for UNF in the U.S., the majority of UNF is currently moved into welded DSCs and DPCs designed by Orano TN, NAC, and Holtec. As the DSCs/DPCs were neither designed nor licensed for disposal and may not be able to be emplaced in a geologic repository due to physical emplacement constraints, near-term thermal limitations, or long-term criticality issues, the UNF in these existing DSCs/DPCs may need to be repackaged into transportation, aging, and disposal canisters (TADs), generic standard TADs (STADs), transportation casks, new cask/canister systems, and/or cask/canister/package systems suitable for disposal. These DSCs/DPCs may also be opened to simply remove the UNF in preparation for recycling, re-storage, or placement into a waste package suitable for disposal. Regardless of need, the DSCs/DPCs would require to be cut open by a potentially large scale operation. This project examined the multiple means for cutting welded metal systems and considered several factors to determine an optimal approach. Issues arose around some of the cutting approaches when applied to systems with 2 or 3 lids and with pre-cutting gas testing required. The resulting preferences in cutting methods with an optimized application for the opening of DSCs/DPCs are presented. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1990

Probing the Interstellar Medium of External Galaxies Using Quasar Absorption Lines: the 3C 232/NGC 3067 System

Quasar absorption lines offer unique opportunities to probe the interstellar medium of external galaxies. Researchers present new optical and UV absorption line spectroscopy of the quasar 3C232 (z=0.55) revealing new detail in the foreground absorption system due to the bright, spiral galaxy NGC 3067 (cz=1420 km/s). Specifically, the spectra show evidence for two and possibly three separate absorption components in CaII and Na I spanning approx. 150 km/s. The original HI detection of Haschick and Burke (1975) corresponds to the strongest of these metal systems which exhibits doublet ratios consistent with saturation in both CaII and Na I. Due to the recent detection in HI emission of a tidal tail or finger of HI extending from the western edge of NGC 3067 through the position of 3C 232 (Carilli, van Gorkom and Stocke, 1989), the morphology of the HI absorber is now known and is not either a warped disk nor a spherical halo as had been proposed. New deep continuum and H alpha imaging provides a sensitive upper limit on the the ionizing continuum impinging upon this cloud (and thus a limit on the intensity of the extragalactic ionizing radiation field). Together with the observed UV spectrum of 3C 232, the optical emission line ratios and the deep H alpha imaging set a minimum distance between the quasar and the HI cloud disregarding redshift information. This limit strains the non-cosmological redshift interpretation for 3C 232 -- and this quasar is one of the original 5 3C quasars found to be too close to NGC galaxies as if by chance (Burbidge, Burbidge, Solomon and Strittmatter, 1972).

Stocke, John T.↗
DOE OSTI2024

Core-to-core X-ray emission spectra from Wannier based multiplet ligand field theory

Recent advances using Density Functional Theory (DFT) to augment Multiplet Ligand Field Theory (MLFT) have led to ab-initio calculations of many formerly empirical parameters. This development makes MLFT more predictive instead of interpretive, thus improving its value for studies of highly correlated 3 d , 4 d , and ƒ-electron systems. Synchrotron time is always at a premium, and tools that provide predictive capabilities have clear value when it comes to planning studies. Here, in this work, we develop a DFT + MLFT based approach for core-to-core Kα x-ray emission spectra (XES) and evaluate its performance for a range of transition metal systems. We find good agreement between theory and experiment, as well as the ability to capture key spectral trends related to spin and oxidation state. We also discuss limitations of the model in the context of the remaining free parameters and suggest directions forward.

Ab initio theoretical treatment↗
DOE OSTI2024

Theory of Nonlinear Diffusion with a Physical Gapped Mode

In a system with one conserved charge the charge diffusion is modified by nonlinear self-interactions within an effective field theory (EFT) of diffusive fluctuations. We include the slowest ultraviolet (UV) mode, constructing a UV-regulated EFT. The relaxation time of this UV mode is protected from renormalization, as supported by experimental data in a bad metal system. Furthermore, the retarded density-density Green’s function acquires four branch points, eventually increasing the range of applicability. We discuss the fate of long time tails as well as implications for the quark gluon plasma. Published by the American Physical Society 2024

Physics↗
NASA NTRS2005

New Approach for Thermal Protection System of a Probe During Entry

One of the biggest challenges for any thermal protection system (TPS) of a probe is to provide a sufficient barrier for heat generated during descent in order to keep the temperature inside of the probe low enough to support operational temperature of equipment. Typically, such a goal is achieved by having the ceramic tiles and blankets like on the Space Shuttle, silicon based ablators, or metallic systems to cover the probe external surface. This paper discusses the development of an innovative technique for TPS of the probe. It is proposed to use a novel TPS which comprises thermal management of the entry vehicle. It includes: a) absorption of the heat during heat pick load by a Phase Change Material (PCM), b) separation of the compartment which contains PCM from the rest of the space vehicle by a gap with a high thermal resistance, c) maintaining temperature of the internal wall of s/c cabin temperature by transfer heat from the internal wall to the "cold" side of the vehicle and to reject heat into the space during the flight and on a ground, d) utilization of an advanced heat pipe, so called Loop Heat Pipe to transfer heat from the cabin internal wall to the cold side of the s/c and to reject the heat into environment outside of the vehicle. A Loop Heat Pipe is capable of transferring heat against gravity

Yendler, Boris↗
DOE OSTI2021

Tritium Transport Phenomena in Molten-Salt Reactors: Molten Salt Tritium Transport Experiment Design

Tritium is produced from neutron interactions with both lithium and beryllium. Large quantities of tritium are generated in Molten Salt Reactors (MSRs) which use LiF/BeF2 (FLiBe) as the fuel salt. Tritium is unique among the radionuclide hazards as it readily permeates through metal structural materials at high temperatures. All metal surfaces are potential release paths for tritium. For adequate safety analysis and eventual licensing of new reactors, predictive models for tritium transport and release from MSRs must be developed. These models must account for the multiple transport phenomena involved with tritium: fuel salt phase mass transport, dissociation/recombination reactions on metal surfaces, interstitial diffusion through the metal structure, and salt or gas phase mass transport in the downstream fluid. These models also must also be validated with representative experiments. Our previous report outlined tritium transport phenomena involved in MSRs, made suggestions on gaps in the transport dataset, and proposed an experimental test stand to test combined transport effects – tritium transport through pipe walls in a convective salt flow. In this report, we summarize an updated analysis framework for tritium transport in MSRs, report our results on hydrogen and deuterium permeation through Hastelloy N, and describe the final design of the Molten Salt Tritium Transport Experiment (MSTTE, pronounced “misty”). The MSRE provides the only wholistic experimental data set for tritium transport in MSRs and understanding the transport phenomena involved in the MSRE is crucial for future model development. One set of parameters in our analysis framework was unknown for the MSRE—surface reaction rates for tritium on Hastelloy N. This warranted our hydrogen and deuterium permeation campaign to assess the permeability, diffusivity, and solubility of hydrogen isotopes in clean Hastelloy N. Surface reaction rate constants were probed by low pressure measurements, however, no surface effects were observed in the limits of our permeation apparatus. Permeation experiments on oxidized Hastelloy N were not performed for this report but are planned in future work. The experimental test stand, MSTTE, measures combined transport properties of the salt-metal system. MSTTE is a forced convection FLiBe loop with custom designed test section to measure tritium transport through candidate structural materials. We use MSRE relevant dimensionless numbers to design and scale the test section. Hastelloy N is a candidate loop and test section material due to the relevance for the MSRE and related designs, however, other metals are being considered (e.g. 316H SS) which may better align with current vendor concepts.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2003

A Dry-Etch Process for Low Temperature Superconducting Transition Edge Sensors for Far Infrared Bolometer Arrays

The next generation of ultra-low power bolometer arrays, with applications in far infrared imaging, spectroscopy and polarimetry, utilizes a superconducting bilayer as the sensing element to enable SQUID multiplexed readout. Superconducting transition edge sensors (TES s) are being produced with dual metal systems of superconductinghormal bilayers. The transition temperature (Tc) is tuned by altering the relative thickness of the superconductor with respect to the normal layer. We are currently investigating MoAu and MoCu bilayers. We have developed a dry-etching process for MoAu TES s with integrated molybdenum leads, and are working on adapting the process to MoCu. Dry etching has the advantage over wet etching in the MoAu system in that one can achieve a high degree of selectivity, greater than 10, using argon ME, or argon ion milling, for patterning gold on molybdenum. Molybdenum leads are subsequently patterned using fluorine plasma.. The dry-etch technique results in a smooth, featureless TES with sharp sidewalls, no undercutting of the Mo beneath the normal metal, and Mo leads with high critical current. The effects of individual processing parameters on the characteristics of the transition will be reported.

Allen, Christine A.↗
DOE OSTI2022

Predicting and Controlling Corrosion (Abbreviated Final Report)

Corrosion accumulates significant replacement costs in the transportation, utility, manufacturing, and infrastructure sectors. It also underpins several of LLNL’s core missions in stockpile stewardship, defense, and energy security. Whereas most corrosion and aging models are empirically parameterized to describe well-defined conditions late in the reaction, the factors that determine the early stages of corrosion—during which mitigation could be most impactful— are poorly understood. This project addressed the critical need for new approaches to predict the kinetics of corrosion initiation based on firm physical and chemical understanding. The activities encompassed degradation of relevant metals in both hydrogen-rich and environmental corrosion scenarios. The team integrated state-of-the-art multiscale simulation, in situ characterization, and data science within three technical thrusts: hydriding of Ti alloys; aqueous corrosion of Al and Ni-Cr alloys; and degradation of additively manufactured 316L stainless steel. In each case, novel capabilities were developed to identify and track the impacts of key atomistic, compositional, and microstructural features on the metal systems. For hydriding, protocols were developed to tightly integrate multiscale models, advanced multimodal characterization, and machine learning to determine how hydrogen interacts with native passivating surface oxides and nucleates new undesired phases, shedding new light on the critical role of grain boundaries, interfaces, and atomically disordered regions. For aqueous corrosion, the project demonstrated methods to predict dissolution rates of metal surfaces in corrosive solutions, to measure and understand microstructural and grain orientation effects on corrosion susceptibility, and to investigate competing growth and dissolution kinetics of surface oxides. For additively manufactured metals, analysis using state-of-the-art microscopy techniques revealed the role of specific heterogeneities invoked during laser processing, including cellular structure, dislocations, and precipitates, on corrosion susceptibility. In addition to new capabilities and understanding, the project provided an avenue for workforce development, as well as key partnerships with stakeholders in corrosion science.

08 HYDROGEN↗
NASA NTRS1982

Cell and module formation research area

Metallization is discussed. The influence of hydrogen on the firing of base-metal pastes in reducing atmospheres is reported. A method for optimization of metallization patterns is presented. A process sequence involving an AR coating and thick-film metallization system capable of penetrating the AR coating during firing is reported. Design and construction of the NMA implantation machine is reported. Implanted back-surface fields and NMA primary (front) junctions are discussed. The use of glass beads, a wave-soldering device, and ion milling is reported. Processing through the module fabrication and environmental testing of its design are reported. Metallization patterns by mathematical optimization are assessed.

Bickler, D. B.↗