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At least 235 records · Page 13

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DOE OSTI2023

GaAs solar cells grown on acoustically spalled GaAs substrates with 27% efficiency

Acoustic spalling presents a potentially low-cost reuse pathway for III–V epitaxial growth substrates via exfoliation of device layers with recovery and reuse of the substrate. However, surface features formed during spalling can reduce the performance of subsequently grown devices. Here, we develop an understanding of how the surface morphology of acoustically spalled substrates affects GaAs solar cell performance and develop strategies to mitigate these impacts. We demonstrate that minor planarization of the surface by wet chemical etching and/or epitaxial growth, or the redesign of the device structure to thicken critical layers, prevents performance degradation. Using these strategies, we demonstrate a 0.25 cm 2 single-junction GaAs device with 26.9% ± 0.2% photovoltaic conversion efficiency under the AM1.5G spectrum grown on an acoustically spalled substrate. These results enable the growth of high-performance III–V devices on non-traditional substrates with the potential for significantly reduced device costs.

14 SOLAR ENERGY↗

NASA NTRS1985

New high-efficiency silicon solar cells

A design for silicon solar cells was investigated as an approach to increasing the cell open-circuit voltage and efficiency for flat-plate terrestrial photovoltaic applications. This deviates from past designs, where either the entire front surface of the cell is covered by a planar junction or the surface is textured before junction formation, which results in an even greater (up to 70%) junction area. The heavily doped front region and the junction space charge region are potential areas of high recombination for generated and injected minority carriers. The design presented reduces junction area by spreading equidiameter dot junctions across the surface of the cell, spaced about a diffusion length or less from each other. Various dot diameters and spacings allowed variations in total junction area. A simplified analysis was done to obtain a first-order design optimization. Efficiencies of up to 19% can be obtained. Cell fabrication involved extra masking steps for selective junction diffusion, and made surface passivation a key element in obtaining good collection. It also involved photolithography, with line widths down to microns. A method is demonstrated for achieving potentially high open-circuit voltages and solar-cell efficiencies.

Daud, T.↗

DOE OSTI2025

Chemical and Chemical-Mechanical Polishing of Surface Roughness on L-PBF/GRCop-42 Cu-Cr-Nb Additive Manufactured 10-GHz RF Structures

Laser-based powder bed fusion (L-PBF) allows additive manufacture (AM) of lower hybrid current drive (LHCD) radio-frequency (RF) launchers from Glenn Research Copper, a Cr 2 Nb precipitation-hardened alloy (GRCop-42) in configurations unachievable with conventional machining. Rough surfaces in AM components increase RF losses and lead to arcing in high-power vacuum RF applications. Chemical polishing, chemical-mechanical polishing, or a combination of both were utilized to planarize the internal surfaces of RF structures, resulting in surface roughness as low as R a = 0.2 µm. Refinement in polishing techniques now enables GRCop-42 alloys (4 at. % Cr, 2 at. % Nb) to achieve similar surface roughness to GRCop-84 (8 at. % Cr, 4 at. % Nb) and equivalent cavity losses to extruded oxygen-free copper waveguides at 10 GHz.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1986

Archean metamorphic sequence and surfaces, Kangerdlugssuaq Fjord, East Greenland

The characteristics of Archean metamorphic surfaces and fabrics of a mapped sequence of rocks older than about 3000 Ma provide information basic to an understanding of the structural evolution and metamorphic history in Kangerdlugssuaq Fjord, east Greenland. This information and the additional results of petrologic and geochemical studies have culminated in an extended chronology of Archean plutonic, metamorphic, and tectonic events. The basis for the chronology is considered, especially the nature of the metamorphic fabrics and surfaces in the Archean sequence. The surfaces, which are planar mineral parageneses, may prove to be mappable outside Kangerdlugssuaq Fjord, and if so, will be helpful in extending the events that they represent to other Archean sequences in east Greenland. The surfaces will become especially important reference planes if the absolute ages of their metamorphic assemblages can be determined in at least one location where strain was low subsequent to their recrystallization. Once an isochron is obtained, the dynamothermal age of the regionally identifiable metamorphic surface is determined everywhere it can be mapped.

Kays, M. A.↗

DOE OSTI2021

Efficient passivation of n-type and p-type silicon surface defects by hydrogen sulfide gas reaction

An efficient surface defect passivation is observed by reacting clean Si in a dilute hydrogen sulfide-argon gas mixture (< 5% H2S in Ar) for both n-type and p-type Si wafers with planar and textured surfaces. Surface recombination velocities of 1.5 and 8 cm/s are achieved on n-type and p-type Si wafers, respectively, at an optimum reaction temperature of 550oC that are comparable to the best surface passivation quality used in high efficiency Si solar cells. Surface chemical analysis using x-ray photoelectron spectroscopy shows that sulfur is primarily bonded in a sulfide environment, and synchrotron-based soft x-ray emission spectroscopy of the adsorbed sulfur atoms suggests the formation of S-Si bonds. Furthermore, the sulfur surface passivation layer is unstable in air, attributed to surface oxide formation and a simultaneous decrease of sulfide bonds. However, the passivation can be stabilized by a low-temperature (300oC) deposited amorphous silicon nitride (a-Si:NX:H) capping layer.

14 SOLAR ENERGY↗

NASA NTRS1990

Analytical and Photogrammetric Characterization of a Planar Tetrahedral Truss

Future space science missions are likely to require near-optical quality reflectors which are supported by a stiff truss structure. This support truss should conform closely with its intended shape to minimize its contribution to the overall surface error of the reflector. The current investigation was conducted to evaluate the planar surface accuracy of a regular tetrahedral truss structure by comparing the results of predicted and measured node locations. The truss is a 2-ring hexagonal structure composed of 102 equal-length truss members. Each truss member is nominally 2 meters in length between node centers and is comprised of a graphite/epoxy tube with aluminum nodes and joints. The axial stiffness and the length variation of the truss components were determined experimentally and incorporated into a static finite element analysis of the truss. From this analysis, the root mean square (RMS) surface error of the truss was predicted to be 0.11 mm (0004 in). Photogrammetry tests were performed on the assembled truss to measure the normal displacements of the upper surface nodes and to determine if the truss would maintain its intended shape when subjected to repeated assembly. Considering the variation in the truss component lengths, the measures rms error of 0.14 mm (0.006 in) in the assembled truss is relatively small. The test results also indicate that a repeatable truss surface is achievable. Several potential sources of error were identified and discussed.

Wu, K. Chauncey↗

DOE OSTI2025

Effect of Thermal Oxidation on the Structure, Surface Texturing, and Microstructure Evolution in Nanocrystalline Ga-O-N Films

An extensive examination of the nanoscale, crystallographic growth dynamics of the system, which is impacted by the thermal energy given to the GaN, is carried out to derive a deeper understanding of the growth kinetics, morphology and microstructure evolution, chemical bonding, and optical properties of Ga-O-N films. Thermal annealing of GaN films is performed in the temperature range of 900–1200 °C. Crystal structure, phase formation, chemical composition, surface morphology, and microstructure evolution of Ga-O-N films are investigated as a function of temperature. Increasing temperature induces surface oxidation, which results in the formation of stable β-Ga2O3 phase in the GaN matrix, where the overall film composition evolves from nitride (GaN) to oxynitride (Ga-O-N). While GaN surfaces are smooth, planar, and featureless, oxidation induced granular-to-rod shaped morphology evolution is seen with increasing temperature to 1200 °C. The considerable texturing and stability of the nanocrystalline Ga-O-N on Si substrates can be attributed to the surface and interface driven modification because of thermal treatment. Corroborating with structure and chemical changes, Raman spectroscopic analyses also indicate that the chemical bonding evolution progresses from fully Ga-N bonds to Ga-O-N. While the GaN oxidation process starts with the formation of β-Ga 2 O 3 at an annealing temperature of 1000 °C, higher annealing temperatures induce structural distortion with the potential formation of Ga-O-N bonds. The structure-phase-chemical composition correlation, which will be useful for nanocrystalline materials for selective optoelectronic applications, is established in Ga-O-N films made by thermal treatment of GaN.

36 MATERIALS SCIENCE↗

NASA NTRS1982

Charging and discharging characteristics of dielectric materials exposed to low- and mid-energy electrons

Charging and discharging characteristics of dielectric samples exposed to 1-25 keV and 25-100 keV electrons in a laboratory environment are reported. The materials examined comprised OSR, Mylar, Kapton, perforated Kapton, and Alphaquartz, serving as models for materials employed on spacecraft in geosynchronous orbit. The tests were performed in a vacuum chamber with electron guns whose beams were rastered over the entire surface of the planar samples. The specimens were examined in low-impedance-grounded, high-impedance-grounded, and isolated configurations. The worst-case and average peak discharge currents were observed to be independent of the incident electron energy, the time-dependent changes in the worst case discharge peak current were independent of the energy, and predischarge surface potentials are negligibly dependent on incident monoenergetic electrons.

Coakley, P.↗

NASA NTRS1993

An evaluation of three-dimensional sensors for the extravehicular activity helper/retreiver

The Extravehicular Activity Retriever/Helper (EVAHR) is a robotic device currently under development at the NASA Johnson Space Center that is designed to fetch objects or to assist in retrieving an astronaut who may have become inadvertently de-tethered. The EVAHR will be required to exhibit a high degree of intelligent autonomous operation and will base much of its reasoning upon information obtained from one or more three-dimensional sensors that it will carry and control. At the highest level of visual cognition and reasoning, the EVAHR will be required to detect objects, recognize them, and estimate their spatial orientation and location. The recognition phase and estimation of spatial pose will depend on the ability of the vision system to reliably extract geometric features of the objects such as whether the surface topologies observed are planar or curved and the spatial relationships between the component surfaces. In order to achieve these tasks, accurate sensing of the operational environment and objects in the environment will therefore be critical. The qualitative and quantitative results of empirical studies of three sensors that are capable of providing three-dimensional information to the EVAHR, but using completely different hardware approaches are documented. The first of these devices is a phase shift laser with an effective operating range (ambiguity interval) of approximately 15 meters. The second sensor is a laser triangulation system designed to operate at much closer range and to provide higher resolution images. The third sensor is a dual camera stereo imaging system from which range images can also be obtained. The remainder of the report characterizes the strengths and weaknesses of each of these systems relative to quality of data extracted and how different object characteristics affect sensor operation.

Magee, Michael↗

DOE OSTI2025

Alloying of Mn with Bi‐Rich Surfaces of Bi 2 Te 3 by Topotactic Reaction

Interfacing topological insulators (TI) with magnetic materials enables accessing quantum effects for advanced devices. The synthesis of such heterostructures faces challenges due to interlaying mixing and the often-complex multicomponent materials required to combine the desired properties. An alternative synthesis to direct growth is the modification of 2D materials by topotactic reactions to introduce new functionalities into pre-formed single or few-component 2D sheets. Here, the self-formation of bismuthene (a bilayer of Bi; Bi 2 ) is utilized by thermal decomposition of Bi 2 Te 3 as a platform to create novel 2D overlayers on the TI- substrate. Specifically, the Bi 2 layer is modified by reacting it with vapor deposited Mn in an attempt to induce magnetic properties. Scanning tunneling microscopy indicates that the Mn modified surface remains in a planar 2D layer, indicating the formation of an ordered Mn-rich surface layer. Density functional theory (DFT) is used to develop models of both the Bi-rich Bi 2 Te 3 surface as well as their subsequent Mn-modified structure. The DFT models indicate the possibility of magnetic ordering of the high spin Mn 2+ ions. The successful synthesis of planar MnBi alloys on a van der Waals material illustrates topotactic reactions as an alternative for creating novel layered heterostructures.

2D materials↗

NASA NTRS1971

The topology of the regularized integral surfaces of the 3-body problem

Momentum, angular momentum, and energy of integral surfaces in the planar three-body problem are considered. The end points of orbits which cross an isolating block are identified. It is shown that this identification has a unique extension to an identification which pairs the end points of orbits entering the block and which end in a binary collision with the end points of orbits leaving the block and which come from a binary collision. The problem of regularization is that of showing that the identification of the end points of crossing orbits has a continuous, unique extension. The regularized phase space for the three-body problem was obtained, as were regularized integral surfaces for the problem on which the three-body equations of motion induce flows. Finally the topology of these surfaces is described.

Easton, R.↗

NASA NTRS2009

Piecewise-Planar Parabolic Reflectarray Antenna

The figure shows a dual-beam, dualpolarization Ku-band antenna, the reflector of which comprises an assembly of small reflectarrays arranged in a piecewise- planar approximation of a parabolic reflector surface. The specific antenna design is intended to satisfy requirements for a wide-swath spaceborne radar altimeter, but the general principle of piecewise-planar reflectarray approximation of a parabolic reflector also offers advantages for other applications in which there are requirements for wideswath antennas that can be stowed compactly and that perform equally in both horizontal and vertical polarizations. The main advantages of using flat (e.g., reflectarray) antenna surfaces instead of paraboloidal or parabolic surfaces is that the flat ones can be fabricated at lower cost and can be stowed and deployed more easily. Heretofore, reflectarray antennas have typically been designed to reside on single planar surfaces and to emulate the focusing properties of, variously, paraboloidal (dish) or parabolic antennas. In the present case, one approximates the nominal parabolic shape by concatenating several flat pieces, while still exploiting the principles of the planar reflectarray for each piece. Prior to the conception of the present design, the use of a single large reflectarray was considered, but then abandoned when it was found that the directional and gain properties of the antenna would be noticeably different for the horizontal and vertical polarizations.

Hodges, Richard↗

DOE OSTI2025

Elastomeric Nanocomposite with Solvent‐Free, One Step, In Situ Shear Exfoliation of Graphite to Graphene

A graphene nanoflake (GNF)‐enhanced elastomeric nanocomposite (G‐EMC) is fabricated following an innovative, cost‐effective, single‐step, in situ shear exfoliation (ISE) method from low‐cost bulk material, graphite, where uniform mixing happens simultaneously within the elastomer matrix. Electron microscopy, atomic force microscopy, and photo‐induced force microscopy results show good dispersion of GNFs with exfoliation to a few layers and uniform distribution in the elastomer matrix. X‐ray photoelectron spectroscopy analysis shows less than 1% oxygen‐containing functional groups/impurity, enhanced bonding through the formation of edge sites as fracture occurs across the GNF basal plane, and pi‐pi interactions with newly exfoliated planar basal plane surfaces of the GNFs. Raman spectroscopy results confirm the formation of GNFs with only a few layers of graphene formed by the ISE process. Fabricated 10 wt.% G‐EMC nanocomposites show a 400%–500% increase in strength and fracture toughness. And 35 wt.% G‐EMCs provide an electrical conductivity of 25.64 S m −1 and a sensor gauge factor of 45. The resulting intrinsic piezo resistivity of the fabricated nanocomposite has been exploited to fabricate a multi‐functional wired and wireless sensor for detecting different body movements, speech, human vital functions, solvents, and biomolecules.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design, fabrication, simulation, and testing of additively manufactured lattice-based copper heat sinks

Here, this study investigates the potential advantages of lattice structure-based bound metal material extrusion (MEX) 3D printing for fabricating high-performance copper heat sinks. Copper powder-filled polymer filaments, with a copper content of > 90 wt.%, were developed specifically for the bound metal MEX 3D printing process. Three types of structures—planar, strut, and surface lattices—were 3D printed to facilitate efficient heat transfer pathways within the heat sinks. Subsequent post-processing steps, including polymer removal and sintering, were performed to achieve dense copper parts. Hot isostatic pressing was further employed to enhance the sintered density from 93 to 98%. Finite element analysis (FEA) simulations were conducted to assess the heat transfer efficiency of the designs, and heat transfer experiments were performed using a custom setup to validate the simulation results. Additionally, this research explores the use of extended hold times during pre-sintering and a reduced atmosphere to enhance the %IACS values (electrical conductivity) and thermal performance of the bound metal MEX 3D printed copper heat sinks. The investigation combines experimental analysis, including simulations and heat transfer experiments, to gain insights into the structure-material property relationships and optimize the thermal performance of the printed heat sinks.

Ajjarapu, Kameswara Pavan Kumar [Oak Ridge Nationa↗

DOE OSTI2026

Oak Ridge National Laboratory Building Envelope Library (ORNOBEL)

The Oak Ridge National Laboratory Building Envelope Library (ORNOBEL) is a collection of dense exterior building-facade point clouds acquired using a survey-grade terrestrial laser scanner. Each file represents an individual facade from a building on the Oak Ridge National Laboratory (ORNL) campus or in Knoxville, Tennessee, with an average point-cloud resolution of approximately 3 mm. The points in each facade are semantically labeled into three classes: (1) window/door, representing openings in the building envelope; (2) wall, representing planar opaque envelope surfaces; and (3) other, representing the remaining facade-adjacent elements, architectural features, and protrusions. ORNOBEL supports the development, training, and evaluation of advanced deep-learning methods for automated building-envelope segmentation, geometric reconstruction, and building information modeling (BIM).

Maldonado Puente, Bryan [ORNL] (ORCID:000000033880↗

NASA NTRS1974

Computer program for calculating laminar, transitional, and turbulent boundary layers for a compressible axisymmetric flow

Finite-difference computer program calculates viscous compressible boundary layer flow over either planar or axisymmetric surfaces. Flow may be initially laminar and progress through transitional zone to fully turbulent flow, or it may remain laminar, depending on imposed boundary conditions, laws of viscosity, and numerical solution of momentum and energy equations.

Albers, J. A.↗

NASA NTRS1974

Computer program for calculating laminar, transitional, and turbulent boundary layers for a compressible axisymmetric flow

A finite-difference program is described for calculating the viscous compressible boundary layer flow over either planar or axisymmetric surfaces. The flow may be initially laminar and progress through a transitional zone to fully turbulent flow, or it may remain laminar, depending on the imposed boundary conditions, laws of viscosity, and numerical solution of the momentum and energy equations. The flow may also be forced into a turbulent flow at a chosen spot by the data input. The input may contain the factors of arbitrary Reynolds number, free-stream Mach number, free-stream turbulence, wall heating or cooling, longitudinal wall curvature, wall suction or blowing, and wall roughness. The solution may start from an initial Falkner-Skan similarity profile, an approximate equilibrium turbulent profile, or an initial arbitrary input profile.

Albers, J. A.↗

NASA NTRS1980

A three-dimensional turbulent compressible subsonic duct flow analysis for use with constructed coordinate systems

An approximate analysis, applicable to nonorthogonal coordinate systems having a curved centerline and planar transverse coordinate surfaces normal to the centerline, is presented for computation of three-dimensional subsonic flow in straight and curved diffusers. The formulation is intended to facilitate the use of constructed coordinates in circumstances where it is difficult to maintain smooth behavior in higher derivatives; the use of local Cartesian variables and fluxes leads to governing equations which require only first derivatives of the coordinate transformation. The analysis is applied to a particular family of duct and diffuser geometries having curved centerlines and superelliptic cross sections. Qualitative agreement with experimental measurements is observed with regard to streamwise vortices and distortion of the primary flow.

Levy, R.↗