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Results for “Digital Fabrication”

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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Nonscanning climate sensor study

The Nonscanning Climate Sensor represents a new instrument for climate research and global monitoring of the earth radiation budget. It contains a mosaic of array of detectors which measures the outgoing radiation of the earth in all directions without the need for mechanical scanning. The goal is to eliminate all moving parts and obtain highly calibrated measurements for up to one solar cycle (11 years) without being susceptible to mechanical failure. Over set intervals of time, the angular measurements are integrated up to produce total reflected and emitted flux values from each target area on the Earth. To achieve the require sensitivity while maintaining a flat spectral response, an improved dual cavity detector with digital control loop was developed. The detector is self calibrating to maintain high precision over the life of the instrument. Prototype detectors and a complete set of electronics with a microprocessor controller were fabricated and tested. Measurements show that the new detectors are more than an order of magnitude more sensitive than previous versions.

Hoffman, James W.↗
NASA NTRS1986

Practical design of magnetic heading sensors

Although fluxgate magnetometers have been in use for many years, and a number of theoretical studies of these sensors are available, very little information has been published on the engineering choices relating to the detailed design of magnetometers intended for navigational applications in aircraft and other vehicles. This paper addresses some of the problems encountered in the design of the sensing head, the choice of operating mode, and the design of the supporting electronics for a simple low-cost magnetometer system which will produce a digital readout of the magnetic heading of the vehicle in which it is mounted. A major goal of this study has been to develop a design which minimizes circuit complexity, is easy to fabricate and calibrate, and utilizes a minimum of specialized components. Such a magnetometer system is intended either as a stand-alone indicating instrument or as a source of magnetic heading information for a more sophisticated navigational system.

Garner, H. D.↗
NASA NTRS2019

Characterizing Damage Accumulation in CMCs

Silicon carbide / silicon carbide ceramic matrix composites (SiC/SiC CMCs) are structural ceramics that are well-suited for the extreme environment conditions of aerospace applications largely due to their low weight, creep resistance, damage tolerance, and high specific strength. In CMCs, the initiation and evolution of damage is influenced by a number of factors including characteristics of the constituent landscape (porosity, interfacial properties, and geometric distribution of CMC constituents), thermo-mechanical loading parameters, and environmental conditions. However, much is still unknown about these factors and the interactions between them. In order to accurately predict the lifetimes of these advanced composites, it is critical to understand the evolution of damage and to characterize which early damage mechanisms (and their relationship to key microstructural features) subsequently lead to crack coalescence and macroscopic failure. This research focuses on the use of a multi-modal, experimental approach to examine the relative activity of surface and subsurface damage mechanisms in CMCs. The impact of fabrication choices on the evolution of damage to final failure, and the influence of constituent architecture on early damage mechanisms, are investigated. This approach combines acoustic emission (AE) with microscale deformation tracking via digital image correlation inside a scanning electron microscope (SEM-DIC). The potential application of this combined approach towards characterization of damage in SiC/SiC CMCs under more complex testing conditions is explored.

Swaminathan, Bhavana↗
NASA NTRS2019

T2SL meta-surfaced digital focal plane arrays for earth remote sensing applications

Long-wavelength infrared (LWIR) focal plane arrays (FPAs) needed for Earth Science imaging, spectral imaging, and sounding applications have always been among the most challenging in infrared photodetector technology due to the rigorous material growth, device design and fabrication demands. Future small satellite missions will present even more challenges for LWIR FPAs, as operating temperature must be increased so that cooler (and radiator) volume, mass, and power can be reduced.

Hill, Cory↗
NASA NTRS1983

Advanced 3-V semiconductor technology assessment

Components required for extensions of currently planned space communications systems are discussed for large antennas, crosslink systems, single sideband systems, Aerostat systems, and digital signal processing. Systems using advanced modulation concepts and new concepts in communications satellites are included. The current status and trends in materials technology are examined with emphasis on bulk growth of semi-insulating GaAs and InP, epitaxial growth, and ion implantation. Microwave solid state discrete active devices, multigigabit rate GaAs digital integrated circuits, microwave integrated circuits, and the exploratory development of GaInAs devices, heterojunction devices, and quasi-ballistic devices is considered. Competing technologies such as RF power generation, filter structures, and microwave circuit fabrication are discussed. The fundamental limits of semiconductor devices and problems in implementation are explored.

Nowogrodzki, M.↗
DOE OSTI2023

Glass Additive and Subtractive Manufacturing of a Fiber Optic Rotary Encoder for Downhole Pressure Sensing

This article presents a fiber optic rotary encoder-based pressure sensor for downhole applications. The rotary encoder, which is composed of an encoding pad and an all-glass optical fiber sensing head, converts the rotation angles of a pressure transducer to digital codes. The optical fiber only serves as the telemetry channel to directly transmit the data in digital format such that the environmental temperature influence and the long-time drift are minimized. The glass additive and subtractive manufacturing (ASM) techniques are used to embed the multichannel optical fibers into a bulk-fused silica glass substrate. Because the fused silica glass shares a similar material property to the optical fiber (e.g., thermal expansion coefficient), the optical fiber sensing head is well sealed and fixed even at an elevated temperature. The picosecond laser blackening technique is used to fabricate the high reflectivity contrast encoding pad with high accuracy. Here, the proposed pressure sensor was manufactured and experimentally verified to have a signal-to-noise ratio (SNR) of 23 dB and a linear pressure response with a root-mean-square error (RMSE) of 0.37. During the 400-h 250 °C long-term stability test, there was no digital code variation. In addition, a mathematical model to study the relationships between the sensor’s performances and design parameters was established. According to the model, a 12-bit encoder (0.02% pressure sensitivity) can be achieved with a radius of 20 mm.

02 PETROLEUM↗
DOE OSTI2024

Time-resolved synchrotron light source X-ray detection with Low-Gain Avalanche Diodes

Low Gain Avalanche Diodes (LGADs) represent the state-of-the-art in timing measurements and will instrument future timing detectors at the High Luminosity Large Hadron Collider (HL-LHC) experiments. While conceived as a sensor for charged particles, the intrinsic gain of LGADs makes it possible to detect low energy X-rays with good energy resolution and excellent timing (tens of picoseconds). Here, using the Stanford Synchrotron Radiation Lightsource (SSRL) at SLAC, several LGADs designs were characterized with energies from 5 to 35 keV. The SSRL provides 10 ps pulsed X-ray bunches separated by 2.1 ns intervals, and with an energy dispersion (ΔE/E) of 1 X 10 -4 . LGADs fabricated by Hamamatsu Photonics (HPK) and Brookhaven National Laboratory (BNL) with different thicknesses ranging from 20 µm to 50 µm and different gain layer designs were read out a two stage fast amplification circuit and digitized with a high bandwidth, high sampling rate oscilloscope. PIN devices from HPK were characterized as well. A systematic and detailed characterization of the devices’ energy linearity, resolution and timing resolution as a function of X-ray energy was performed for different biasing voltages at room temperature

Charge multiplication↗
NASA NTRS1976

Inspection of composites using a computer-based real-time radiographic facility

A radiographic inspection facility was developed at the NASA Lewis Research Center. The facility uses a digital computer to provide enhanced images in near real-time. Some capabilities of the facility are demonstrated in the inspection of a fan frame ring for an experimental aircraft gas turbine. The ring was fabricated from a carbon-fiber-reinforced epoxy composite material. Inspection procedures were evaluated, and comparisons were made with an ultrasonic C-scan and conventional film X-ray.

Roberts, E., Jr.↗
NASA NTRS1982

Evaluation of methods for characterizing surface topography of models for high Reynolds number wind-tunnels

Current work by the National Bureau of Standards at the NASA National Transonic Facility (NTF) to evaluate the performance of stylus instruments for determining the topography of models under investigation is described along with instrumentation for characterization of the surface microtopography. Potential areas of surface effects are reviewed, and the need for finer surfaced models for the NTF high Reynolds number flows is stressed. Current stylus instruments have a radii as large as 25 microns, and three models with surface finishes of 4-6, 8-10, and 12-15 micro-in. rms surface finishes were fabricated for tests with a stylus with a tip radius of 1 micron and a 50 mg force. Work involving three-dimensional stylus profilometry is discussed in terms of stylus displacement being converted to digital signals, and the design of a light scattering instrument capable of measuring the surface finish on curved objects is presented.

Teague, E. C.↗
NASA NTRS2004

The Development of a Plan for the Assessment, Improvement and Deployment of a Radar Acoustic Sounding System (RASS) for Wake Vortex Detection

This report describes the activities completed under a grant from the NASA Langley Research Center to develop a plan for the assessment, improvement, and deployment of a Radar Acoustic Sounding System (RASS) for the detection of wake vortices. A brief review is provided of existing alternative instruments for wake vortex detection. This is followed by a review of previous implementations and assessment of a RASS. As a result of this review, it is concluded that the basic features of a RASS have several advantages over other commonly used wake vortex detection and measurement systems. Most important of these features are the good fidelity of the measurements and the potential for all weather operation. To realize the full potential of this remote sensing instrument, a plan for the development of a RASS designed specifically for wake vortex detection and measurement has been prepared. To keep costs to a minimum, this program would start with the development an inexpensive laboratory-scale version of a RASS system. The new instrument would be developed in several stages, each allowing for a critical assessment of the instrument s potential and limitations. The instrument, in its initial stages of development, would be tested in a controlled laboratory environment. A jet vortex simulator, a prototype version of which has already been fabricated, would be interrogated by the RASS system. The details of the laboratory vortex would be measured using a Particle Image Velocimetry (PIV) system. In the early development stages, the scattered radar signal would be digitized and the signal post-processed to determine how extensively and accurately the RASS could measure properties of the wake vortex. If the initial tests prove to be successful, a real-time, digital signal processing system would be developed as a component of the RASS system. At each stage of the instrument development and testing, the implications of the scaling required for a full-scale instrument would be considered. It is concluded that a RASS system, developed for the specific application of wake vortex detection, could become part of a robust Aircraft Vortex Spacing System (AVOSS). This system, in turn, could contribute to Reduced Spacing Operations (RSO) in US airports and improvements in Terminal Area productivity (TAP).

Morris, Philip J.↗
DOE OSTI2021

Mask Free OLED Fabrication Process for Non-Tunable and Tunable White OLED Panels

In this program we demonstrated a method for mask free fabrication of OLEDs. Conventional OLEDs use at least 2 shadowmasks during the fabrication process to define the deposition pattern for the organic layers and for the cathode layer. Although effective, the use of masks requires mask handling and mask change equipment which increases the cost of the OLED deposition system. New sets of masks are required for every new product design, and the mask sets require frequent cleaning as organic material builds up on the masks over time and can be a source of particle defects resulting in yield loss. The method investigated in this program uses laser removal of organic material to pattern the organic layers and define a moisture impermeable seal region. This method is digital and can be applied to any new panel design, avoiding the costs of new masks sets and associated yield loss. In addition, we developed a platform technology for producing white color tunable or dim-to-warm white OLEDs and demonstrated patterning of tunable white OLEDs using the low-cost mask free fabrication process.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1982

Airborne multispectral linear array instruments at Goddard Space Flight Center

The fabrication of airborne instruments is contributing to the development of multispectral linear array technology at NASA's Goddard Space Flight Center. The linear array pushbroom radiometer (LAPR-I), was built to demonstrate capabilities for acquiring digital image data using linear arrays. The LAPR-I employed three arrays of 512 silicon photodiodes each to simultaneously acquire three channels of data for spectral bands within the visible and near-infrared portions of the spectrum. A second instrument, LAPR-II, uses four arrays each consisting of 512 silicon detectors. A filter wheel containing six spectral filters is used in conjunction with each array to allow filter changes in flight. This capability will facilitate studies into the utility of various bands within the visible and near infrared portions of the spectrum. The LAPR-II's aircraft mounting will allow off-nadir pointing (plus-or-minus 50 deg fore-and-aft and side-to-side) which will enable investigations of the radiometric and geometric effects of off-nadir viewing. A short wave infrared radiometer is also described.

Irons, J. R.↗
DOE OSTI2023

Digital Light Processing (DLP): 3D printing of polymer-based graphene oxide nanocomposites—Efficient antimicrobial material for biomedical devices

Bacterial infections are one of the major causes of surgical implant inefficiency and failure. Herein, we present a Nanocomposite (NC) produced by the addition of Poly(N-vinyl carbazole)-Graphene Oxide dispersion (PVK-GO) as a nanofiller to a commercial photopolymer acrylate resin and 3D printed as coatings via the Digital Light Processing technique. Characterization and bioassay results against Escherichia coli and Staphylococcus aureus confirmed the elevated thermomechanical properties and efficient antibacterial activity of the printed NC-based coatings. In conclusion, the present study demonstrates the fabrication and optimization of a PVK-GO-based NC and its potential utilization as a 3D-printable material for biomedical applications.

2D materials↗
DOE OSTI2021

Characterization of edge damage induced on REBCO superconducting tape by mechanical slitting

Abstract Rare-earth barium-copper-oxide (REBCO) superconductors are high-field superconductors fabricated in a tape geometry that can be utilized in magnet applications well in excess of 20 T. Due to the multilayer architecture of the tape, delamination is one cause of mechanical failure in REBCO tapes. During a mechanical slitting step in the manufacturing process, edge cracks can be introduced into the tape. These cracks are thought to be potential initiation sites for crack propagation in the tapes when subjected to stresses in the fabrication and operation of magnet systems. We sought to understand which layers were the mechanically weakest by locating the crack initiation layer and identifying the geometrical conditions of the slitter that promoted or suppressed crack formation. The described cracking was investigated by selectively etching and characterizing each layer with scanning electron microscopy, laser confocal microscopy, and digital image analysis. Our analysis showed that the average crack lengths in the REBCO, LaMnO 3 (LMO) and Al 2 O 3 layers were 34 μ m, 28 μ m, and 15 μ m, respectively. The total number of cracks measured in 30 mm of wire length was between 3000 and 5700 depending on the layer and their crack densities were 102 cracks mm −1 for REBCO, 108 cracks mm −1 for LMO, and 183 cracks mm −1 for Al 2 O 3 . These results indicated that there are separate crack initiation mechanisms for the REBCO and the LMO layers, as detailed in the paper. With a better understanding of the crack growth behavior exhibited by REBCO tapes, the fabrication process can be improved to provide a more mechanically stable and cost-effective superconductor.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Radiation-Hard Smart-Pixel Detector ASIC ReadOut with Digital AI in 28nm

Detectors at future high energy colliders will face enormous technical challenges. Disentangling the unprecedented numbers of particles expected in each event will require highly granular silicon pixel detectors with billions of readout channels. With event rates as high as 40 MHz, these detectors will generate petabytes of data per second. To enable discovery within strict bandwidth and latency constraints, future trackers must be capable of fast, power efficient, and radiation hard data-reduction at the source. This effort is pursuing the co-design development of high-performance readout smart pixel ASICs for a future Phase III High Luminosity upgrade of the Large Hadron Collider. A 1.6mm2 ASIC prototype was designed by Fermilab in CMOS 28 nm bulk process and submitted for manufacturing in February 2024. It leverages the analog front-end pixel design of a previous prototype fabricated and tested in 2023, which achieved a simulated detection level of ~400e- with 30fF input capacitance. The ROIC consists of two matrices of 16×16 smart pixels, each 25×25 μm2 in size. Each smart pixel contains a charge-sensitive preamplifier with leakage current compensation and three auto-zero comparators for a 2-bit flash-type ADC. There is digital space for the integration of our fully combinatorial AI that performs momentum classification at the bunch crossing rate. The total power consumption is ∼6μW per pixel, which corresponds to ~1mW/cm2. The ASIC incorporates programmable front-end charge injection circuitry to generate pixel cluster charges during characterization. The cluster profile will be generated to duplicate hit characteristics of various momentum (pT). We will present early results from chip testing.

Parpillon, Benjamin↗
DOE OSTI2023

Mitigating challenges in aberration-corrected electron-beam lithography on electron-opaque substrates

Aberration-corrected electron-beam lithography (AC-EBL) using ultra-thin electron transparent membranes has achieved single-digit nanometer resolution in two widely used electron-beam resists: poly (methyl methacrylate) (PMMA) and hydrogen silsesquioxane. On the other hand, AC-EBL implementation on thick, electron-opaque substrates is appealing for conventional top-down fabrication of quantum devices with nanometer-scale features. To investigate the performance of AC-EBL on thick substrates, we measured the lithographic point spread function of a 200 keV aberration-corrected scanning transmission electron microscope by defining both positive and negative patterns in PMMA thin films, spin-cast on thick SiO 2 /Si substrates. We present the problems encountered during pre-exposure beam focusing and discuss methods to overcome them. In addition, applying some of these methods using commercial 50 nm thick SiN X membranes with thick Si support frames, we printed arrays of holes in PMMA with pitches around 26 nm on SiN X /Si substrates with increasing Si thickness. Here, our results show that proximity effects from even 50 nm thick SiN X membranes limit hole arrays to 20 nm pitch; however, down to this limit, the effect of the substrate thickness on the pattern quality is minimal. These results highlight the need for novel resists less susceptible to proximity effects, or resists which can be used directly, after development, as the dielectric material in periodic gates in 2D quantum devices.

2D quantum devices↗
DOE OSTI2024

A Modular 512-Channel Neural Signal Acquisition ASIC for High-Density 4096 Channel Electrophysiology

The complexity of information processing in the brain requires the development of technologies that can provide spatial and temporal resolution by means of dense electrode arrays paired with high-channel-count signal acquisition electronics. In this work, we present an ultra-low noise modular 512-channel neural recording circuit that is scalable to up to 4096 simultaneously recording channels. The neural readout application-specific integrated circuit (ASIC) uses a dense 8.2 mm × 6.8 mm 2D layout to enable high-channel count, creating an ultra-light 350 mg flexible module. The module can be deployed on headstages for small animals like rodents and songbirds, and it can be integrated with a variety of electrode arrays. The chip was fabricated in a TSMC 0.18 µm 1.8 V CMOS technology and dissipates a total of 125 mW. Each DC-coupled channel features a gain and bandwidth programmable analog front-end along with 14 b analog-to-digital conversion at speeds up to 30 kS/s. Additionally, each front-end includes programmable electrode plating and electrode impedance measurement capability. We present both standalone and in vivo measurements results, demonstrating the readout of spikes and field potentials that are modulated by a sensory input.

47 OTHER INSTRUMENTATION↗
NASA NTRS1984

Experimental results for the rapid determination of the freezing point of fuels

Two methods for the rapid determination of the freezing point of fuels were investigated: an optical method, which detected the change in light transmission from the disappearance of solid particles in the melted fuel; and a differential thermal analysis (DTA) method, which sensed the latent heat of fusion. A laboratory apparatus was fabricated to test the two methods. Cooling was done by thermoelectric modules using an ice-water bath as a heat sink. The DTA method was later modified to eliminate the reference fuel. The data from the sample were digitized and a point of inflection, which corresponds to the ASTM D-2386 freezing point (final melting point), was identified from the derivative. The apparatus was modifified to cool the fuel to -60 C and controls were added for maintaining constant cooling rate, rewarming rate, and hold time at minimum temperature. A parametric series of tests were run for twelve fuels with freezing points from -10 C to -50 C, varying cooling rate, rewarming rate, and hold time. Based on the results, an optimum test procedure was established. The results showed good agreement with ASTM D-2386 freezing point and differential scanning calorimetry results.

Mathiprakasam, B.↗