Search NASA⌕ Search

SEARCH · Search NASA

Results for “casting technology”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS1982

Interim review of the Energy Efficient Engine /E3/ Program

The NASA-sponsored Energy Efficient Engine (E3) Program, which is now in its fourth year, is assessed from the viewpoint of one of its research contractors. Attention is given to the development status of the shroudless fan, segmented combustor and exhaust mixer components which are encompassed by the program. The shroudless fan blades are two-thirds hollow for lightness, and are fabricated by means of plies and cores subjected to hot isostatic pressing diffusion bonding. The combustor's segmented liner is cast from turbine blade materials. Exhaust mixer flow visualization tests are described. Consideration is given to the effects of integrating the technology described with the low and high pressure advanced turbines whose development is also part of the E3 program.

Gardner, W. B.↗
NASA NTRS2000

Characterizing the Use of Ultrasonic Energy in Promoting Uniform Composite Growth in Immiscible Alloys

The results of experimental investigation and mathematical modeling for immiscible alloys subjected to ultrasonic influence are presented. It is known that in inoculated light alloy melts, ultrasonic treatment creates a new type of cast structure with extremely fine grains of uniform composition. This effect is produced across a wide range of freezing rates and technologies. However, it has not been demonstrated that the process can be successfully applied during controlled directional solidification processing. In this work we present the results from a set of directional solidification experiments and suggest describing the droplet size versus ultrasonic frequency and amplitude using an energy approach, followed with a more detailed analysis through numerical modeling of the ultrasonic field.

Grugel, Richard N.↗
DOE OSTI2017

Nitrate Salt Based Melt Cast Materials

Three new low melting compositions have been developed here based on the ingredients amino-1,2,4-triazolium nitrate, 3,5-diamino-1,2,4-triazolium nitrate and ammonium nitrate, to create the formulation AAD, in addition to mixtures comprising guanidinium 5-amino-tetrazolate and ammonium nitrate in either a 1 : 3 or 1 : 6 mole ratio (GAN13 and GAN16 respectively). The materials melt in the range of 95–100 °C and do not begin to decompose until >195 °C. The formulations are insensitive to impact, spark and friction and were calculated to show promising explosive performance properties (V D =8.78–9.0 km/s, P CJ =28.4–30.6 GPa). HMX mixtures of AAD, GAN13 and GAN16 were also prepared and these materials were characterized with respect to their safety and performance as well.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2018

FY2017 Materials Annual Progress Report

The Materials Technology subprogram supports the Vehicle Technology Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced Lightweight Materials research enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25 percent weight reduction for light-duty vehicles including body, chassis, and interior as compared to a 2012 baseline at no more than a $5/lb-saved increase in cost; and (2) validate a 25 percent improvement in high temperature (300°C) component strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency light-duty engines.

36 MATERIALS SCIENCE↗
DOE OSTI2013

A Deployable Fast-Neutron Coded-Aperture Imager for Quantifying Nuclear Material

This brief report describes a newly constructed fast-neutron coded-aperture imager intended for performing quantitative measurements of plutonium holdup at fuel cycle facilities. The present report was prepared in fulfillment of milestone M4FT-13OR0402053, “Construct Imager,” of Fuel Cycle R&D Material Protection, Accounting, and Control Technology (MPACT) work package FT-13OR040205, “Fast-Neutron Imaging to Quantify Nuclear Materials - ORNL.” The first measurements taken with the imager will be reported later this year. For quantifying plutonium holdup, fast-neutron imaging is an appealing mode of measurement in scenarios where contact measurements with non-imaging detectors may be impractical or their results ambiguous because of surrounding material or nearby sources. The use of fast neutrons (as opposed to the more numerous gamma rays) is appealing because of their ability to penetrate equipment and nuclear material that is opaque to gamma radiation. However, the ability of fast neutrons to penetrate material also leads to challenges in constructing a fast-neutron imager sufficiently compact to be amenable for use in a facility while remaining sufficiently sensitive to neutron emanations from plutonium or other actinides. Furthermore, while fast-neutron detection is commonly achieved via organic liquid scintillators, use of the imager in a production environment favors mechanically robust detectors that do not contain flammable liquid. In response to these challenges, Oak Ridge National Laboratory (ORNL) has built a fast-neutron imager that has a compact footprint and whose segmented neutron detectors are built from the first cast plate of the recently developed plastic scintillator with pulse shape discrimination properties developed by Lawrence Livermore National Laboratory and commercially available from Eljen Technologies as experimental scintillator EJ-299-34.

Hausladen, Paul↗
DOE OSTI2019

Materials 2018 Annual Progress Report

The Materials Technology Program supports the Vehicles Technologies Office’s mission to help consumers and businesses reduce their transportation energy costs while meeting or exceeding vehicle performance expectations. The propulsion materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needs of a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. Advanced lightweight materials enable improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron and traditional steel components with lightweight materials such as high-strength steel, magnesium (Mg), aluminum (Al), and polymer composites can directly reduce a vehicle’s fuel consumption. Materials technology activities focus on the following cost and performance targets: (1) enable a 25% weight reduction for light-duty (LD) vehicles including body, chassis, and interior as compared to a model year 2012 baseline at no more than a $\$$5/lb-saved increase in cost; and (2) validate a 25% improvement in high-temperature (300°C) development of engine exhaust catalyst materials strength relative to components made with 2010 baseline cast Al alloys (A319 or A356) for improved efficiency LD engines.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2013

The Deployable Fast-Neutron Coded-Aperture Imager: Demonstration of Locating One or More Sources in Three Dimensions

This brief report describes commissioning measurements performed using a newly constructed fast neutron coded-aperture imager intended for performing quantitative measurements of plutonium holdup at fuel cycle facilities. The present report was prepared in fulfillment of milestone M3FT-13OR0402054, “Imager commissioning and 3D source configuration measurements” of Fuel Cycle R&D Material Protection, Accounting, and Control Technology (MPACT) work package FT-13OR040205, “Fast Neutron Imaging to Quantify Nuclear Materials - ORNL.” In addition to representing the first measurements made with the new device, these measurements also demonstrate for the first time the ability to localize one or more neutron sources in three dimensions by combining imaging data from multiple measurements in which the imager was positioned at different locations. The development and use of fast-neutron imaging technology are motivated by a desire to locate and quantify plutonium holdup in scenarios where contact measurements with non-imaging detectors may be impractical or their results ambiguous because of surrounding material or nearby sources. Considering the goal of quantitative measurements, fast neutrons (as opposed to the more numerous gamma rays) are preferred in many situations because of their ability to penetrate equipment and nuclear material that are essentially opaque to gamma radiation. However, there are many challenges associated with constructing a practical imager for fast neutrons. For example, the ability of fast neutrons to penetrate material also leads to challenges in constructing a fast-neutron imager that is sufficiently compact to be suitable for use in a facility while remaining sufficiently sensitive to neutron emanations from plutonium or other actinides. Moreover, use of the imager in a production environment favors mechanically robust detectors that do not contain flammable liquid, unlike the organic liquid scintillators that are typically used to achieve fast-neutron detection. Last of all, a single-sided measurement geometry, as is typically used in imaging applications, necessitates accurate measurement of the location of a deposit of plutonium holdup in three dimensions in order to correctly infer the source strength. In response to these challenges, Oak Ridge National Laboratory (ORNL) has built a fast-neutron imager that has a compact footprint and whose segmented neutron detectors are built from the first cast plate of the recently developed plastic scintillator with pulse shape discrimination properties developed by Lawrence Livermore National Laboratory and commercially available from Eljen Technologies as experimental scintillator EJ-299-34. This report presents a description and preliminary analysis of mock holdup measurements intended to determine the three-dimensional location of one or more neutron sources placed in prototypical equipment from a set of imaging measurements that scanned the extent of the equipment.

Hausladen, Paul↗
DOE OSTI2016

Numerical modeling of heat-transfer and the influence of process parameters on tailoring the grain morphology of IN718 in electron beam additive manufacturing

The fabrication of 3-D parts from CAD models by additive manufacturing (AM) is a disruptive technology that is transforming the metal manufacturing industry. The correlation between solidification microstructure and mechanical properties has been well understood in the casting and welding processes over the years. This paper focuses on extending these principles to additive manufacturing to understand the transient phenomena of repeated melting and solidification during electron beam powder melting process to achieve site-specific microstructure control within a fabricated component. In this paper, we have developed a novel melt scan strategy for electron beam melting of nickel-base superalloy (Inconel 718) and also analyzed 3-D heat transfer conditions using a parallel numerical solidification code (Truchas) developed at Los Alamos National Laboratory. The spatial and temporal variations of temperature gradient (G) and growth velocity (R) at the liquid-solid interface of the melt pool were calculated as a function of electron beam parameters. By manipulating the relative number of voxels that lie in the columnar or equiaxed region, the crystallographic texture of the components can be controlled to an extent. The analysis of the parameters provided optimum processing conditions that will result in columnar to equiaxed transition (CET) during the solidification. Furthermore, the results from the numerical simulations were validated by experimental processing and characterization thereby proving the potential of additive manufacturing process to achieve site-specific crystallographic texture control within a fabricated component.

43 PARTICLE ACCELERATORS↗
NASA NTRS1987

Creep-rupture behavior of a developmental cast-iron-base alloy for use up to 800 deg C

A promising iron-base cast alloy is being developed as part of the DOE/NASA Stirling Engine Systems Project under contract DEN 3-282 with the United Technologies Research Center. This report presents the results of a study at the Lewis Research Center of the alloy's creep-rupture properties. The alloy was tested under a variety of conditions and was found to exhibit the normal 3-stage creep response. The alloy compared favorably with others being used or under consideration for the automotive Stirling engine cylinder/regenerator housing.

Titran, Robert H.↗
NASA NTRS2011

Inside NanoSail-D: A Tiny Satellite with Big Ideas

"Small But Mighty" certainly describes the NanoSail-D experiment and mission. Its unique goals and designs were simple, but the implications of this technology are far reaching. From a tiny 3U CubeSat, NanoSail-D deployed a 10 square meter solar sail. This was the first sail vehicle to orbit the earth and was only the second time a sail was unfurled in space. The NanoSail-D team included: two NASA centers, Marshall and Ames, the universities of Alabama in Huntsville and Santa Clara in California, the Air Force Research Laboratory and many contractors including NeXolve, Gray Research and several others. The collaborative nature was imperative to the success of this project. In addition, the Army Space and Missile Defense Command, the Von Braun Center for Science and Innovation and Dynetics Inc. jointly sponsored the NanoSail-D project. This paper presents in-depth insight into the NanoSail-D development. Its design was a combination of left over space hardware coupled with cutting edge technology. Since this NanoSail-D mission was different from the first, several modifications were necessary for the second NanoSail-D unit. Unforeseen problems arose during refurbishment of the second unit and the team had to overcome these obstacles. Simple interfaces, clear responsibilities and division of effort allowed the team members to work independently on the common goal. This endeavor formed working relationships lasting well beyond the end of this mission. NanoSail-D pushed the technology envelop with future applications for all classes of satellites. NanoSail-D is truly a small but mighty satellite, which may cast a very big shadow for years to come.

Alhorn, Dean C.↗
DOE OSTI2025

Manufacturing of Al-Ce/Metal-Matrix-Composites (MMC) for Harsh Environments

An integrated modeling/simulation and experimental approach will be used to design and synthesize Al-Ce/MMC for use in key technologies where improved energy efficiency and performance is harsh environments is required. Modeling and simulation work including thermodynamic modeling, DFT calculations, and continuum modeling of casting processes and mechanical behavior, will be combined with lab-scale synthesis to identify potential matrix and reinforcing phase compositions for large-scale synthesis. The experimental synthesis work will rely on lab-scale casting and gas atomization to identify the optimal matrix compositions for pilot/commercial-scale synthesis is Al-Ce/MMC. Selected Al-Ce/MMC will be synthesized by commercial scale melt processing, powder metallurgy and thermomechanical processing. The corrosion resistance, mechanical properties as a function of temperature, and thermal conductivity of the composites will be characterized to validate target properties are met or exceeded. This work will focus on two selected applications; however, the design framework will have broad applicability for composites for numerous harsh service condition applications. We will have synthesized Al-Ce/MMC that exhibit better performance in harsh environments than currently used materials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Development of flexible, free-standing, thin films for additive manufacturing and localized energy generation

Film energetics are becoming increasingly popular because a variety of technologies are driving a need for localized energy generation in a stable, safe and flexible form. Aluminum (Al) and molybdenum trioxide (MoO{sub 3}) composites were mixed into a silicon binder and extruded using a blade casting technique to form flexible free-standing films ideal for localized energy generation. Since this material can be extruded onto a surface it is well suited to additive manufacturing applications. This study examines the influence of 0-35% by mass potassium perchlorate (KClO{sub 4}) additive on the combustion behavior of these energetic films. Without KClO{sub 4} the film exhibits thermal instabilities that produce unsteady energy propagation upon reaction. All films were cast at a thickness of 1 mm with constant volume percent solids to ensure consistent rheological properties. The films were ignited and flame propagation was measured. The results show that as the mass percent KClO{sub 4} increased, the flame speed increased and peaked at 0.43 cm/s and 30 wt% KClO{sub 4}. Thermochemical equilibrium simulations show that the heat of combustion increases with increasing KClO{sub 4} concentration up to a maximum at 20 wt% when the heat of combustion plateaus, indicating that the increased chemical energy liberated by the additional KClO{sub 4} promotes stable energy propagation. Differential scanning calorimeter and thermogravimetric analysis show that the silicone binder participates as a fuel and reacts with KClO{sub 4} adding energy to the reaction and promoting propagation.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Structural Benchmark Testing of Superalloy Lattice Block Subelements Completed

Superalloy lattice block panels, which are produced directly by investment casting, are composed of thin ligaments arranged in three-dimensional triangulated trusslike structures (see the preceding figure). Optionally, solid panel face sheets can be formed integrally during casting. In either form, lattice block panels can easily be produced with weights less than 25 percent of the mass of a solid panel. Inconel 718 (IN 718) and MarM-247 superalloy lattice block panels have been developed under NASA's Ultra-Efficient Engine Technology Project and Higher Operating Temperature Propulsion Components Project to take advantage of the superalloys' high strength and elevated temperature capability with the inherent light weight and high stiffness of the lattice architecture (ref. 1). These characteristics are important in the future development of turbine engine components. Casting quality and structural efficiency were evaluated experimentally using small beam specimens machined from the cast and heat treated 140- by 300- by 11-mm panels. The matrix of specimens included samples of each superalloy in both open-celled and single-face-sheet configurations, machined from longitudinal, transverse, and diagonal panel orientations. Thirty-five beam subelements were tested in Glenn's Life Prediction Branch's material test machine at room temperature and 650 C under both static (see the following photograph) and cyclic load conditions. Surprisingly, test results exceeded initial linear elastic analytical predictions. This was likely a result of the formation of plastic hinges and redundancies inherent in lattice block geometry, which was not considered in the finite element models. The value of a single face sheet was demonstrated by increased bending moment capacity, where the face sheet simultaneously increased the gross section modulus and braced the compression ligaments against early buckling as seen in open-cell specimens. Preexisting flaws in specimens were not a discriminator in flexural, shear, or stiffness measurements, again because of redundant load paths available in the lattice block structure. Early test results are available in references 2 and 3; more complete analyses are scheduled for publication in 2004.

Source record↗
NASA NTRS2000

High Cycle Fatigue Crack Initiation Study of Case Blade Alloy Rene 125

This study was conducted in order to investigate and document the high cycle fatigue crack initiation characteristics of blade alloy Rene 125 as cast by three commercially available processes. This alloy is typically used in turbine blade applications. It is currently being considered as a candidate alloy for high T3 compressor airfoil applications. This effort is part of NASA's Advanced Subsonic Technology (AST) program which aims to develop improved capabilities for the next generation subsonic gas turbine engine for commercial carriers. Wrought alloys, which are customarily used for airfoils in the compressor, cannot meet the property goals at the higher compressor exit temperatures that would be required for advanced ultra-high bypass engines. As a result cast alloys are currently being considered for such applications. Traditional blade materials such as Rene 125 have the high temperature capabilities required for such applications. However, the implementation of cast alloys in compressor airfoil applications where airfoils are typically much thinner does raise some issues of concern such as thin wall castability, casting cleaningness, and susceptibility to high-cycle fatigue (HCF) loading.

Kantzos, P.↗
DOE OSTI2019

Molecular packing control enables excellent performance and mechanical property of blade-cast all-polymer solar cells

All-polymer solar cells (all-PSCs) are the most promising power generators for flexible and portable devices due to excellent morphology stability and outstanding mechanical property. Prior work suggests high crystallinity is beneficial to device performance but detrimental to mechanical property, therefore identifying the optimized ratio between crystalline and amorphous domains becomes important. In this work, we demonstrated highly efficient and mechanically robust all-PSCs by blade-coating technology in ambient environment based on PTzBI:N2200 system. By controlling the aggregation in solution state and ultrafast film formation process, a weakly ordered molecular packing morphology as well as small phase separation is obtained, which leads to not only the good photovoltaic performance (8.36%-one of the best blade-cast device in air) but also prominent mechanical characteristic. The controlled film reflects a remarkable elongation with the crack onset strain of 15.6%, which is the highest result in organic solar cells without adding elastomers. These observations indicate the great promise of the developed all-PSCs for practical applications toward large-area processing technology.

42 ENGINEERING↗
DOE OSTI2022

Causes of fuel–ablator mix inferred from modeling of monochromatic time-gated radiography of OMEGA cryogenic implosions

Here, we present evidence, in the context of OMEGA cryogenic target implosions, that laser imprint, known to be capable of degrading laser-direct-drive target performance, plays a major role in generating fuel–ablator mix. OMEGA cryogenic target implosions show a performance boundary correlated with acceleration-phase shell stability; for sufficiently low adiabats (where the adiabat is the ratio of the pressure to the Fermi pressure) and high in-flight aspect ratios (IFAR's), the neutron-weighted shell areal density and neutron yield relative to the clean simulated values sharply decline. Direct evidence of Rayleigh–Taylor fuel–ablator mixing was previously obtained using a Si Heα backlighter driven by an ~20-ps short pulse generated by OMEGA EP. The shadow cast by the shell shortly prior to stagnation, as diagnosed using backlit radiographs, shows a softening near the limb, which is evidence of an ablator–fuel mix region for a low-adiabat implosion (α ~ 1.9, IFAR = 14) but not for a moderate adiabat implosion (α ~ 2.5, IFAR = 10). We find good agreement between experimental and synthetic radiographs in simulations that model laser imprint and account for uncertainty in the initial ablator thickness. Furthermore, we further explore the role of other mechanisms such as classical instability growth at the fuel–ablator interface, species concentration diffusion, and long-wavelength drive and target asymmetries.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2016

Transmutation Fuels Development in the Advanced Fuels Campaign

Metallic fuels have a history of use that spans the entire nuclear age, especially in association with the development of the LMFBR. Initially, metallic fuels were employed due to their ease of fabrication and high heavy metal density (which led to the most favorable breeding efficiencies in fast reactors). During subsequent decades of use, metallic fuel technology has matured significantly, leading to the realization of major benefits in the areas of fuel reliability and burnup, proliferation-resistant recycling, remote fabrication, and passive reactor safety. Such characteristics continue to make metallic fuels a highly attractive technology, especially for use with future sodium fast reactors. Current research and development activities on metallic fuels in DOE's Advanced Fuels Campaign are focused on their potential use for actinide transmutation in advanced SFRs. In such a mission, metallic fuels would be employed as part of a closed fuel cycle into which plutonium and minor actinides (Am, Np) recovered from LWR spent fuel would be incorporated. All actinides in this metallic fuel would be fissioned or transmuted in a fast reactor to eliminate the extremely long-lived, heat-producing actinides in order to reduce the volume, heat load, and radio-toxicity burden on a future geological repository. Thus, the need exists to demonstrate reliable performance of metallic fuels with Pu and minor actinide constituents to very high burnup. As part of this application, there is also a need for a near zero-loss fabrication process, since losses during fuel fabrication are a potential source of long-lived actinides destined for geologic disposal. This paper presents the current state and future direction of the development of metallic fuels for actinide transmutation in the US. Metallic fuels have had a long history of use in sodium-cooled fast reactors. Continued research, development, and design innovation over a period of decades have demonstrated this fuel technology to be safe and reliable to extremely high burnups over a wide range of compositions. Their simple fabrication has historically given them a significant economic advantage over other fuel forms. Research and development on metallic fuels continues, with particular emphasis on showing that this fuel technology can incorporate significant quantities of plutonium and minor actinides for the purpose of efficiently and economically transmuting these elements in a fast-spectrum reactor. New fabrication methods to improve retention of the volatile fuel constituents during the casting process (and reduce waste generation), are being developed. Irradiation testing of the new metallic fuels has so far indicated that the new compositions, although differing significantly both in the quantities of Pu and minor actinides included and in the Zr alloying addition, perform as a function of fission density very analogously to the historic U-Zr and U-Pu-Zr fuels. In the next few years it is anticipated that a new casting furnace prototype will demonstrate that these new metallic fuel alloys can be fabricated at engineering scale, in a remote environment, with no significant fuel loss or waste generation. Irradiation tests currently underway will provide the performance data needed to assess fuel reliability/burnup capability and identify any unique behaviors that are a result of the new compositions. If these future results are consistent with the intermediate data available at present, metallic fuels are expected to continue to be a strong contender for the fuel technology choice of future fast reactors. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

1366 Direct Wafer™: Demolishing the Cost Barrier for Silicon Photovoltaics

The goal of 1366 Direct Wafer™ is to drastically reduce the cost of silicon-based PV by eliminating the cost barrier imposed by sawn wafers. The key characteristics of Direct Wafer are 1) kerf-free, 156-mm standard silicon wafers 2) high throughput for very low CAPEX and rapid scale up. Together, these characteristics will allow Direct Wafer™ to become the new standard for silicon PV wafers and will enable terawatt-scale PV – a prospect that may not be possible with sawn wafers. Our single, high-throughput step will replace the expensive and rate-limiting process steps of ingot casting and sawing, thereby enabling drastically lower wafer cost. This High-Impact PV Supply Chain project addressed the challenges of scaling Direct Wafer technology for cost-effective, high-throughput production of commercially viable 156 mm wafers. The Direct Wafer process is inherently simple and offers the potential for very low production cost, but to realize this, it is necessary to demonstrate production of wafers at high-throughput that meet customer specifications. At the start of the program, 1366 had demonstrated (with ARPA-E funding) increases in solar cell efficiency from 10% to 15.9% on small area (20cm2), scaling wafer size up to the industry standard 156mm, and demonstrated initial cell efficiency on larger wafers of 13.5%. During this program, the throughput of the Direct Wafer furnace was increased by more than 10X, simultaneous with quality improvements to meet early customer specifications. Dedicated equipment for laser trimming of wafers and measurement methods were developed to feedback key quality metrics to improve the process and equipment. Subsequent operations served both to determine key operating metrics affecting cost, as well as generating sample product that was used for developing downstream processing including texture and interaction with standard cell processing. Dramatic price drops for silicon wafers raised the bar significantly, but the developments made under this program have increased 1366 confidence that Direct Wafers can be produced for ~$\$$0.10/W, still nearly 50% lower than current industry best practice. Wafer quality also steadily improved throughout the program, both in electrical performance and geometry. The improvements to electrical performance were achieved through a combination of optimized heat transfer during growth, reduction of metallic impurities to below 10 ppbw total metals, and lowering oxygen content to below 2e17 atoms/cc. Wafer average thickness has been reduced below 200µm with standard deviation less than 20µm. Measurement of spatially varying thickness shortly after wafer growth is being used to continually improve uniformity by adjusting thermal conditions. At the conclusion of the program, 1366 has developed strong relationships with four leading Tier1 cell manufactures and several have demonstrated 17% cell efficiency on Direct Wafer. Sample volumes were limited, with the largest trial consisting of 300 Direct Wafers, and there remains strong pull for larger quantities necessary for qualification before sales contracts can be signed. This will be the focus of our pilot manufacturing scale up in 2014.

14 SOLAR ENERGY↗