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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Design of high pressure waterjet nozzles

The Hydroblast Research Cell at Marshall Space Flight Center is used to investigate the use of high pressure waterjets to strip paint, grease, adhesive and thermal spray coatings from various substrates. Current methods of cleaning often use ozone depleting chemicals (ODC) such as chlorinated solvents. High pressure waterjet cleaning has proven to be a viable alternative to the use of solvents. A popular method of waterjet cleaning involves the use of a rotating, multijet, high pressure water nozzle which is robotically controlled. This method enables rapid cleaning of a large area, but problems such as incomplete coverage and damage to the substrate from the waterjet have been observed. This report summarizes research consisting of identifying and investigating the basic properties of rotating, multijet, high pressure water nozzles, and how particular designs and modes of operation affect such things as stripping rate, standoff distance and completeness of coverage. The study involved computer simulations, an extensive literature review, and experimental studies of different nozzle designs.

Mazzoleni, Andre P.↗
DOE OSTI2026

Semi-Transparent Perovskite Solar Cells in a Stacked Tandem Module: Cooperative Research and Development Final Report, CRADA Number CRD-19-00810

This project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, anti-reflection layer composition and deposition process, and cell to module integration processes. Modification 5: The proposed project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically-stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, passivation layers including in module scribes, anti-reflection layer composition and deposition process, and cell to module integration processes. Advanced metrology and characterization will be performed on perovskite films, cells and module. Furthermore, we will examine module or materials recycling for circular economy considerations. Modifcation 6: Gigahertz frequency microwave pump-probe spectroscopies are highly sensitive to thin film semiconductor photoconductivity of individual and stacks of layers that comprise perovskite solar cells. As such, these techniques will be used to qualify reproducibility and quality correlations during the manufacturing process. Modification 7: Mechanical adhesion of top contacts within perovskite modules significantly impacts the durability of the module when exposed to accelerated degradation testing. The adhesion between the perovskite/transport layer interface and the transport layer/top contact interface are both very sensitive small changes in processing. ALD processing conditions of the transport layer will be tuned to optimize the mechanical adhesion within the perovskite module stack.

14 SOLAR ENERGY↗
NASA NTRS1990

Advanced Reusable Foam Cryogenic Insulation

Lightweight, reusable cryogenic containers reduce costs of operation of advanced hypersonic airplanes and space launch vehicles. Specimens demonstrated in temperature range of negative 420 to positive 400 degrees F (negative 251 to positive 204 degrees C). Prototype reusable cryogenic foam insulation developed. Consists of two discrete layers of closed-cell polymethacrylimide foam of density 6.9 lb/ft to the 3rd power (111 kg/m to the 3rd power) bonded together with epoxy adhesive. Additionally reinforced with 0.003-in. (0.08-mm)-thick layer of fiberglass cloth. Wrapped with precut and preformed vapor-barrier cover. Such containers useful on Earth in laboratories, factories, and transportation systems.

Taylor, Allan H.↗
NASA NTRS2011

Capacitors with low equivalent series resistance

An electric double layer capacitor (EDLC) in a coin or button cell configuration having low equivalent series resistance (ESR). The capacitor comprises mesh or other porous metal that is attached via conducting adhesive to one or both the current collectors. The mesh is embedded into the surface of the adjacent electrode, thereby reducing the interfacial resistance between the electrode and the current collector, thus reducing the ESR of the capacitor.

Fleig, Patrick Franz↗
NASA NTRS1980

Screenable silver and base metal solar cell contacts

The metallurgical soundness of the all-metal screenable thick film electrode system is established for silver and copper electrodes. Silver fluoride was identified as a successful etchant material and is found most effective in the liquid phase (435-460 C). Best results were achieved with the eutectic alloys of dopants and semiconductors. The air-fired silver inks were strongly adherent, rugged, and solderable, whereas the hydrogen-fired silver inks had very poor adhesion. A two-step firing process was devised in which copper inks containing silver fluoride were activated in a nitrogen atmosphere, with sintering done at the same or higher temperatures in hydrogen. Good solar cells were made using the copper paste back contacts demonstrating that the electrodes are not the limiting factors in efficiency.

Ross, B.↗
NASA NTRS1981

Testing of solar cell covers and encapsulants conducted in a simulated space environment

The materials included in the evaluation were 0211 micro-sheet, FEP-A used as a cover and as an adhesive, DC 93-500 adhesive, PFA "hard coat" used as a cover, GE 615/UV-24 used as a cover, GR 650 used as a cover, and electrostatically bonded 7070 glass. The test environments were 1 MeV electron irradiation interspersed with thermal cycling, 0.5 MeV proton irradiation interspersed with thermal cycling and UV exposure interspersed with thermal cycling. Summary data is given describing the response of the test materials both visually and electrically to the three different environments.

Russell, D. A.↗
DOE OSTI2024

Isostatic pressing of multilayer pouch cells and its implications for battery manufacturing

Here, we report a comprehensive investigation into the impact of isostatic pressure (ISP) processing on multilayer pouch cells. The study compares baseline electrodes fabricated using conventional manufacturing processes with isostatically pressed counterparts under varying conditions. Extensive characterization is carried out to assess the differences between baseline cells and those that underwent the isostatic pressing process. The electrochemical performance of the isostatically pressed cathodes was evaluated through impedance spectroscopy and galvanostatic charge-discharge tests. The results indicated that ISP led to notable improvements in porosity, adhesion, and rate performance compared to the baseline cathodes. This work elucidates the microstructural changes induced by ISP in lithium-ion battery cathodes and highlights the technology’s promise for advancing battery manufacturing. The findings contribute to a better understanding of how ISP can be effectively integrated into cell assembly, fostering the development of more efficient and scalable battery manufacturing techniques for current Li-ion and solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Novel Zwitterionic Polyurethane-in-Salt Electrolytes with High Ion Conductivity, Elasticity, and Adhesion for High-Performance Solid-State Lithium Metal Batteries

This study presents a novel polymer-in-salt (PIS) zwitterionic polyurethane-based solid polymer electrolyte (zPU-SPE) that offers high ionic conductivity, strong interaction with electrodes, and excellent mechanical and electrochemical stabilities, making it promising for high-performance all solid-state lithium batteries (ASSLBs). The zPU-SPE exhibits remarkable lithium-ion (Li+) conductivity (3.7 × 10⁻⁴ S cm−1 at 25 °C), enabled by exceptionally high salt loading of up to 90 wt.% (12.6 molar ratio of Li salt to polymer unit) without phase separation. It addresses the limitations of conventional SPEs by combining high ionic conductivity with a Li+ transference number of 0.44, achieved through the incorporation of zwitterionic groups that enhance ion dissociation and transport. The high surface energy (338.4 J m−2) and elasticity ensure excellent adhesion to Li anodes, reducing interfacial resistance and ensuring uniform Li+ flux. When tested in Li||zPU||LiFePO₄ and Li||zPU||S/C cells, the zPU-SPE demonstrated remarkable cycling stability, retaining 76% capacity after 2000 cycles with the LiFePO4 cathode, and achieving 84% capacity retention after 300 cycles with the S/C cathode. Molecular simulations and a range of experimental characterizations confirm the superior structural organization of the zPU matrix, contributing to its outstanding electrochemical performance. The findings strongly suggest that zPU-SPE is a promising candidate for next-generation ASSLBs.

Wang, Kun↗
DOE OSTI2026

Minimized aging of isocyanurate-based rigid cellular foams for buildings through tailored barrier facers and optimized formulation

The thermal resistivity (h·ft 2 ·°F/Btu/in.) of closed-cell rigid foam insulation materials significantly decreases over time. Diffusion-tight facers are designed to significantly enhance initial thermal resistivity and long-term thermal performance by preventing gas diffusion into the foam cells and inhibiting the escape of low thermal conductivity blowing agents. In addition to the gas diffusion property of the facer film, adhesion between the foam and the facer is crucial for achieving diffusion-tight bonding. Here, this study addresses the challenge of thermal aging by investigating how facer film properties and foam formulation influence the durability of thermal performance. A systematic evaluation was conducted to understand the effects of polymeric barrier films, surface treatments, facer coverage, and foam matrix rigidity on thermal resistivity over time. Key findings reveal that diffusion-tight facers, particularly those with metallized layers and compatible heat seal layers, significantly reduce gas exchange and improve foam-facer adhesion. The optimized system, incorporating barrier facers and a tailored polyisocyanurate foam formulation, achieved initial and aged thermal resistivity values after 200 days of approximately 8.3 and 7.4 h ft 2 ·°F/Btu/in., respectively representing only a 10 % reduction compared to a 17 % reduction observed in control samples without facers. Notably, polyurethane spray foams with facers exhibited only a 4 % reduction in thermal resistivity, compared to a 23 % decrease in control samples, demonstrating nearly six times better retention of thermal performance. This innovative facer technology presents a promising solution for reducing energy costs and represents a significant advancement in optimizing energy management for building envelopes in future technologies. This technology can also be adapted for other applications that necessitate the preservation of long-term thermal performance.

Wanasinghe, Shiwanka Vidarshi [Oak Ridge National ↗
NASA NTRSDate not supplied

Passive Charge Dissipating Work Function Matching Coating for Reducing Adhesion of Lunar Dust

The NASA Glenn Research Center Environmental Effects and Coatings Branch is developing a passive coating for lunar dust mitigation. This simple, transparent, conductive coating will be capable of reducing lunar dust adhesion to surfaces and dissipating surface charge. Anticipated benefits include compatibility with active dust mitigation strategies, improved efficiency and performance of solar cells and thermal control surfaces, and protection of astronauts and equipment on the lunar surface.

Lunar dust↗
NASA NTRS1983

Investigation of accelerated stress factors and failure/degradation mechanisms in terrestrial solar cells

Results of an ongoing research program into the reliability of terrestrial solar cells are presented. Laboratory accelerated testing procedures are used to identify failure/degradation modes which are then related to basic physical, chemical, and metallurgical phenomena. In the most recent tests, ten different types of production cells, both with and without encapsulation, from eight different manufacturers were subjected to a variety of accelerated tests. Results indicated the presence of a number of hitherto undetected failure mechanisms, including Schottky barrier formation at back contacts and loss of adhesion of grid metallization. The mechanism of Schottky barrier formation is explained by hydrogen, formed by the dissociation of water molecules at the contact surface, diffusing to the metal semiconductor interface. This same mechanism accounts for the surprising increase in sensitivity to accelerated stress conditions that was observed in some cells when encapsulated.

Lathrop, J. W.↗
NASA NTRS1975

Sinter of uniform, predictable, blemish-free nickel plaque for large aerospace nickel cadmium cells

A series of nickel slurry compositions were tested. Important slurry parameters were found to be the nature of the binder, a pore former and the method of mixing. A slow roll mixing which is non-turbulent successfully eliminated entrapped air so that bubbles and pockets were avoided in the sinter. A slurry applicator was developed which enabled an equal quantity of slurry to be applied to both sides of the grid. Sintering in a furnace having a graded atmosphere characteristic, ranging from oxidizing to strongly reducing, improved adhesion of porous sinter to grid and resulted in a uniform welding of nickel particles to each other throughout the plaque. Sintering was carried out in a horizontal furnace having three heating zones and 16 heating control circuits. Tests used for plaque evaluation include (1) appearance, (2) grid location and adhesion, (3) mechanical strength, (4) thickness, (5) weight per unit area, (6) void volume per unit area, (7) surface area and (8) electrical resistance. Plaque material was impregnated using Heliotek proprietary processes and 100 AH cells were fabricated.

Seiger, H. N.↗
NASA NTRS1979

Improved method of solar-cell assembly

Method bonds solar-cell modules between rigid or flexible base and plastic protective cover. Method relies on using one of several commercially-available, transparent, silicone adhesives as bonding agent. Should it ever be necessary to repair or replace some part of assembly, it may be possible to remove cover without destroying package since adhesive remains flexible.

Broder, J. D.↗
NASA NTRS1984

MOD silver metallization for photovoltaics

Photovoltaic cells require back side metallization and a collector grid system on the front surface. Both front and back surface metallizations should have good adhesion, low contact resistance, low sheet resistance, long term stability, and their deposition methods should not degrade the n-p junction. Advantages and disadvantages of different deposition methods are discussed.

Vest, G. M.↗
DOE OSTI2024

Designing metal halide perovskite solar modules for thermomechanical reliability

There is a significant deficiency in perovskite solar module (PSM) stability under thermomechanical stressors which is not well-understood. In this perspective, common issues seen with perovskite solar cell device fabrication related to thermomechanical reliability of PSM processing are discussed, with a focus on how the robustness of device layers and interlayer adhesion can be improved. Film stresses, adhesion of charge transport layers, and instability under light and heat are discussed with the purpose of providing insight on designing PSMs for durability. Processing conditions of encapsulation of PSMs and critical parameters to consider are also examined, and accelerated testing protocols for PSMs are discussed that probe mechanical degradation modes and ensure reliability of devices in the field.

14 SOLAR ENERGY↗
NASA NTRS1986

Laser-assisted solar cell metallization processing

The status of the laser-assisted solar cell metallization processing is described. Metallo-organic silver films were spun-on by argon ion laser beam pyrolysis. The metallo-organic decomposition (MOD) film was spun-on an evaporated Ti/Pd film to produce tood adhesion. In a maskless process, the argon ion laser writes the contact pattern. The film is then built up to obtain the required conductivity using conventional silverplating process. The Ti/Pd film in the field is chemically etched using the plated silver film as the mask. The width of the contact pattern is determined by the power of the laser. Widths as thin as 20 microns were obtained using 0.66 W of laser power. Cells fabricated with the 50 micron line widths of 4 ohm-cm floating zone (Fz) silicon-produced efficiencies of 16.6% (no passivation) which were equivalent to the best cells using conventional metallization/lithography and no passivation.

Meier, D. L.↗
NASA NTRS1978

Ultraviolet irradiation at elevated temperatures and thermal cycling in vacuum of FEP-A covered silicon solar cells

Silicon solar cells covered with FEP-A were irradiated in vacuum with ultraviolet light and then subjected to thermal cycling. These accelerated laboratory conditions are believed to be equivalent to those experienced by FEP-A covered cells on the ATS-6 spacecraft and the results indicate a probable mechanism for the faster degradation of the FEP-A covered cells. Heat-bonded FEP-A covers apparently embrittle when exposed to four months of space UV radiation at elevated temperatures, and crack when subjected to thermal cycling during the eclipse period. Low energy proton radiation can then penetrate to the junction of the cell causing degradation of the open circuit voltage and maximum power to occur. An alternate method of application of FEP-A, such as with adhesives, may prevent such cracking.

Broder, J. D.↗