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All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Lightweight, Flexible Solar Cells on Stainless Steel Foil and Polymer for Space and Stratospheric Applications

The availability of low-cost, lightweight and reliable photovoltaic (PV) modules is an important component in reducing the cost of satellites and spacecraft. In addition, future high-power spacecraft will require lightweight PV arrays with reduced stowage volume. In terms of the requirements for low mass, reduced stowage volume, and the harsh space environment, thin film amorphous silicon (a-Si) alloy cells have several advantages over other material technologies (1). The deposition process is relatively simple, inexpensive, and applicable to large area, lightweight, flexible substrates. The temperature coefficient has been found to be between -0.2 and -0.3 %/degC for high-efficiency triple-junction a-Si alloy cells, which is superior for high temperature operation compared to crystalline Si and triple-junction GaAs/InGaP/Ge devices at 0.53 %/degC and 0.45 %/degC, respectively (2). As a result, the reduction in efficiency at high temperature typical in space conditions is less for a-Si alloy cells than for their crystalline counterparts. Additionally, the a-Si alloy cells are relatively insensitive to electron and proton bombardment. We have shown that defects that are created by electrons with energies between 0.2 to 2 MeV with fluence up to 1x10(exp 15) e/sq cm and by protons with energy in the range 0.3 MeV to 5 MeV with fluence up to 1x10(exp 13) p/sq cm can be annealed out at 70 C in less than 50 hours (1). Further, modules incorporating United Solar s a-Si alloy cells have been tested on the MIR space station for 19 months with only minimal degradation (3). For stratospheric applications, such as the high altitude airship, the required PV arrays are typically of considerably higher power than current space arrays. Airships typically have a large area available for the PV, but weight is of critical importance. As a result, low cost and high specific power (W/kg) are key factors for airship PV arrays. Again, thin-film a-Si alloy solar cell technology is well suited to such applications.

Beernink, Kevin↗
NASA NTRS2019

Oil-Free Enabling Technology: Gas Foil Bearings

NASA has developed and commercialized high temperature coatings and bearings for extreme conditions. These technologies are now under consideration by industry for automotive applications such as turbochargers, fuel cell compressors and exhaust gas path mechanism applications. In this presentation, a review of Oil-Free technologies and their current state-of-development is introduced. Key NASA contributions to the field as documented by patents, research papers and technology demonstrations is also presented.

lubrication↗
NASA NTRS2017

Results of All Polyimide, Etched Foil Heater Qualification and Failure Limit Testing

Standard FEP (Fluorinated Ethylene Propylene resin) polyimide (SFP) or Kapton film heaters—which have a long history of space flight—are output-power limited by the melting point of Teflon which is used as an adhesive and insulator between the encasing layers of Kapton. The limit is expressed as a power density or through maximum operating temperature limits. All-polyimide (AP) heaters (also known as adhesive-less heaters) do not contain FEP Teflon between the layers of Kapton so the heaters are unconstrained by the melting point of Teflon. Thus, AP heaters have a higher maximum power density and operating temperature. AP heaters have not been qualified or flown on JPL missions but could be useful in applications that require a higher power density (Watt density) than the SFP heaters can support. The purpose of this paper is to document the qualification and property testing of the AP heaters for flight purposes. JPL (Jet Propulsion Lab.) tested several varieties of all-polyimide heaters to determine their functional equivalence to the standard heater which has substantial flight heritage and to determine their maximum limits. Tests included standard in-air burn-in tests, maximum power testing, lead pull strength, process qualification verification (PQV), long duration thermal cycling, and electro-magnetic compatibility shielding properties for copper-cladded shielded heaters. The results show that the all-polyimide heater appears to be functionally equivalent to the standard heater and has a higher Watt density and maximum operating temperature limit. The tests, test articles, failure analysis of the test articles, and results are described herein. These test results indicate that the all-polyimide heater is ready for flight applications.

Cucullu, Gordon C., III↗
NASA NTRS2004

Research Capabilities for Oil-Free Turbomachinery Expanded by New Rotordynamic Simulator Facility

A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.

Howard, Samuel A.↗
NASA NTRS1992

The interstellar gas experiment: Analysis in progress

The interstellar gas experiment (IGE) exposed thin metallic foils in order to collect neutral interstellar particles which penetrate the solar system due to their motion relative to the sun. These atoms were entrapped in the collecting foils along with precipitating magnetospheric ions and with ambient atmospheric atoms. For the entire duration of the LDEF mission, seven of the foils collected particles arriving from seven different directions as seen from the spacecraft. In the mass spectrometric analysis of the trapped noble gas component, we detected the He-3, He-4, Ne-20, and Ne-22 isotopes. In order to infer the isotopic ratios in the interstellar medium from the measured concentrations found in the foil piece, several lines of investigation had to be initiated. The flux of incident noble gas atoms from the ambient atmosphere was estimated by detailed calculations. The contributions proved to be negligible, supporting the experimental evidence. Foil and machine backgrounds for the four isotopes which were measured had to be assessed individually. While this was easy for He-4, spurious foil background of He-3 had to be monitored carefully by analyzing unflown foil pieces. Trapped Ne concentrations are not far above the background. During the flight, a stuck electrical relay precluded the foil-trays from sequencing as designed. Therefore, we could not use the seasonal variation of the direction of the incoming interstellar atoms to make the distinction between interstellar and magnetospheric components of the trapped particles. Instead, we had to try the method of stepwise heating to extract the interstellar component at lower temperatures than we use to extract the magnetospheric component (the interstellars hit the foil with lower energies than most of the magnetospherics). New limiting values for the isotopic composition of the interstellar medium, unavailable yet from any other method of measurement, are emerging from this analysis.

Buehler, F.↗
NASA NTRS1993

The Interstellar Gas Experiment: Analysis in progress

The Interstellar Gas Experiment (IGE) exposed thin metallic foils aboard the LDEF spacecraft in low Earth orbit in order to collect neutral interstellar particles which penetrate the solar system due to their motion relative to the sun. By mechanical penetration these atoms were imbedded in the collecting foils along with precipitating magnetospheric ions and, possibly, with ambient atmospheric atoms. During the entire LDEF mission, seven of these foils collected particles arriving from seven different directions as seen from the spacecraft. After the foils were returned to Earth, a mass spectrometric analysis of the noble gas component of the trapped particles was begun. The isotopes of He-3, He-4, Ne-20, and Ne-22 were detected. We have given a first account of the experiment. In order to infer the isotopic ratios in the interstellar medium from the concentrations found in the foils, several lines of investigation had to be initiated. The flux of ambient atmospheric noble gas atoms moving toward the foils due to the orbital motion of LDEF was estimated by detailed calculations. Any of these particles which evaded the baffles in the IGE collector could be entrapped in the foils as a background flux. However, the calculations have shown that this flux is negligible, which was the intent of the experiment hardware design. This conclusion is supported by the measurements. However, both the concentration of trapped helium and its impact energy indicate that the flux of magnetospheric ions which was captured was larger than had been expected. In fact, it appears that the magnetospheric particles constitute the largest fraction of the particles in the foils. Since little is known about this particle flux, their presence in the IGE foils appears fortunate. The analysis of these particles provides information about their isotropic composition and average flux.

Buehler, F.↗
NASA NTRS1998

Optical Property Enhancement and Durability Evaluation of Heat Receiver Aperture Shield Materials

Under the Solar Dynamic Flight Demonstration (SDFD) program, NASA Lewis Research Center worked with AlliedSignal Aerospace, the heat receiver contractor, on the development, characterization and durability testing of refractory metals to obtain appropriate optical and thermal properties for the SDFD heat receiver aperture shield. Molybdenum and tungsten foils were grit-blasted using silicon carbide or alumina grit under various grit-blasting conditions for optical property enhancement. Black rhenium coated tungsten foil was also evaluated. Tungsten, black rhenium-coated tungsten, and grit-blasted tungsten screens of various mesh sizes were placed over the pristine and grit-blasted foils for optical property characterization. Grit-blasting was found to be effective in decreasing the specular reflectance and the absorptance/emittance ratio of the refractory foils. The placement of a screen further enhanced these optical properties, with a grit-blasted screen over a grit-blasted foil producing the best results. Based on the optical property enhancement results, samples were tested for atomic oxygen and vacuum heat treatment durability. Grit-blasted (Al2O3 grit) 2 mil tungsten foil was chosen for the exterior layer of the SDFD heat receiver aperture shield. A 0.007 in. wire diameter, 20 x 20 mesh tungsten screen was chosen to cover the tungsten foil. Based on these test results, a heat receiver aperture shield test unit has been built with the screen covered grit-blast tungsten foil exterior layers. The aperture shield was tested and verified the thermal and structural durability of the outer foil layers during an off-pointing period.

deGroh, Kim K.↗
NASA NTRS2004

Modification of Bushing Test Rig and Research of Variable Inlet Guide Vane Bushings For Further Development of PM304 Bushings

PS304 is a high temperature solid lubricant coating comprised of a nickel-chrome binder, chrome oxide hardener, barium-calcium fluoride high temperature lubricant, and silver as the low temperature lubricant. This coating is used to lubricate Oil-Free Foil Air Bearings as they experience friction and wear during start up and shut down. The coating deposition process begins with undercutting the shaft. This area is then sandblasted to provide a rough surface for the coating to adhere to. The coating powder is then sent through the plasma spray gun and a reasonably thick layer is applied to the undercut area of the shaft. The coating is then ground down even with the surface of the shaft and gets a nice polished finish. The foil air bearings use the solid lubricant, as mentioned above, during start up and shut down. During normal operating conditions, generally above 2000RPM, the bearings utilize air as their lubricant. Foil air bearings are comprised of a thin top foil and a corrugated bump foil. They have an interference fit with the shaft before operation. As the air gets "trapped" between the top foil and the shaft, it presses the top foil against the bump foil, in turn compressing the bumps. As the bumps compress, it allows for the air to separate the top foil from the shaft, therefore, utilizing the trapped air as its lubricant.

Yanke, Anne↗
NASA NTRS2004

Strain-Gauge Measurement of Weight of Fluid in a Tank

A method of determining the amount of fluid in a tank is based on measurement of strains induced in tank supports by the weight of the fluid. Unlike most prior methods, this method is nonintrusive: there is no need to insert instrumentation in the tank and, hence, no need to run wires, cables, or tubes through the tank wall. Also unlike most prior methods, this method is applicable even if the fluid in the tank is at supercritical pressure and temperature, because it does not depend on the presence of a liquid/gas interface (as in liquid-level-measuring methods). The strain gauges used in this method may be of two types: foil and fiber-optic. Four foil gauges (full bridge) are mounted on each of the tank-supporting legs. As the tank is filled or emptied, the deformation in each leg increases or decreases, respectively. Measured deformations of all legs are added to obtain a composite deformation indicative of the change in weight of the tank plus fluid. An initial calibration is performed by recording data at two points (usually, empty and full) for which the mass or weight of fluid is known. It is assumed that the deformations are elastic, so that the line passing through the two points can be used as a calibration curve of mass (or weight) of fluid versus deformation. One or more fiber-optic gauges may be used instead of the foil gauges. The resolution of the fiber-optic and foil gauges is approximately the same, but the fiber-optic gauges are immune to EMI (electromagnetic interference), are linear with respect to temperature over their entire dynamic range (as defined by the behavior of the sample), and measure thermally induced deformations as predictable signals. Conversely, long term testing has demonstrated that the foil gauges exhibit an erratic behavior whenever subjected to direct sun radiation (even if protected with a rubberized cover). Henceforth, for deployment in outdoor conditions, fiber-optic gauges are the only option if one is to rely on the system for an extended period of time when a recalibration procedure may not be acceptable. A set of foil gauges had been tested on the supports of a 500-gallon (1,900-liter) tank. The gauges were found to be capable of measuring the deformations (up to 22 micro-strain) that occurred during filling and emptying of the tank. The fluid masses calculated from the gauge readings were found to be accurate within 4.5 percent. However, the reliability of the foil gauges over a few hours was not acceptable. Therefore, the foil sensor system is acceptable for use only in controlled environments (complete shade, or indoors).

Figueroa, Jorge↗
NASA NTRS1992

Hypervelocity impact microfoil perforations in the LEO space environment (LDEF, MAP AO-023 experiment)

The Microabrasion Foil Experiment comprises arrays of frames, each supporting two layers of closely spaced metallic foils and a back-stop plate. The arrays, deploying aluminum and brass foil ranging from 1.5 to some 30 microns were exposed for 5.78 years on NASA's LDEF at a mean altitude of 458 km. They were deployed on the North, South, East, West, and Space pointing faces; results presented comprise the perforation rates for each location as a function of foil thickness. Initial results refer primarily to aluminum of 5 microns thickness or greater. This penetration distribution, comprising 2,342 perforations in total, shows significantly differing characteristics for each detector face. The anisotropy confirms, incorporating the dynamics of particulate orbital mechanics, the dominance of incorporating extraterrestrial particulates penetrating thicknesses greater than 20 microns in Al foil, yielding fluxes compatible with hyperbolic geocentric velocities. For thinner foils, a disproportionate increase in flux of particles on the East, North, and South faces shows the presence of orbital particulates which exceed the extraterrestrial component perforation rate at 5 micron foil thickness by a factor of approx. 4.

Mcdonnell, J. A. M.↗
NASA NTRS2007

Heat Transfer in High Temperature Multilayer Insulation

High temperature multilayer insulations have been investigated as an effective component of thermal-protection systems for atmospheric re-entry of reusable launch vehicles. Heat transfer in multilayer insulations consisting of thin, gold-coated, ceramic reflective foils and Saffil(TradeMark) fibrous insulation spacers was studied both numerically and experimentally. A finite volume numerical thermal model using combined conduction (gaseous and solid) and radiation in porous media was developed. A two-flux model with anisotropic scattering was used for radiation heat transfer in the fibrous insulation spacers between the reflective foils. The thermal model was validated by comparison with effective thermal conductivity measurements in an apparatus based on ASTM standard C201. Measurements were performed at environmental pressures in the range from 1x10(exp -4) to 760 torr over the temperature range from 300 to 1300 K. Four multilayer samples with nominal densities of 48 kg/cu m were tested. The first sample was 13.3 mm thick and had four evenly spaced reflective foils. The other three samples were 26.6 mm thick and utilized either one, two, or four reflective foils, located near the hot boundary with nominal foil spacing of 1.7 mm. The validated thermal model was then used to study relevant design parameters, such as reflective foil spacing and location in the stack-up and coating of one or both sides of foils.

Daryabeigi, Kamran↗