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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

US DOE Regional Test Centers Program - 2016 Annual Report.

The US Department of Energy’s Regional Test Center (RTC) program provides outdoor validation and bankability data for innovative solar technologies at five sites across the US representing a range of climate conditions. Data helps get new technologies to market faster and improves US industry competitiveness. Managed by Sandia National Laboratories and the National Renewable Energy Laboratory (NREL), the RTC program partners with US manufacturers of photovoltaic (PV) technologies, including modules, inverters, and balance-of-system equipment. The study is collaborative, with manufacturers (also known as RTC industry partners) and the national labs working together on a system design and validation strategy that meets a clearly defined set of performance and reliability objectives.

14 SOLAR ENERGY↗
DOE OSTI2019

Roll-to-Roll SOFC Manufacturing for Low Cost Energy Generation

Oak Ridge National Laboratory (ORNL) and Redox Power Systems, LLC. collaborated on this project to develop an integrated, continuous roll-to-toll (R2R) manufacturing processes to produce solid oxide fuel cells (SOFCs). SOFCs are ceramic-based electrochemical devices that efficiently produce electricity from hydrogen-containing fuels, including natural gas. Standard processes for manufacturing SOFCs include tape casting of the anode and electrolyte, followed by stacking of the layers, and lamination using a uniaxial press or isostatic press. After high temperature firing, the cathode and electrical contact are screen printed and fired once again to complete the cell. This effort aimed to further develop R2R tape fabrication processes for green cell fabrication with the DOE Battery Manufacturing Facility (BMF) at ORNL as next generation improvements to current methods, focusing on R2R calendering and slot die coating for lower cost, high volume approaches for multilayer green cell fabrication. Two paths were investigated in parallel in this project. The first path was to optimize R2R processing using traditional tape cast materials from the Redox production chain on the BMF’s heated calender for compressing and laminating multilayer materials. The second path was to use BMF’s pilot-scale slot-die coater for R2R manufacturing as an alternative to tape casting of some or all of the layers in the green cell. Processes have been developed and and process conditions have been identified. Additionally, basic process economics were estimated for comparison to Redox current manufacturing approaches for the applicable process modules. The SBV program results will enable Redox to advance lower cost R2R manufacturing processes to produce millions of green cells per year on a single production line. As a result of this work, one invention disclosure has been submitted. In addition, one paper is under preparation for submission to a peer-reviewed journal.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163, (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a singlepiece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment are the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗
NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163 (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The Orion MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a single-piece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment were the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗
DOE OSTI2020

Effects of Photovoltaic Module Materials and Design on Module Deformation Under Load

Static structural finite element models of an aluminum-framed crystalline silicon (c-Si) photovoltaic (PV) module and a glass-glass thin film PV module were constructed and validated against experimental measurements of deflection under uniform pressure loading. Parametric analyses using Latin Hypercube Sampling (LHS) were performed to propagate simulation input uncertainties related to module material properties, dimensions, and manufacturing tolerances into expected uncertainties in simulated deflection predictions. This exercise verifies the applicability and validity of finite element modeling for predicting mechanical behavior of solar modules across architectures and enables computational models to be used with greater confidence in assessment of module mechanical stressors and design for reliability. Sensitivity analyses were also performed on the uncertainty quantification data sets using linear correlation coefficients to elucidate the key parameters influencing module deformation. This information has implications on which materials or parameters may be optimized to best increase module stiffness and reliability, whether the key optimization parameters change with module architecture or loading magnitudes, and whether parameters such as frame design and racking must be replicated in reduced-scale reliability studies to adequately capture full module mechanical behavior.

14 SOLAR ENERGY↗
NASA NTRS2008

Extreme Universe Space Observatory (EUSO) Optics Module

A demonstration part will be manufactured in Japan on one of the large Toshiba machines with a diameter of 2.5 meters. This will be a flat PMMA disk that is cut between 0.5 and 1.25 meters radius. The cut should demonstrate manufacturing the most difficult parts of the 2.5 meter Fresnel pattern and the blazed grating on the diffractive surface. Optical simulations, validated with the subscale prototype, will be used to determine the limits on manufacturing errors (tolerances) that will result in optics that meet EUSO s requirements. There will be limits on surface roughness (or errors at high spatial frequency); radial and azimuthal slope errors (at lower spatial frequencies) and plunge cut depth errors in the blazed grating. The demonstration part will be measured to determine whether it was made within the allowable tolerances.

Young, Roy↗
DOE OSTI2018

Analysis of Supply Chains and Advanced Manufacturing of Small Hydropower Systems

Clean energy manufacturing is a sector of increasing importance both in the United States and worldwide. In the United States, it has been presented as an engine for job creation in a sector of the U.S. economy that was hit hard by the 2008-2009 recession. The Clean Energy Manufacturing Analysis Center (CEMAC), sponsored by the U.S. Department of Energy (DOE), conducts credible, objective, industry-relevant, recurring, and consistent analyses of clean energy technologies. In this project, the National Renewable Energy Laboratory (NREL) and the Oak Ridge National Laboratory (ORNL) collaborated in a hydropower manufacturing and supply chain analysis primarily for U.S. small hydropower (SHP) market to provide insights on supply chain constraints, manufacturing cost, location factors, and opportunities for hydropower using advanced manufacturing technologies. The goal of the project is to improve understanding of the manufacturing opportunities in the U.S. hydropower supply chain, specific competitive advantages, and factors for manufacturing location decisions for SHP. These insights could be used to inform investment and research strategies, policy, and other decisions that could promote economic growth and strengthen U.S. manufacturing capabilities. The project scope included a design for manufacturing and assembly (DFMA) costs analysis and a levelized cost of electricity (LCOE) sensitivity analysis of modular, representative SHP turbines. A representative SHP system was chosen to be made up of two 5 megawatt (MW) turbines, as these Kaplan style turbines could be useable for many non-powered dams (NPDs) across the U.S. The sensitivity analysis used the Integrated Design and Assessment (IDEA) tool, which has helped highlight the impact of the turbine equipment cost on the potential capital expenditure (CAPEX) and LCOE of the installed, representative system. In addition, the project team analyzed international tradeflows (e.g., export and import of hydropower turbines and the parts used in hydropower systems). As part of this project, hydropower stakeholder interviews were undertaken to help identify insights related to hydropower manufacturing opportunities for U.S. players in SHP, the country-specific manufacturing advantages in the United States and threats, and key factors behind manufacturing location decisions made by the SHP industry. Key opportunities for the US SHP market and industry include: Foreign export markets such as Chile, China, Columbia, India and Japan, have an estimated 71,795 MW of technical potential that could be serviced with SHP installations. Utilization of existing manufacturing capacity and expertise, along with economies of scale benefits, could result in increased global competitiveness through lower investment requirements and component costs, which could lead to increased U.S. strength in the export of SHP systems and components. Technology advances such as modular turbine designs, standardized units for conduit systems, precast systems, and improved powertrain technologies could help reduce costs, particularly for manufacturing a small number of units. The DOE is also exploring modular hydropower designs, which would integrate standard independently-produced components, validated to meet multiple specifications. Using modules in product design simplifies manufacturing activities such as inspection, testing, assembly, and purchasing, may increase economies of scale to lower total system cost. There are significant opportunities for the use of composites and Additive Manufacturing (AM) for hydropower components, when design changes are made to hydropower systems. By taking advantage of the corrosion resistance, light-weighting and structural benefits, composites and AM could help significantly alter hydropower structures and installations.

13 HYDRO ENERGY↗
DOE OSTI2025

Screening Metal Halide Perovskite Solar Modules for Premature Field Failures

Developing metal halide perovskite (MHP) photovoltaic (PV) devices into reliable large-area solar modules could accelerate global solar energy deployment. Many MHP devices are susceptible to degradation under light and elevated temperature (LT). Published research on LT testing is limited at the module level, and LT testing has not yet been developed for qualification testing of commercial PV products. This report assesses whether results of LT testing at moderately elevated temperatures correlate with those of field-tested modules from the same batch. Six batches of samples from four manufacturers are assessed. It is shown that modules with a robust package that can maintain over 80% of their peak efficiency during LT testing at 55 °C for 100 h are more likely to retain over 80% of their peak efficiency during outdoor operation for 10 weeks. This finding is a step towards developing a validated test protocol that could be incorporated into a qualification standard for the commercialization of MHP PV technologies.

14 SOLAR ENERGY↗
DOE OSTI2018

Development of a Pre-combustion CO 2 Capture Process Using High-Temperature PBI Hollow-Fiber Membranes

The overall goal of this research project was to develop a high-temperature, membrane-based CO 2 capture technology for coal gasification facilities and make progress toward meeting overall fossil energy performance goals of CO 2 capture with 95% CO 2 purity at a cost of electricity (COE) 30% less than baseline capture approaches. The primary objectives of the project were to evaluate, at a bench-scale size, a technically and economically viable CO 2 capture system based on a high-temperature polybenzimidazole (PBI) polymer hollow-fiber membrane (HFM) separation system, and to optimize the process for integration of that system into an integrated gasification combined cycle (IGCC) plant. The specific objectives of the proposed project are to: (1) fabricate high-performance PBI-HFMs for H 2 /CO 2 separation; (2) collect laboratory data for separating hydrogen from simulated synthesis gas using PBI-based membrane modules; (3) transfer the membrane fabrication technology to an industrial firm that specializes in the manufacture of HFMs; (4) fabricate membrane modules to process a syngas stream (50 kWth) equivalent to that of shifted gas from an oxygen-blown gasifier; (5) obtain design and steadystate performance data for membrane modules using syngas from an operating coal gasifier; (6) estimate the cost of CO 2 capture from pre-combustion gas streams integrated into a 550-MW (net) power plant; and (7) conduct a process environmental health & safety (EH&S) assessment.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1978

Block 2 solar cell module environmental test program

Environmental tests were performed of on 76 solar cell modules produced by four different manufacturers. The following tests were performed: (1) 28 day temperature and humidity; (2) rain and icing; (3) salt fog; (4) sand and dust; (5) vacuum/steam/pressure; (6) fungus; (7) temperature/altitude; and (8) thermal shock. Environmental testing of the solar cell modules produced cracked cells, cracked encapsulant and encapsulant delaminations on various modules. In addition, there was some minor cell and frame corrosion.

Holloway, K. L.↗
NASA NTRS1994

Advances in polycrystalline thin-film photovoltaics for space applications

Polycrystalline, thin-film photovoltaics represent one of the few (if not the only) renewable power sources which has the potential to satisfy the demanding technical requirements for future space applications. The demand in space is for deployable, flexible arrays with high power-to-weight ratios and long-term stability (15-20 years). In addition, there is also the demand that these arrays be produced by scalable, low-cost, high yield, processes. An approach to significantly reduce costs and increase reliability is to interconnect individual cells series via monolithic integration. Both CIS and CdTe semiconductor films are optimum absorber materials for thin-film n-p heterojunction solar cells, having band gaps between 0.9-1.5 ev and demonstrated small area efficiencies, with cadmium sulfide window layers, above 16.5 percent. Both CIS and CdTe polycrystalline thin-film cells have been produced on a laboratory scale by a variety of physical and chemical deposition methods, including evaporation, sputtering, and electrodeposition. Translating laboratory processes which yield these high efficiency, small area cells into the design of a manufacturing process capable of producing 1-sq ft modules, however, requires a quantitative understanding of each individual step in the process and its (each step) effect on overall module performance. With a proper quantification and understanding of material transport and reactivity for each individual step, manufacturing process can be designed that is not 'reactor-specific' and can be controlled intelligently with the design parameters of the process. The objective of this paper is to present an overview of the current efforts at MMC to develop large-scale manufacturing processes for both CIS and CdTe thin-film polycrystalline modules. CIS cells/modules are fabricated in a 'substrate configuration' by physical vapor deposition techniques and CdTe cells/modules are fabricated in a 'superstrate configuration' by wet chemical methods. Both laser and mechanical scribing operations are used to monolithically integrate (series interconnect) the individual cells into modules. Results will be presented at the cell and module development levels with a brief description of the test methods used to qualify these devices for space applications. The approach and development efforts are directed towards large-scale manufacturability of established thin-film, polycrystalline processing methods for large area modules with less emphasis on maximizing small area efficiencies.

Lanning, Bruce R.↗
DOE OSTI2026

Performance Evaluation of an Additively Manufactured ultra-High Operating Temperature SiC Solar-Thermal Air Receiver (HOTSSTAR) Test Module

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal and solar power systems. GE Aerospace Research in collaboration with Heliogen Inc and Sandia National Laboratories (SNL) is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. HOTSSTAR goal is to demonstrate SiC receiver with air exit temperatures up to 1100oC. We discuss fabrication and on-sun test results of a prototype 50kWth test module. The receiver architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around central absorber. These components were fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the thermo-mechanical reliability of SiC test articles in thermal gradient/ shock environment of the application, the components were laminated with GE’s MI SiC CMC. A dedicated test facility was constructed at SNL Solar Tower to evaluate the operational performance of HOTSSTAR module under solar fluxes >200 W/cm2. We report on our final 50kW test module fabrication, integration at the test facility at Sandia, and discuss on-sun test results. We compare the performance of HOTSSTAR module relative to our model predictions.

14 SOLAR ENERGY↗
DOE OSTI2026

Open-Air Manufacturing of Efficient Large-Area Perovskite Solar Cells to Meet Stability and Cost Targets

This SETO-funded project (DE-EE0009516) developed a fully open-air manufacturing pathway for perovskite solar cells and modules, eliminating vacuum-based processing steps while improving device stability. Open-air ultrasonic spray deposition, solution combustion synthesis, rapid thermal processing, and atmospheric plasma curing were developed and optimized for all functional device layers — perovskite absorber, hole transport layers (HTLs), electron transport layers (ETLs), transparent conducting oxides (TCOs), and rear electrodes — without reliance on vacuum. Sprayed organic ETLs preserved perovskite crystal structure and enabled power conversion efficiencies exceeding 20%, and open-air processed TCOs and rear electrodes achieved optoelectronic performance comparable to sputtered alternatives at substantially lower manufacturing cost. Device stability was assessed through accelerated aging protocols aligned with IEC and ISOS standards, combined with high-throughput optical diagnostics that identified key degradation mechanisms and antagonistic interactions among heat, humidity, and illumination stressors. A comprehensive technoeconomic analysis quantified the cost and throughput advantages of open-air manufacturing over conventional vacuum-based processes, identifying vacuum deposition as the dominant cost driver and demonstrating a clear pathway toward the $0.02/kWh target. The project produced five peer-reviewed journal publications, eleven conference presentations, two patents/applications, and five Ph.D. dissertations.

14 SOLAR ENERGY↗
DOE OSTI2015

Quantifying Reliability - The Next Step for a Rapidly Maturing PV Industry and China's Role

PV customers wish to know how long their PV modules will last, but quantitatively predicting service life is difficult because of the large number of ways that a module can fail, the variability of the use environment, the cost of the testing, and the short product development time, especially when compared with the long desired lifetime. China should play a key role in developing international standards because China manufactures most of the world's PV modules. The presentation will describe the steps that need to be taken to create a service life prediction within the context of a defined bill of materials, process window and use environment. Worldwide standards for cost-effective approaches to service-life predictions will be beneficial to both PV customers and manufacturers since the consequences of premature module failure can be disastrous for both.

14 SOLAR ENERGY↗
DOE OSTI2017

Comprehensive study of performance degradation of field‐mounted photovoltaic modules in India

Abstract The All India Survey of Photovoltaic Module Reliability 2014 is an enhanced version of the survey conducted in the previous year, with detailed characterization of PV modules including current‐voltage, infrared and electroluminescence imaging, visual inspection, insulation resistance test and interconnect breakage test. More than a thousand modules were inspected in the field and the main results of the survey are presented in this paper. The average P max degradation rate for the so‐called ‘good’ modules (Group X) is 1.33%/year which is higher than that commonly projected by manufacturers, and widely employed in financial calculations. Modules falling in the ‘not‐so‐good’ category (Group Y) show even higher degradation rates, and it is at least partly due to higher number of micro‐cracks in the modules, and increased degradation of the packaging materials like encapsulant, backsheet, etc. Modules in ‘Hot’ climates degrade faster than modules in the ‘Non‐Hot’ climates. Degradation in fill factor is the primary cause for performance degradation in the young modules (ages <5 years), whereas short‐circuit current degradation is the main contributor to power degradation in the older modules. Small installations (<100 kW p capacity) show higher degradation than large systems, which may be partly due to lack of proper due diligence by the owner at the time of procurement and installation.

Dubey, Rajiv↗
DOE OSTI2017

Integrated Computational Materials Engineering Development of Advanced High Strength Steel for Lightweight Vehicles

The goal of the ICME 3GAHSS project was to successfully demonstrate the applicability of Integrated Computational Materials Engineering (ICME) for the development and deployment of third generation advanced high strength steels (3GAHSS) for immediate weight reduction in passenger vehicles. The ICME approach integrated results from well-established computational and experimental methodologies to develop a suite of material constitutive models (deformation and failure), manufacturing process and performance simulation modules, a properties database, as well as the computational environment linking them together for both performance prediction and material optimization. This is the Final Report for the ICME 3GAHSS project, which achieved the fol-lowing objectives: 1) Developed a 3GAHSS ICME model, which includes atomistic, crystal plasticity, state variable and forming models. The 3GAHSS model was implemented in commercially available LS-DYNA and a user guide was developed to facilitate use of the model. 2) Developed and produced two 3GAHSS alloys using two different chemistries and manufacturing processes, for use in calibrating and validating the 3GAHSS ICME Model. 3) Optimized the design of an automotive subassembly by substituting 3GAHSS for AHSS yielding a design that met or exceeded all baseline performance requirements with a 30% mass savings. A technical cost model was also developed to estimate the cost per pound of weight saved when substituting 3GAHSS for AHSS. The project demonstrated the potential for 3GAHSS to achieve up to 30% weight savings in an automotive structure at a cost penalty of up to $0.32 to $1.26 per pound of weight saved. The 3GAHSS ICME Model enables the user to design 3GAHSS to desired mechanical properties in terms of strength and ductility.

36 MATERIALS SCIENCE↗
NASA NTRS1985

FSA future directions: Reliability and engineering sciences FY85-FY86 activities and plans

Objectives were listed for four areas: engineering science, reliability physics, module development, and module performance and failure analysis. The engineering science efforts are to develop module design requirements for large-scale photovoltaic (PV) applications and to develop generic module and array design and construction technology to meet the needed performance, safety, reliability, and system interfaces. The reliability physics effort is to develop the technology for 30-year life modules. The module development efforts are to transfer new technology to PV manufacturers and their products, and to evaluate these advanced modules. The module performance and failure analysis efforts are to determine PV module performance, to identify needed development, and to assess suitability for large-scale use.

Ross, R. G., Jr.↗