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Material requirements for the adoption of unconventional silicon crystal and wafer growth techniques for high-efficiency solar cells
Silicon wafers comprise approximately 40% of crystalline silicon module cost and represent an area of great technological innovation potential. Paradoxically, unconventional wafer-growth techniques have thus far failed to displace multicrystalline and Czochralski silicon, despite four decades of innovation. One of the shortcomings of most unconventional materials has been a persistent carrier lifetime deficit in comparison to established wafer technologies, which limits the device efficiency potential. In this perspective article, we review a defect-management framework that has proven successful in enabling millisecond lifetimes in kerfless and cast materials. Control of dislocations and slowly diffusing metal point defects during growth, coupled to effective control of fast-diffusing species during cell processing, is critical to enable high cell efficiencies. As a result, to accelerate the pace of novel wafer development, we discuss approaches to rapidly evaluate the device efficiency potential of unconventional wafers from injection-dependent lifetime measurements.
Stabilizing Ultrathin CsPbBr 3 Nanoplatelet Films for Deterministic Strong Light-Matter Coupling
While the excitons in perovskite nanomaterials possess interesting properties central to their use in optoelectronic technologies, their instability limits real world applicability. In this study, we describe a method to stabilize the structures of cesium lead bromide (CsPbBr 3 ) nanoplatelets (NPLs) in spin-casted films. We apply this method to design, fabricate, and characterize exciton cavity polaritons formed from these nanomaterials. These studies show that we can form exciton cavity polaritons from CsPbBr 3 in precisely designed Fabry−Perot microresonators and suggest that the structures of these materials can be stabilized toward their use in other solution-processed optoelectronic devices.
Additive Manufacturing of Fuel Injectors
Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventional manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project were: • Powder metal input stock: Powder characterization, dimensional accuracy, metallurgical characterization, and mechanical properties evaluation. • Process parameters: Laser parameter effects, post-printing heat-treatment development, mechanical properties evaluation, and post-finishing technique. • Material design curves: Room and elevated temperature tensiles, low cycle fatigue, and creep rupture properties curves generated. • AM specifications: Key metal powder characteristics, laser parameters, and heat-treatment controls identified.
Cost Models for MMC Manufacturing Processes
Processes for the manufacture of advanced metal matrix composites are rapidly approaching maturity in the research laboratory and there is growing interest in their transition to industrial production. However, research conducted to date has almost exclusively focused on overcoming the technical barriers to producing high-quality material and little attention has been given to the economical feasibility of these laboratory approaches and process cost issues. A quantitative cost modeling (QCM) approach was developed to address these issues. QCM are cost analysis tools based on predictive process models relating process conditions to the attributes of the final product. An important attribute, of the QCM approach is the ability to predict the sensitivity of material production costs to product quality and to quantitatively explore trade-offs between cost and quality. Applications of the cost models allow more efficient direction of future MMC process technology development and a more accurate assessment of MMC market potential. Cost models were developed for two state-of-the art metal matrix composite (MMC) manufacturing processes: tape casting and plasma spray deposition. Quality and Cost models are presented for both processes and the resulting predicted quality-cost curves are presented and discussed.
Dismantling of primary shielding with prototype machines in a compact sodium cooled reactor - 15463
The Compact Sodium Cooled Reactor Facility Karlsruhe (KNK), a prototype reactor to demonstrate the Fast Breeder Reactor Technology in Germany, was in operation from 1971 to 1991. The dismantling activities started in 1991. The project aim is the green field in 2020. Most of the reactor internals as well as the primary and secondary cooling loops have already been dismantled. The contaminated sodium inventory has already been disposed of completely. Only the highly activated reactor vessel shielding structures remain. Due to their high dose rates, these structures must be dismantled remotely. For the removal of the primary shielding of the reactor vessel, 12 stacked cast iron blocks with a total mass of 90 Mg and individual masses of up to 15.5 Mg, a remote-controlled multifunctional dismantling device (HWZ) was designed, manufactured and tested in a mock-up. Since it is not possible to remove the segments in one piece for offsite treatment, a special prototype band-saw (BWZ) had to be developed for sawing the segments both horizontally and vertically into smaller pieces. The resulting sub-segments are transferred directly into repository containers. After the successful approval of the test sequences by the authorities and intensive training of the operational staff, both prototype machines were installed inside the reactor building containment for final assembly. The dismantling started in 2013. The present paper covers the successful dismantling of the primary shielding as well as the experiences gained through the development, use and improvement of these prototype machines. (authors)
Progress in ceramic component fabrication technology
Net shape techniques have been used in the production of rotating and static vehicular engine high-temperature components composed of sintered Alpha-SiC (SASC). Injection-molded rotors have been cold spin tested, as well as a slip-cast combustor assembly hot rig. SASC pistons and cylinder liners have also been constructed for an opposed piston, two-cycle diesel test rig while test results are presented. An uncooled, minimum-friction internal combustion engine with multi-fuel capability due to its elevated combustion temperatures appears to be achievable in the near term by means of SASC techniques. The flexural strength of SASC at 1500 C is 446 MPa, identical to that at room temperature, and excellent strength retention has been demonstrated after 3500 hours of cyclic exposure.
Local Modification of Cast Aluminum Alloys via the Cast-and-Print Process
Casting of aluminum alloys is a cost-effective way to mass manufacture bulk aluminum parts for automotive applications. However, the casting process requires filling of a mold, which imposes some limitations on the geometries that can be successfully cast and limits parts to be a uniform material. Therefore, we proposed that a hybrid casting plus additive manufacturing approach, Cast-and-Print, which could be used to locally modify the properties and geometry of cast parts to create difficult-to-cast, functional features. Here, we report the results of the properties of deposited materials on cast substrate, the properties of the interface of the deposited and cast material, and the application of the Cast-and-Print method to deposit rivet tabs on high-pressure die cast plates. Ultimately, the approach appears viable, but there are engineering challenges present to reliable additive processing of aluminum wires that need to be overcome for successful implementation of the technology.
MSAT-X: A technical introduction and status report
A technical introduction and status report for the Mobile Satellite Experiment (MSAT-X) program is presented. The concepts of a Mobile Satellite System (MSS) and its unique challenges are introduced. MSAT-X's role and objectives are delineated with focus on its achievements. An outline of MSS design philosophy is followed by a presentation and analysis of the MSAT-X results, which are cast in a broader context of an MSS. The current phase of MSAT-X has focused notably on the ground segment of MSS. The accomplishments in the four critical technology areas of vehicle antennas, modem and mobile terminal design, speech coding, and networking are presented. A concise evolutionary trace is incorporated in each area to elucidate the rationale leading to the current design choices. The findings in the area of propagation channel modeling are also summarized and their impact on system design discussed. To facilitate the assessment of the MSAT-X results, technology and subsystem recommendations are also included and integrated with a quantitative first-generation MSS design.
Liquid Droplet Printing
The center has recently invested in a new additive manufacturing technology known as liquid metal jetting or liquid droplet printing. The Additec ElemX machine’s process utilizes wire feedstock fed into a ceramic crucible, where it is melted and ejected by pulsed Lorentz force using an external coil. The team will start with material characterization of various commercially available aluminum alloys to establish process parameters, repeatability, mechanical properties, and microstructure. Future research will consider additional alloys and explore concepts that may potentially adapt the technology for relevance in zero or low gravity environments. The printer has a 12”x12”x4.7” build volume and 0.24mm minimum layer height, with surface finishes comparable to sand castings.
Developments of Bosch Process Architectures for ISRU Terrestrial Applications
To effectively realize NASA’s goals of a sustainable presence on the Moon and be-yond, In-Situ Resource Utilization (ISRU) must be leveraged. To reduce launch mass for space missions, commodities such as oxygen and carbon can be produced in-situ. Oxygen can be used for life support and as a propellant, and carbon can be used for battery production, filtration, additive manufacturing, and steel casting. Carbon is a required reactant in the carbothermal reduction process, a leading candidate for oxygen production on the lunar surface. To pro-duce these consumables, the Carbon Utilization Technology for Lunar and Atmospheric Systems (CUTLAS) project is developing architectures that leverage the Bosch process. The Bosch process re-acts CO 2 and H 2 to produce carbon powder and water, which can then be electrolyzed, leaving O 2 and recycled H 2 . This process is also applicable to carbon dioxide emissions on Earth.
Investigations for the Recycle of Pyroprocessed Uranium
Given the renewed interest in uranium from the pyroprocessing of used nuclear fuel in a molten salt system, the two biggest hurdles for marketing the uranium are radiation levels and transuranic content. A radiation level as low as possible is desired so that handling operations can be performed directly with the uranium. The transuranic content of the uranium will affect the subsequent waste streams generated and, thus also should be minimized. Although the pyroprocessing technology was originally developed without regard to radiation and transuranic levels, adaptations to the process have been considered to market the uranium. Process conditions have been varied during the distillation and casting cycles of the process with increasing temperature showing the largest effect on the reduction of radiation levels. Transuranic levels have been reduced significantly by incorporating a pre-step in the salt distillation operation to remove a majority of the salt prior to distillation.
Ultra-Light Precision Membrane Optics
SRS Technologies and NASA Marshall Space Flight Center have conducted a research effort to explore the possibility of developing ultra-lightweight membrane optics for future imaging applications. High precision optical flats and spherical mirrors were produced under this research effort. The thin film mirrors were manufactured using surface replication casting of CPI(Trademark), a polyimide material developed specifically for UV hardness and thermal stability. In the course of this program, numerous polyimide films were cast with surface finishes better than 1.5 nanometers rms and thickness variation of less than 63 nanometers. Precision membrane optical flats were manufactured demonstrating better than 1/13 wave figure error when measured at 633 nanometers. The aerial density of these films is 0.037 kilograms per square meter. Several 0.5-meter spherical mirrors were also manufactured. These mirrors had excellent surface finish (1.5 nanometers rms) and figure error on the order of tens of microns. This places their figure error within the demonstrated correctability of advanced wavefront correction technologies such as real time holography.
Aerospace castings produced from magnesium- lithium-silicon alloy.
Aerospace castings from light ternary Mg-Li-Si alloy, discussing fabrication development
ChatGPT and Other Large Language Models for Cybersecurity of Smart Grid Applications
Cybersecurity breaches targeting electrical substations constitute a significant threat to the integrity of the power grid, necessitating comprehensive defense and mitigation strategies. Any anomaly in information and communication technology (ICT) should be detected for secure communications between devices in digital substations. This paper proposes large language models (LLMs), e.g., ChatGPT, for the cybersecurity of IEC 61850-based communications. Multi-cast messages such as generic object oriented system events (GOOSE) and sampled values (SV) are used for case studies. The proposed LLM-based cybersecurity framework includes, for the first time, data pre-processing of communication systems and human-in-the-loop (HITL) training (considering the cybersecurity guidelines recommended by humans). The results show a comparative analysis of detected anomaly data carried out based on the performance evaluation metrics for different LLMs. A hardware-in-the-loop (HIL) testbed is used to generate and extract a dataset of IEC 61850 communications.
Metal Matrix Composite Materials for Aerospace Applications
Metal matrix composites (MMC) are attractive materials for aerospace applications because of their high specific strength, high specific stiffness, and lower thermal expansion coefficient. They are affordable since complex parts can be produced by low cost casting process. As a result there are many commercial and Department of Defense applications of MMCs today. This seminar will give an overview of MMCs and their state-of-the-art technology assessment. Topics to be covered are types of MMCs, fabrication methods, product forms, applications, and material selection issues for design and manufacture. Some examples of current and future aerospace applications will also be presented and discussed.
Advanced Material Developments with Laser Engineered Net Shaping
The Laser Engineered Net Shaping (LENS(Trademark)) process is a new technology to fabricate three-dimensional metallic components directly from CAD solid models. It directly fabricates metal hardware by injecting the metal powder of choice into the focal point of a 700W Nd:Yag laser as it traces the perimeter and fills of a part. The Rapid Prototype Laboratory at Marshall Space Flight Center is currently operating a OPTOMEC 750 LENS machine in evaluation experiments involving integration of this technology into various manufacturing processes associated with aerospace applications. This paper will cover our research finding about properties of samples created from Inconel 718 & SS316 using this process versus the same materials in cast & wrought conditions.
New Outboard Motor Firing on All Pistons
Seven years ago, NASA was in the planning stages of producing an aluminum alloy with higher strength and resistance at elevated temperatures for aerospace applications. At that time, a major automobile manufacturer happened to approach NASA for solutions to lowering engine emissions and the costs associated with developing aluminum engine pistons. The Space Agency realized the answers to the manufacturer's problems could lie within the proposed alloy. Jonathan Lee, a structural materials engineer at Marshall Space Flight Center s Materials, Processes, and Manufacturing Department, and PoShou Chen, a scientist with Huntsville, Alabama-based Morgan Research Corporation, partook in the development project as the inventors. The resulting NASA High-Strength Aluminum Alloy, or "MSFC-398," was capable of casting metal components at both high volume and low cost, making it extremely attractive for commercial application, not just in automotives, but in a variety of other industries, as well. NASA patented the technology and introduced it for public licensing in 2001.