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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1932

Rolling Moments Due to Rolling and Yaw for Four Wing Models in Rotation

This report presents the results of a series of autorotation and torque tests on four different rotating wing systems at various rates of roll and at several angles of yaw. The investigation covered an angle of attack range up to 90 degrees and angles of yaw of 0 degree, 5 degrees, 10 degrees, and 20 degrees. The tests were made in a 5-foot, closed-throat atmospheric wind tunnel. The object of the tests was primarily to determine the effects of various angles of yaw on the rolling moments of the rotating wings up to large angles of attack. It was found that at angles of attack above that of maximum lift the rolling moments on the wings due to yaw (or side slip) from 5 degrees to 20 degrees were roughly of the same magnitude as those due to rolling. There was a wide variation in magnitude of the rolling moment due to yaw angle. The rates and ranges of stable autorotation for the monoplane models were considerably increased by yaw, whereas for an unstaggered biplane they were little affected. The immediate cause of the rolling moment due to yaw is apparently the building up of large loads on the forward wing tip and the reduction of loads on the rearward wing tip.

Knight, Montgomery↗
DOE OSTI2021

Techno-economic analysis of roll-to-roll production of perovskite modules using radiation thermal processes

Perovskite solar technology can produce economically viable photovoltaic devices due to low cost of materials and scalable manufacturing. Solution phase deposition of all active layers lends itself to roll-to-roll fabrication methods which are well-established and have production rates of several hundred square meters per minute. In this techno-economic analysis, the opportunity to scale at this production throughput is considered with manufacturing rates exceeding one gigawatt per year in a single plant. Intense pulsed light is used for the post deposition process to minimize costs associated with the footprint, equipment, and operation. The analysis is limited to the operation of a roll-to-roll manufacturing facility producing a perovskite solar film that can be incorporated into photovoltaic modules. Costs associated with materials, labor, and equipment are considered along with utilities determined from the fundamental engineering calculations. Furthermore, the results show that at very large-scale operations of several gigawatts, the costs to produce the solar films range between $0.04-$0.10 per watt.

14 SOLAR ENERGY↗
DOE OSTI2018

Hot Roll Bonding of Aluminum to Twin-Roll Cast (TRC) Magnesium and Its Subsequent Deformation Behavior

In an experiment in which twin-roll cast AZ31 magnesium alloy and commercial purity aluminum (AA 1050) sheets were bonded by hot rolling as Al/Mg/Al laminate composites, it was found that increasing the preheating temperatures up to 400 °C enhances the bonding strength of composites. Further increases in the preheating temperatures accelerate the magnesium oxide growth and thus reduce the bonding strength. The influence of the reduction ratio on the bonding properties was also studied, whereby it was observed that increasing the rolling reduction led to an increase in the bonding strength. The experimental results show that the optimum bonding strength can be obtained at rolling temperatures of 375-400 °C with a 50-60% reduction in thickness. On the other hand, the subsequent deformation behavior of composite was assessed using plane strain compression and deep drawing tests. We demonstrate that the composites produced using the optimum roll bonding conditions exhibited sufficient bonding during subsequent deformation and did not reveal any debonding at the bonding interface.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Scaling-Up and Roll-to-Roll Processing if Highly Conductive Sulfide Solid-State Electrolytes (CRADA 510)

This project aims to identify and address key technical barriers in scale-up synthesis and roll-to-roll processing of highly conductive solid-state electrolytes (SSEs) by leveraging PNNL’s patent pending SSEs, Ampcera Inc.’s environmentally friendly manufacturing capability, and UW’s rollto-roll processing. The ultimate goals are 1) development of novel sulfide SSEs with room temperature Li+ conductivity > 5 mS/cm and Li/SSE interfacial resistance <5 Ωcm2, 2) scalable production of sulfide SSEs at 1 metric ton/year, and 3) a high throughput roll-to-roll processing of highly conductive (>1 mS/cm) and ultra-thin solid film (10-100 μm). The materials and the solid film achieved in the project will be tested at practical conditions and validated in a realistic pouch cell format with achievable energy > 300 Wh/Kg.

36 MATERIALS SCIENCE↗
NASA NTRS2007

Human Ocular Counter-Rolling and Roll Tilt Perception during Off-Vertical Axis Rotation after Spaceflight

Ocular counter-rolling (OCR) induced by whole body tilt in roll has been explored after spaceflight as an indicator of the adaptation of the otolith function to microgravity. It has been claimed that the overall pattern of OCR responses during static body tilt after spaceflight is indicative of a decreased role of the otolith function, but the results of these studies have not been consistent, mostly due to large variations in the OCR within and across individuals. By contrast with static head tilt, off-vertical axis rotation (OVAR) presents the advantage of generating a sinusoidal modulation of OCR, allowing averaged measurements over several cycles, thus improving measurement accuracy. Accordingly, OCR and the sense of roll tilt were evaluated in seven astronauts before and after spaceflight during OVAR at 45 /s in darkness at two angles of tilt (10 and 20 ). There was no significant difference in OCR during OVAR immediately after landing compared to preflight. However, the amplitude of the perceived roll tilt during OVAR was significantly larger immediately postflight, and then returned to control values in the following days. Since the OCR response is predominantly attributed to the shearing force exerted on the utricular macula, the absence of change in OCR postflight suggests that the peripheral otolith organs function normally after short-term spaceflight. However, the increased sense of roll tilt indicates an adaptation in the central processing of gravitational input, presumably related to a re-weigthing of the internal representation of gravitational vertical as a result of adaptation to microgravity.

Clement, Gilles↗
DOE OSTI2017

Roll-to-roll light directed electrophoretic deposition system and method

A roll-to-roll light directed electrophoretic deposition system and method advances a roll of a flexible electrode web substrate along a roll-to-roll process path, where a material source is positioned to provide on the flexible electrode web substrate a thin film colloidal dispersion of electrically charged colloidal material dispersed in a fluid. A counter electrode is also positioned to come in contact with the thin film colloidal dispersion opposite the flexible electrode web substrate, where one of the counter electrode and the flexible electrode web substrate is a photoconductive electrode. A voltage source is connected to produce an electric potential between the counter electrode and the flexible electrode web substrate to induce electrophoretic deposition on the flexible electrode web substrate when the photoconductive electrode is rendered conductive, and a patterned light source is arranged to illuminate the photoconductive electrode with a light pattern and render conductive illuminated areas of the photoconductive electrode so that a patterned deposit of the electrically charged colloidal material is formed on the flexible electrode web substrate.

42 ENGINEERING↗
DOE OSTI2017

Roll-to-Roll Printed Large-Area All-Polymer Solar Cells with 5% Efficiency Based on a Low Crystallinity Conjugated Polymer Blend

The challenge of continuous printing in high-efficiency large-area organic solar cells is a key limiting factor for their widespread adoption. We present a materials design concept for achieving large-area, solution-coated all-polymer bulk heterojunction solar cells with stable phase separation morphology between the donor and acceptor. The key concept lies in inhibiting strong crystallization of donor and acceptor polymers, thus forming intermixed, low crystallinity, and mostly amorphous blends. Based on experiments using donors and acceptors with different degree of crystallinity, the results show that microphase separated donor and acceptor domain sizes are inversely proportional to the crystallinity of the conjugated polymers. This particular methodology of using low crystallinity donors and acceptors has the added benefit of forming a consistent and robust morphology that is insensitive to different processing conditions, allowing one to easily scale up the printing process from a small-scale solution shearing coater to a large-scale continuous roll-to-roll (R2R) printer. Large-area all-polymer solar cells are continuously roll-to-roll slot die printed with power conversion efficiencies of 5%, with combined cell area up to 10 cm 2 . This is among the highest efficiencies realized with R2R-coated active layer organic materials on flexible substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Roll-to-roll Manufacturing of Continuous Perovskite Modules

This project researched the development of inks that were roll-to-roll compatible and that could reduce processing time to achieve high speed operation. This necessitated the development of two nanoparticle inks, tin oxide (SnO 2 ) and nickel oxide (NiO) as electron transport layer (ETL) and hole transport layer (HTL) respectively. Several PVSK inks were also developed including a methyl ammonium lead iodide (MAPI), a mixed cation chemistry (MC) and a triple cation (TC) chemistry. All of these layers were demonstrated in roll-to-roll compatible processes utilizing Intense Pulsed Light (IPL) processing.

14 SOLAR ENERGY↗
DOE OSTI2016

In-situ Roll-to-Roll Printing of Highly Efficient Organic Solar Cells

This project focuses on developing a roll-to-roll printing setup for organic solar cells with the capability to follow the film formation in situ with small and wide angle X-ray scattering, and to improve the performance of printed organic solar cells. We demonstrated the use of the printing setup to capture important aspects of existing industrial printing methods, which ensures that the solar cell performance achieved in our printing experiments would be largely retained in an industrial fabrication process. We employed both known and newly synthesized polymers as the donor and acceptor materials, and we studied the morphological changes in real time during the printing process by X-ray scattering. Our experimental efforts are also accompanied by theoretical modeling of both the fluid dynamic aspects of the printing process and the nucleation and crystallization kinetics during the film formation. The combined insight into the printing process gained from the research provides a detailed understanding of the factors governing the printed solar cell’s performance. Finally using the knowledge we gained, we demonstrated large area ( > 10 cm2) printed organic solar cells with more than 5 percent power conversion efficiency, which is best achieved performance for roll-to-roll printed organic solar cells.

14 SOLAR ENERGY↗
DOE OSTI2018

Scalar bispectrum beyond slow-roll in the unified EFT of inflation

We introduce a complete formulation of the scalar bispectrum in the unified effective field theory(EFT) of inflation, which includes the Horndeski and beyond-Horndeski Gleyzes-Langlois-Piazza-Vernizzi classes, in terms of a set of simple one-dimensional integrals. These generalized slow-rollexpressions remain valid even when slow-roll is transiently violated and encompass all configurationsof the bispectrum. We demonstrate analytically that our expressions explicitly preserve the squeezed-limitconsistency relation beyond slow-roll. As an example application of our results, we compute thescalar bispectrum in a model in which potential-driven G-inflation at early times transitions tochaotic inflation at late times, showing that our expressions accurately track the bispectrum whenslow-roll is violated and conventional slow-roll approximations fail

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2019

Roll-to-Roll Integrated Substrates for OLED Lighting (Final Report)

OLED lighting has immense potential as aesthetically pleasing, energy-efficient general illumination. Unlike other light sources, such as incandescents, fluorescents, and inorganic LEDs, OLEDs naturally emit over a large-area surface. They are glare free, do not need to be shaded, and are cool to the touch, requiring no heatsink. The best efficiencies and lifetimes reported are on par with or better than current forms of illumination. However, the cost for OLED lighting remains high – so much so that these products are not market competitive and there is very low consumer demand. We believe that flexible, plastic-based devices will highlight the advantages of aesthetically-pleasing OLED lighting systems while paving the way for lowering both materials and manufacturing costs. These flexible devices require new development in substrate and support technology, which was the focus of the work reported here. Sinovia Technologies, as part of a collaborative team, has developed integrated plastic substrates to serve as supports for flexible OLED lighting. These substrates include a barrier to protect the OLED from moisture and oxygen-related degradation, a smooth, highly conductive transparent anode to define the OLED area, and a light scattering layer to improve emission efficiency. To ensure low cost, the anode pattern must be defined using high throughput, continuous processing, and any pattern shape should be possible. No current patterning technique meets all of these requirements. This SBIR work demonstrated the use of flexographic printing as an effective method of patterning for integrated substrates. Flexography is a letterpress process commonly used for many types of everyday items including boxes, retail bags, milk cartons, food packaging, disposable cups, adhesive tapes, envelopes, wallpaper, and newspaper. The printing process can go as fast as 600 meters per minute with feature resolution around 10 microns, showing promise for low-cost with high throughput. In this case, Sinovia has successfully used this technique to print transparent anode patterns roll-to-roll as part of our integrated substrate for OLED lighting. We have characterized the printed films and tailored the edges of the printed areas for OLED compatibility. We followed this by making white OLEDs using these anodes. To ensure that our anodes were compatible with different OLED stack structures, we fabricated solution-processed polymer white OLEDs, as well as collaborated with OLEDWorks to fabricate evaporated small-molecule devices. Comparing to results from our previous studies, we find that the flexography process does not have any detrimental effects to our overall substrate. We were able to show that our flexographically printed integrated substrate improves OLED efficiency by 24 – 35%, similar to previous results demonstrated using batch-patterning techniques. The success of this work represents two substantial opportunities for OLED lighting manufacturers. The first to first facilitate flexible lighting panels at scale, and the second to lower costs for by enabling roll-to-roll manufacture of the entire device stack. When realized, both of these will help OLED to become market competitive with other forms of general illumination.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

In-situ Photophysical Monitors and Corrective Algorithms for Photovoltaic Film Deposition and Rapid Thermal Processing in Scalable Roll-to-Roll Manufacturing

This project evaluated three photophysics-based approaches for in situ process monitoring of the scalable deposition of perovskite photovoltaic films. Based on stakeholder input and the results of laboratory trials and literature analysis, two techniques, angle resolved elastic light scattering (ARLS) and time-resolved photoluminescence (TRPL) were prototyped and demonstrated with a mixture of simulation, offline and online tests. Also, a hybrid gas flow and humidity control enclosure was constructed and demonstrated to stabilize the ambient conditions around the slot die deposition process and were demonstrated to meet the target humidity control in situ. Due in part to a delayed start and COVID-related lab restrictions and personnel changes, some of the milestones were not met. In spite of these challenges, however, both techniques were prototyped through several iterations and demonstrated significant promise for rapid in line perovskite characterization within the targeted characterization time windows and these techniques are under further development for use in DE-FOA000235:2357-1586. The TRPL system was fully mounted and demonstrated on the scaled slot die roll to roll and sheet coating systems at the Washington Clean Energy Testbeds (WCET). Motivated by significant internal and stakeholder interest, the successful prototyping achieved here, the ongoing need for in-situ characterization for the scale-up of perovskite manufacturing, and the benefits of in situ photophysical characterization for future funded process development research, we are continuing with the principle aims of the project to develop effect in situ photophysical probes for fast analysis of the optoelectronic and structural quality of sheet based and roll to roll process perovskites. TRPLS and ARLS probes proposed in the project are to be completed with external support from the Washington Research Foundation at the WCET. We are currently actively engaged in the acquisition of components and plan to complete and test the probes within three months. It is our intention that these probes will then be used in ongoing perovskite development with our research and commercialization partners including First Solar and other member of the US MAP consortium in future funded development work.

14 SOLAR ENERGY↗
NASA NTRS1973

Model support roll balance and roll coupling

The design concepts of two specialized wind tunnel model support mechanisms are described. The forced oscillation roll balance mechanism was designed to meet the specific requirement to measure aerodynamic forces and moments to permit determination of the damping-in-roll parameters of winged configurations. A variable speed motor is used to oscillate the model by means of an offset crank. The oscillating motion is resisted by a torsion spring to provide a restoring torque and is attached to the section forward of the strain-gage balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance. This spring action allows the model to be oscillated at a frequency for velocity resonance, whereby the mechanical spring and any aerodynamic spring balance out the model inertia. The only torque then required to oscillate the model at that particular frequency is equal to that due to aerodynamic damping. The second mechanism, a roll coupling for remotely rotating a model, was designed to invert or roll a model about its longitudinal axis when mounted for testing.

Sharpes, R. E.↗
NASA NTRS1982

Rolling-element fatigue life with traction fluids and automatic transmission fluid in a high-speed rolling-contact rig

Rolling-element fatigue tests were run in standard and high-speed rolling-contact rigs at bar speeds from 5000 to 50,000 rpm to determine the effects of speed and lubricant film parameter on rolling-element fatigue life. AISI 52100 test bars were tested at a maximum Hertz stress of 4.83 GPa (700,000 psi) with three traction fluids and an automatic transmission fluid. Rolling-element fatigue life increased with speed, with the greatest increases occurring from 10,000 to 50,000 rpm. The life data tended to follow published life-versus-lubricant-film-parameter data up to a film parameter of approximately 3.

Parker, R. J.↗
DOE OSTI2018

Roll-to-Roll Gravure Printed Electrochemical Sensors for Wearable and Medical Devices

As recent developments in noninvasive biosensors spearhead the thrust toward personalized health and fitness monitoring, there is a need for high throughput, cost-effective fabrication of flexible sensing components. Toward this goal, in this paper we present roll-to-roll (R2R) gravure printed electrodes that are robust under a range of electrochemical sensing applications. We use inks and electrode morphologies designed for electrochemical and mechanical stability, achieving devices with uniform redox kinetics printed on 150 m flexible substrate rolls. We show that these electrodes can be functionalized into consistently high performing sensors for detecting ions, metabolites, heavy metals, and other small molecules in noninvasively accessed biofluids, including sensors for real-time, in situ perspiration monitoring during exercise. This development of robust and versatile R2R gravure printed electrodes represents a key translational step in enabling large-scale, low-cost fabrication of disposable wearable sensors for personalized health monitoring applications.

42 ENGINEERING↗
DOE OSTI2025

Demonstration of and future perspective on scaling ultrafast-laser-ablation microstructuring of Li-ion battery electrodes to roll-to-roll production and large-format cells

This work demonstrates integration of an ultrafast laser onto a roll-to-roll machine, the laser structuring of a double-sided, 700 m long roll of graphite battery anode and its subsequent manufacture into 27 Ah prismatic cells. The electrode was ablated with a novel hybrid-microstructure composed of both hexagonally arranged pores for enhanced rate performance and channels for fast electrolyte wetting. Subsequently, this anode and a non-ablated baseline anode are paired with an NMC111 cathode for cell building and electrochemical characterization. Compared to the baseline, laser ablated cells demonstrated a reduction in soaking time of at least 60%, an improvement in fast charge capability with >30% more capacity accepted during 6C charging, and an extension of cycle life of >40% during 0.5C cycling. Further, a perspective is provided on scaling ultrafast laser ablation of battery electrodes to industrial throughputs. Additionally, lessons learned from this pilot-scale demonstration are provided in regards to optical architecture, debris removal, and system control. A techno-economic analysis is used to demonstrate that laser ablation can be integrated into existing electrode manufacturing facilities with only ≈$\$$1.3 per kWh increase (≈2%) in manufacturing cost. Preemptive electrode design for laser ablation is discussed as a further method for enhancing performance. Finally, an analysis of available laser systems and beam-scanning architectures is used to determine design requirements to scale process throughput to a state-of-the-art speed of 50 m min −1 . This analysis demonstrates that laser ablating Li-ion battery electrodes has multiple benefits to manufacturing and battery performance, that the technology already exists to achieve high laser-ablation throughputs, and that integrating ultrafast laser ablation to electrode manufacturing will not create a cost or processing bottleneck.

25 ENERGY STORAGE↗
DOE OSTI2017

Primordial black holes and slow-roll violation

For primordial black holes (PBH) to be the dark matter in single-field inflation, the slow-roll approximation must be violated by at least O(1) in order to enhance the curvature power spectrum within the required number of efolds between CMB scales and PBH mass scales. Power spectrum predictions which rely on the inflaton remaining on the slow-roll attractor can fail dramatically leading to qualitatively incorrect conclusions in models like an inflection potential and misestimate the mass scale in a running mass model. We show that an optimized temporal evaluation of the Hubble slow-roll parameters to second order remains a good description for a wide range of PBH formation models where up to a 10 7 amplification of power occurs in 10 e-folds or more.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Roll-to-roll SOFC manufacturing method and system

A method of making a solid oxide fuel cell (SOFC) includes the steps of providing a first SOFC layer laminate tape comprising a first SOFC layer composition attached to a flexible carrier film layer, providing a second SOFC laminate tape comprising a second SOFC layer composition attached to a flexible carrier film layer, and providing a third SOFC layer laminate tape comprising a third SOFC layer composition attached to a flexible carrier film layer. The first SOFC layer laminate tape, the second SOFC layer laminate tape, and the third SOFC layer laminate tape are assembled on rolls positioned along a roll-to-roll assembly line. The laminate tapes are sequentially laminated and calendered and the flexible carrier films removed to provide a composite SOFC precursor laminate that can be sintered and combined with a cathode to provide a completed SOFC. An assembly for making composite SOFC precursor laminates is also disclosed.

Li, Jianlin↗