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The technology and economics of silicon ingot wafering for low cost solar arrays were discussed. Fixed and free abrasive sawing wire, ID, and multiblade sawing, materials, mechanisms, characterization, and innovative concepts were considered.
Design parameters for two large area, low cost solar cells are presented, and electron irradiation testing, thermal alpha testing, and cell processing are discussed. The devices are a 2 ohm-cm base resistivity silicon cell with an evaporated aluminum reflector produced in a dielectric wraparound cell, and a 10 ohm-cm silicon cell with the BSF/BSR combination and a conventional contact system. Both cells are 5.9 x 5.9 cm and require 200 micron thick silicon material due to mission weight constraints. Normalized values for open circuit voltage, short circuit current, and maximum power calculations derived from electron radiation testing are given. In addition, thermal alpha testing values of absorptivity and emittance are included. A pilot cell processing run produced cells averaging 14.4% efficiencies at AMO 28 C. Manufacturing for such cells will be on a mechanized process line, and the area of coverslide application technology must be considered in order to achieve cost effective production.
Two sixty-foot, low-cost, wood composite blades for service on 200 kW Mod-OA wind turbines were constructed. The blades were constructed of epoxy resin-bonded Douglas fir veneers for the leading edge sections, and paper honeycombcored, birch plywood faced panels for the afterbody sections. The blades were joined to the wind turbine hub by epoxy resin-bonded steel load take-off studs embedded into the root end of the blades. The blades were installed on the 200 kW Mod-OA wind turbine facility at Kahuku, Hawaii, The blades completed nearly 8,000 hours of operation over an 18 month period at an average power of 150 kW prior to replacement with another set of wood composite blades. The blades were replaced because of a corrosion failure of the steel shank on one stud. Inspections showed that the wood composite structure remained in excellent condition.
The development and evaluation of a low cost blade concept based on the NASA-Lewis specifications is discussed. A blade structure was designed and construction methods and materials were selected. Complete blade tooling concepts, various technical and economic analysis, and evaluations of the blade design were performed. A comprehensive fatigue test program was conducted to provide data and to verify the design. A test specimen of the spar assembly, including the root end attachment, was fabricated. This is a full-scale specimen of the root end configuration, 20 ft long. A blade design for the Mod '0' system was completed.
The paper describes a low-cost approach to the manned exploration of Mars (which involves an unmanned mission followed two years later by a manned mission) based on near-term technologies and in situ propellant production. Particular attention is given to the basic mission architecture and its major components, including the orbital analysis, the unmanned segment, the Earth Return Vehicle, the aerobrake design, life sciences, guidance, communications, power, propellant production, the surface rovers, and Mars science. Also discussed are the cost per mission over an assumed 8-yr initiative.
A viewgraph presentation on the design of a low cost unmanned aerial vehicle (UAV) doppler radar data system is presented. The topics include: 1) Science and Mission Background; 2) Radar Requirements and Specs; 3) Radar Realization: RF System; 4) Processing of RF Signal; 5) Data System Design Process; 6) Can We Remove the DSP? 7) Determining Approximate Speed Requirements; 8) Radar Realization: Data System; 9) Data System Operation; and 10) Results.
A low-cost beamformer phased array antenna has been developed for expendable launch vehicles, rockets, and missiles. It utilizes a conformal array antenna of ring or individual radiators (design varies depending on application) that is designed to be fed by the recently developed hybrid electrical/mechanical (vendor-supplied) phased array beamformer. The combination of these new array antennas and the hybrid beamformer results in a conformal phased array antenna that has significantly higher gain than traditional omni antennas, and costs an order of magnitude or more less than traditional phased array designs. Existing omnidirectional antennas for sounding rockets, missiles, and expendable launch vehicles (ELVs) do not have sufficient gain to support the required communication data rates via the space network. Missiles and smaller ELVs are often stabilized in flight by a fast (i.e. 4 Hz) roll rate. This fast roll rate, combined with vehicle attitude changes, greatly increases the complexity of the high-gain antenna beam-tracking problem. Phased arrays for larger ELVs with roll control are prohibitively expensive. Prior techniques involved a traditional fully electronic phased array solution, combined with highly complex and very fast inertial measurement unit phased array beamformers. The functional operation of this phased array is substantially different from traditional phased arrays in that it uses a hybrid electrical/mechanical beamformer that creates the relative time delays for steering the antenna beam via a small physical movement of variable delay lines. This movement is controlled via an innovative antenna control unit that accesses an internal measurement unit for vehicle attitude information, computes a beam-pointing angle to the target, then points the beam via a stepper motor controller. The stepper motor on the beamformer controls the beamformer variable delay lines that apply the appropriate time delays to the individual array elements to properly steer the beam. The array of phased ring radiators is unique in that it provides improved gain for a small rocket or missile that uses spin stabilization for stability. The antenna pattern created is symmetric about the roll axis (like an omnidirectional wraparound), and is thus capable of providing continuous coverage that is compatible with very fast spinning rockets. For larger ELVs with roll control, a linear array of elements can be used for the 1D scanned beamformer and phased array, or a 2D scanned beamformer can be used with an NxN element array.
Due to the increasing international competition and growing pressure to lower the cost of launch vehicles, enhanced technologies and competences for efficient, low cost manufacturing have to be developed. In this paper, an innovative manufacturing technology for launch vehicle applications is presented that was developed over the last few years at MT Aerospace AG (MTA) in collaboration with NASA Langley Research Center, the European Space Agency (ESA), Lockheed Martin Corporation (LMCO), Leifeld Metal Spinning and Scot Forge. The Integrally Stiffened Cylinder (ISC) manufacturing method was first investigated in 2010. Early results indicated a high mass saving potential for cylindrical structures for launch vehicle systems, such as cryogenic tank barrels and intertanks, produced using the ISC method. Cost-benefit studies conducted at NASA and MTA estimated up to 50% reduction in manufacturing costs is possible compared to conventional multi-piece, welded fabrication methods. Associated reductions in manufacturing lead times have shown that a 40% faster production rate is possible by the ISC process. Following proof of concept and process development efforts, a cylindrical structure manufactured using the ISC method had its maiden flight in 2015 on a Black Brant sounding rocket at NASA Wallops Flight Facility. Further collaboration between ESA, NASA, MTA, LMCO, and Scot Forge led to manufacturing test campaigns at MT Aerospace in 2017 and 2018 that successfully demonstrated ISC fabrication at a scale representative of commercial launch vehicles. This paper summarizes the status and relevant results of the development sequence of the ISC cylinder manufacturing method. Results of cost / benefit and structural performance analyses are also summarized. Moreover, an outlook will be given on further planned activities and development steps.
Access to and extensive use of fluorometric analyses is limited, despite its extensive utility in environmental transport and fate. Wide-spread application of fluorescent tracers has been limited by the prohibitive costs of research-grade equipment and logistical constraints of sampling, due to the need for high spatial resolutions and access to remote locations over long timescales. Recently, low-cost alternatives to research-grade equipment have been found to produce comparable data at a small fraction of the price for commercial equipment. Here, we prototyped and benchmarked performance of a variety of fluorometer components against commercial units, including performance as a function of tracer concentration, turbidity, and temperature, all of which are known to impact fluorometer performance. While component performance was found to be comparable to the commercial units tested, the best configuration tested obtained a functional resolution of 0.1 ppb, a working concentration range of 0.1 to >300 ppb, and a cost of USD 59.13.
Current approaches for single molecule force spectroscopy are typically constrained by low throughput and high instrumentation cost. Herein, a low-cost, high throughput technique is demonstrated using microfluidics for multiplexed mechanical manipulation of up to ~4000 individual molecules via molecular fluid loading on-a-chip (FLO-Chip). The FLO-Chip consists of serially connected microchannels with varying width, allowing for simultaneous testing at multiple loading rates. Molecular force measurements are demonstrated by dissociating Biotin-Streptavidin and Digoxigenin-AntiDigoxigenin interactions along with unzipping of double stranded DNA of varying sequence under different dynamic loading rates and solution conditions. Rupture force results under varying loading rates and solution conditions are in good agreement with prior studies, verifying a versatile approach for single molecule biophysics and molecular mechanobiology. FLO-Chip enables straightforward, rapid, low-cost, and portable mechanical testing of single molecules that can be implemented on a wide range of microscopes to broaden access and may enable new applications of molecular force spectroscopy.
Abstract Surface passivation of perovskite solar cells (PSCs) using a low‐cost industrial organic pigment quinacridone (QA) is presented. The procedure involves solution processing a soluble derivative of QA, N , N ‐bis(tert‐butyloxycarbonyl)‐quinacridone (TBOC‐QA), followed by thermal annealing to convert TBOC‐QA into insoluble QA. With halide perovskite thin films coated by QA, PSCs based on methylammonium lead iodide (MAPbI 3 ) showed significantly improved performance with remarkable stability. A PCE of 21.1 % was achieved, which is much higher than 18.9 % recorded for the unmodified devices. The QA coating with exceptional insolubility and hydrophobicity also led to greatly enhanced contact angle from 35.6° for the pristine MAPbI 3 thin films to 77.2° for QA coated MAPbI 3 thin films. The stability of QA passivated MAPbI 3 perovskite thin films and PSCs were significantly enhanced, retaining about 90 % of the initial efficiencies after more than 1000 hours storage under ambient conditions.
Abstract Surface passivation of perovskite solar cells (PSCs) using a low‐cost industrial organic pigment quinacridone (QA) is presented. The procedure involves solution processing a soluble derivative of QA, N , N ‐bis(tert‐butyloxycarbonyl)‐quinacridone (TBOC‐QA), followed by thermal annealing to convert TBOC‐QA into insoluble QA. With halide perovskite thin films coated by QA, PSCs based on methylammonium lead iodide (MAPbI 3 ) showed significantly improved performance with remarkable stability. A PCE of 21.1 % was achieved, which is much higher than 18.9 % recorded for the unmodified devices. The QA coating with exceptional insolubility and hydrophobicity also led to greatly enhanced contact angle from 35.6° for the pristine MAPbI 3 thin films to 77.2° for QA coated MAPbI 3 thin films. The stability of QA passivated MAPbI 3 perovskite thin films and PSCs were significantly enhanced, retaining about 90 % of the initial efficiencies after more than 1000 hours storage under ambient conditions.
A low cost strategy is developed for hydrophobization of hollow silica particles without compromising with their structural integrity.
Inchfab Inc. is developing an ultra-low cost suite of micro- and nanofabrication platforms which allows greater process flexibility and short development cycles. In traditional manufacturing environments, virtually all fabrication happens on 6-12” substrates–which requires prohibitively expensive fabrication facilities (“fabs”). By scaling the substrate size down to 1-2”, Inchfab reduces the capital cost and physical footprint of a fab by two to three orders of magnitude, while still retaining a similar level of performance. Additionally, the design of the Inchfab will allow users to develop fully-customizable fabrication processes, accommodating non-traditional materials and process diversity. Ultimately, the Inchfab platform will enable innovative device designs which currently have limited possibility of being realized. This CRADA project worked on preliminary research to test the feasibility of the Inchfab platform by utilizing equipment at Berkeley Lab to evaluate test samples and characterize equipment performance.
The aim of the project titled “Metal Complex Inks for Low-Cost Photovoltaic Material Metallization” was to develop new metal complex conductive inks and pastes for PV, invented and commercialized by Electroninks, Inc. (EI, Austin, TX USA, https://electroninks.com), the only global supplier and scaled-manufacturing company of these metal complex inks. These materials were developed in this work for photovoltaic applications to significantly lower the cost of metallization, improve the manufacturability, and greatly reduce metal usage, while maintaining or improving device efficiencies when compared to traditional nanoparticle-based inks. The new pastes will do so by: 1) lowering the finger resistivity and precious metals usage by printing much denser (and therefore thinner/less material) metal films than possible with traditional particle-based screen-printed pastes; 2) decreasing the firing temperature to help preserve passivation; and 3) enabling a path to move the TW-scale PV industry from Ag to other materials including Ni, Cu, and Ni/Cu alloy pastes while continuing to leverage capital investment and expertise in screen printing metallization.
Work on the development of low cost, high energy per unit area solar cell modules was conducted. Hexagonal solar cell and module efficiencies, module packing ratio, and solar cell design calculations were made. The cell grid structure and interconnection pattern was designed and the module substrates were fabricated for the three modules to be used. It was demonstrated that surface macrostructures significantly improve cell power output and photovoltaic energy conversion efficiency.
Work performed in the field of photovoltaic research by the low cost silicon solar array project of jet propulsion laboratory was described. Background technical information was also furnished.
LANDSAT analysis system is assembled from commercially available components at relatively low cost. Small-scale system is put together for price affordable for state agencies and universities. It processes LANDSAT data for subscene areas on repetitive basis. Amount of time required for processing decreases linearly with number of classifications desired. Computer programs written in FORTRAN IV are available for analyzing data.