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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
NASA NTRS1984

Space station - The next logical step

NASA has been charged with the development, over the next decade, of a permanently manned space station in low earth orbit. The space station system will comprise a manned base and associated unmanned platforms; while one of the platforms will be in polar orbit, another (or several) platforms will, like the manned base, have an orbital inclination of 28.5 deg. Because it is permanent, the space station will have to be semiautonomous from its mission control center. NASA will take a number of steps to foster the commercial utilization of the space station, and one of the design goals of the project is the definition of astronaut facilities that are very 'customer friendly'. Reliance on a single, program-wide contractor has been deemed undesirable; several major aerospace manufacturers will instead distribute responsibility among themselves for the various modules constituting the craft.

Beggs, J. M.↗
NASA NTRS1993

Charge retention test experiences on Hubble Space Telescope nickel-hydrogen battery cells

The Hubble Space Telescope (HST) nickel-hydrogen battery module was designed by Lockheed Missile & Space Co (LMSC) and manufactured by Eagle-Picher Ind. (EPI) for the Marshall Space Flight Center (MSFC) as an Orbital Replacement Unit (ORU) for the nickel-cadmium batteries originally selected for this low earth orbit mission. The design features of the HST nickel hydrogen battery are described and the results of an extended charge retention test are summarized.

Nawrocki, Dave E.↗
NASA NTRS1992

Portable life support system regenerative carbon dioxide and water vapor removal by metal oxide absorbents preprototype hardware development and testing

NASA-Johnson has acquired a preprototype/full-scale metal oxide CO2 and humidity remover (MOCHR), together with its regeneration module. Tests conducted prior to delivery by the MOCHR's manufacturer have demonstrated the concurrent removal of H2O and CO2 at rates, and under conditions, that are applicable to EVA Portable Life Support Systems.

Hart, Joan M.↗
DOE OSTI2017

First-Annual Global Clean Energy Manufacturing Report Shows Strong Domestic Benefits for the United States

The Energy Department’s Office of Energy Efficiency and Renewable Energy (EERE) commissioned the Clean Energy Manufacturing Analysis Center to conduct the first-ever annual assessment of the economic state of global clean energy manufacturing. The report, Benchmarks of Global Clean Energy Manufacturing, makes economic data on clean energy technology widely available.

battery cells↗
DOE OSTI2017

Evaluating the economic viability of CdTe/CIS and CIGS/CIS tandem photovoltaic modules

In this paper, we analyze the potential cost competitiveness of two frameless, glass–glass thin-film tandem photovoltaic module structures, cadmium telluride (CdTe)/CuInSe 2 (CIS) and CuIn 0.3 Ga 0.7 Se 2 (CIGS)/CIS, based on the demonstrated cost of manufacturing the respective component cell technologies in high volume. To consider multiple economic scenarios, we base the CdTe/CIS module efficiency on the current industrial production of CdTe modules, while for CIGS/CIS, we use an aspirational estimate for CIGS efficiency. We focus on four-terminal mechanically stacked structures, thus avoiding the need to achieve current matching between the two cells. The top cell in such a tandem must have a transparent back contact, which has not been successfully implemented to date. However, for the purpose of understanding the economic viability of both tandems, we assume that this can be implemented at a cost similar to that of sputtered indium tin oxide. The cost of both tandem module structures was found to be nearly identical on an equal-area basis and approximately $30/m 2 higher than the single-junction alternatives. Both tandem modules are about 4% (absolute) more efficient than a module by using the top-cell material alone. We find that these tandem modules might reduce total system cost by as much as 11% in applications having a high area-related balance-of-system cost, such as area-constrained residential systems; however, the relative advantage of tandems decreases in the cases where balance-of-system costs are lower, such as in commercial and utility scale systems.

14 SOLAR ENERGY↗
NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism (CBM). The mechanism that effects the structural connection of the CBM halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per CBM. The CBM has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface; see Figure 1. The Powered Bolt Assemblies are preloaded to approximately 19 kilo pounds (KIPs) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes which create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗
NASA NTRS2010

International Space Station Powered Bolt Nut Anomaly and Failure Analysis Summary

A key mechanism used in the on-orbit assembly of the International Space Station (ISS) pressurized elements is the Common Berthing Mechanism. The mechanism that effects the structural connection of the Common Berthing Mechanism halves is the Powered Bolt Assembly. There are sixteen Powered Bolt Assemblies per Common Berthing Mechanism. The Common Berthing Mechanism has a bolt which engages a self aligning Powered Bolt Nut (PBN) on the mating interface (Figure 1). The Powered Bolt Assemblies are preloaded to approximately 84.5 kN (19000 lb) prior to pressurization of the CBM. The PBNs mentioned below, manufactured in 2009, will be used on ISS future missions. An on orbit functional failure of this hardware would be unacceptable and in some instances catastrophic due to the failure of modules to mate and seal the atmosphere, risking loss of crew and ISS functions. The manufacturing processes that create the PBNs need to be strictly controlled. Functional (torque vs. tension) acceptance test failures will be the result of processes not being strictly followed. Without the proper knowledge of thread tolerances, fabrication techniques, and dry film lubricant application processes, PBNs will be, and have been manufactured improperly. The knowledge gained from acceptance test failures and the resolution of those failures, thread fabrication techniques and thread dry film lubrication processes can be applied to many aerospace mechanisms to enhance their performance. Test data and manufactured PBN thread geometry will be discussed for both failed and successfully accepted PBNs.

Sievers, Daniel E.↗
DOE OSTI2025

Design and Analysis of an Integrated Additively Manufactured Test Article for Plasma-Facing Components

Current plasma-facing components (PFCs) used in helium-cooled divertor modules are complex structures with tungsten tile, steel sleeve components, and cartridges, all assembled in a helium-cooled multiple jet (HEMJ) structure. The goal of this project is to simplify the complex PFC design using additive manufacturing techniques to create a single integrated tungsten test article. Apart from the flexibility this opens up in exploring a wide array of geometries for the article, having a single integrated article significantly reduces the number of joints and parts in the article, thus reducing chances of leaks. A process called electron beam melting has shown to produce very high-density samples and unique geometries, enabling HEMJ or similar designs. To validate and optimize this novel design, the model underwent a series of computational fluid dynamics and finite element analysis simulations to replicate steady-state heat flux in the divertors. The simulations presented in this study consider a steady-state base heat flux of 5 MW/m 2 , with water serving as the coolant. Future research will explore the use of helium as a coolant, simulate edge-localized-mode conditions, and include experimental validation. Since 3D-printed tungsten is anisotropic, the build direction versus build plane of the article are taken into consideration for the test article strength. Because of the high operating temperatures and low ductility of tungsten, thermal creep and brittle fracture are important failure mechanisms to consider. In conclusion, the cap is evaluated with various flow velocities and nozzle diameters, and an optimal design choice is made for which this cap will survive the divertor conditions with a conservative safety margin.

Divertor↗
NASA NTRS1978

Evaluation of solar cells and arrays for potential solar power satellite applications

Proposed solar array designs and manufacturing methods are evaluated to identify options which show the greatest promise of leading up to the develpment of a cost-effective SPS solar cell array design. The key program elements which have to be accomplished as part of an SPS solar cell array development program are defined. The issues focussed on are: (1) definition of one or more designs of a candidate SPS solar array module, using results from current system studies; (2) development of the necessary manufacturing requirements for the candidate SPS solar cell arrays and an assessment of the market size, timing, and industry infrastructure needed to produce the arrays for the SPS program; (3) evaluation of current DOE, NASA and DOD photovoltaic programs to determine the impacts of recent advances in solar cell materials, array designs and manufacturing technology on the candidate SPS solar cell arrays; and (4) definition of key program elements for the development of the most promising solar cell arrays for the SPS program.

Almgren, D. W.↗
NASA NTRS1987

Advanced planar array development for space station

The results of the Advanced Planar Array Development for the Space Station contract are presented. The original objectives of the contract were: (1) to develop a process for manufacturing superstrate assemblies, (2) to demonstrate superstrate technology through fabrication and test, (3) to develop and analyze a preliminary solar array wing design, and (4) to fabricate a wing segment based on wing design. The primary tasks completed were designing test modules, fabricating, and testing them. LMSC performed three tasks which included thermal cycle testing for 2000 thermal cycles, thermal balance testing at the Boeing Environmental Test Lab in Kent, Washington, and acceptance testing a 15 ft x 50 in panel segment for 100 thermal cycles. The surperstrate modules performed well during both thermal cycle testing and thermal balance testing. The successful completion of these tests demonstrate the technical feasibility of a solar array power system utilizing superstrate technology. This final report describes the major elements of this contract including the manufacturing process used to fabricate modules, the tests performed, and the results and conclusions of the tests.

Source record↗
DOE OSTI2018

Experimental and numerical studies of helium-cooled modular divertors with multiple jets

As part of the US-Japan PHENIX program, the helium-cooled modular divertor with multiple jets (HEMJ) and a simpler “flat” variant were experimentally studied in a closed helium loop with a redesigned test chamber at coolant inlet temperatures as great as 425 °C, incident heat fluxes as great as 2.2 MW/m 2 and prototypical inlet pressures of ~10 MPa. The data were used to develop correlations for the average Nusselt number and loss coefficient for a range of mass flow rates; these correlations were used in turn to predict the thermal-hydraulic performance of a single divertor module at prototypical conditions. The experimental results suggest that a flat jet array with six holes surrounding one central hole, all of the same diameter, can provide similar average heat transfer coefficients as the HEMJ divertor, albeit with higher pumping power requirements. Because of its smaller cooled surface area, however, this design has lower maximum allowable heat fluxes compared with the HEMJ divertor. Nevertheless, the flat variant could potentially simplify manufacturing and reduce the costs required to fabricate O(10 6 ) “finger” modules.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1994

Flexible manufacturing for photonics device assembly

The assembly of photonics devices such as laser diodes, optical modulators, and opto-electronics multi-chip modules (OEMCM), usually requires the placement of micron size devices such as laser diodes, and sub-micron precision attachment between optical fibers and diodes or waveguide modulators (usually referred to as pigtailing). This is a very labor intensive process. Studies done by the opto-electronics (OE) industry have shown that 95 percent of the cost of a pigtailed photonic device is due to the use of manual alignment and bonding techniques, which is the current practice in industry. At Lawrence Livermore National Laboratory, we are working to reduce the cost of packaging OE devices through the use of automation. Our efforts are concentrated on several areas that are directly related to an automated process. This paper will focus on our progress in two of those areas, in particular, an automated fiber pigtailing machine and silicon micro-technology compatible with an automated process.

Lu, Shin-Yee↗
DOE OSTI2019

Toward Greater Understanding of Upstream and Downstream Manufacturing Processes for Automotive of Li-Ion Batteries

This work focuses on cost associated with extraction and purification of raw materials used in Li-ion batteries such as Co, Ni, Mn and graphite. This work also attempts to expand cost analysis to cover costs associated with cells and modules packaging. Value chain analysis will be used to facilitate understanding of costs in the manufacturing processes of Li-ion batteries.

25 ENERGY STORAGE↗
DOE OSTI2026

Semi-Transparent Perovskite Solar Cells in a Stacked Tandem Module: Cooperative Research and Development Final Report, CRADA Number CRD-19-00810

This project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, anti-reflection layer composition and deposition process, and cell to module integration processes. Modification 5: The proposed project seeks to develop device design, materials composition, and processing tools and parameters to fabricate semi-transparent perovskite solar cells and modules for application in stand-alone products or added to other solar cells in a mechanically-stacked tandem configuration. This technology presents significant advanced manufacturing challenges and opportunities in getting to scale, including development of perovskite inks, scalable perovskite and heterojunction deposition and annealing processes, heterojunction composition, transparent electrode composition and deposition process, passivation layers including in module scribes, anti-reflection layer composition and deposition process, and cell to module integration processes. Advanced metrology and characterization will be performed on perovskite films, cells and module. Furthermore, we will examine module or materials recycling for circular economy considerations. Modifcation 6: Gigahertz frequency microwave pump-probe spectroscopies are highly sensitive to thin film semiconductor photoconductivity of individual and stacks of layers that comprise perovskite solar cells. As such, these techniques will be used to qualify reproducibility and quality correlations during the manufacturing process. Modification 7: Mechanical adhesion of top contacts within perovskite modules significantly impacts the durability of the module when exposed to accelerated degradation testing. The adhesion between the perovskite/transport layer interface and the transport layer/top contact interface are both very sensitive small changes in processing. ALD processing conditions of the transport layer will be tuned to optimize the mechanical adhesion within the perovskite module stack.

14 SOLAR ENERGY↗
DOE OSTI2023

The MOOSE electromagnetics module

The Multiphysics Object-Oriented Simulation Environment (MOOSE) electromagnetics module has been developed to increase MOOSE physics module capabilities, enabling standalone and coupled computational electromagnetics within the MOOSE multiphysics ecosystem. The module is actively being utilized in the areas of plasma physics and advanced manufacturing, and it currently provides initial demonstrated capability in multi-dimensional, complex-valued electromagnetic wave propagation, electrostatic contact, reflection and transmission, and electromagnetic eigenvalue problems. Two-dimensional wave propagation and one-dimensional wave reflection and transmission are showcased as examples in this work. The modularity, parallelism, and plug-in infrastructure for custom future development is inherited from MOOSE itself, and the module can be used with both MOOSE-based and external codes, giving great flexibility.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Toward High Conversion Efficiency of Thermoelectric Modules through Synergistical Optimization of Layered Materials

Abstract Waste‐heat electricity generation using high‐efficiency solid‐state conversion technology can significantly decrease dependence on fossil fuels. Here, a synergistical optimization of layered half‐Heusler (hH) materials and module to improve thermoelectric conversion efficiency is reported. This is realized by manufacturing multiple thermoelectric materials with major compositional variations and temperature‐gradient‐coupled carrier distribution by one‐step spark plasma sintering. This strategy provides a solution to overcome the intrinsic concomitants of the conventional segmented architecture that only considers the matching of the figure of merit ( zT ) with the temperature gradient. The current design is dedicated to temperature‐gradient‐coupled resistivity and compatibility matching, optimum zT matching, and reducing contact resistance sources. By enhancing the quality factor of the materials by Sb‐vapor‐pressure‐induced annealing, a superior zT of 1.47 at 973 K is achieved for (Nb, Hf)FeSb hH alloys. Along with the low‐temperature high‐ zT hH alloys of (Nb, Ta, Ti, V)FeSb, the single stage layered hH modules are developed with efficiencies of ≈15.2% and ≈13.5% for the single‐leg and unicouple thermoelectric modules, respectively, under Δ T of 670 K. Therefore, this work has a transformative impact on the design and development of next‐generation thermoelectric generators for any thermoelectric material families.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

Progress and Strategies for Testing of Materials for Solar Panels

Accelerated testing is key to confident launch of a new product. However, for new products like solar panels, the best approach is not always clear. The challenge for materials manufacturers is that test times can be long. Also, small-coupon testing may not predict the behavior in the full-size module, but testing of the full-size module is too expensive. As a result, solar panel test standards like IEC 61215 are useful, but are not sufficient. Material manufacturers have needed to define their own test protocols. This presentation will review some historical data (e.g., data show that manufacturers are making great progress toward reducing encapsulant discoloration) and describe advances in material testing (for example, new techniques are being demonstrated on how to more quantitatively assess adhesion, detect tendency for delamination, and understand how encapsulant properties affect other properties like cracking of cells). The International PV Quality Assurance Task Force has been researching climate-specific weathering tests toward the goal of defining international standards that would simplify qualification and quality assurance testing for materials. The status of these tests and the strategies for how to organize these standards to best meet the needs of the industry will be discussed.

14 SOLAR ENERGY↗