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At least 469 records · Page 26

Performance improvements in silicon flat-plate cells and modules

This paper reports the development of a flat-plate module based on highly efficient ion-implanted silicon solar cells. The cells developed in this work are 53 sq cm in area and have exhibited AM 1.5 efficiencies of over 18 percent. The use of back surface reflectors to reduce module operating temperature is discussed. A comparison of various approaches to cell design is made, and module test data for these designs are presented. A comparison of float zone and Czochralski silicon is made. Module efficiency of over 15 percent (at 25 C) is reported.

Spitzer, M. B.↗

Effect of a shallow low-viscosity zone on the formation of midplate swells

A finite-element numerical method is used here to analyze the effect of a low-viscosity zone on convection driven by heating from below in the upper mantle, in particular on the formation of midplate swells. The convective temperature and velocity solutions are calculated for different combinations of the viscosity in the top layer, the fluid layer thicknesses, and the Rayleigh number based on the viscosity in the bottom layer. The temperature solutions are used to calculate the geoid, topography, and heat flow anomalies, the elastic plate thickness, the depth of compensation, and an upper bound on the uplift time that result from the flow. The results are compared to data at the Hawaii, Bermuda, Cape Verde, and Marquesas swells. The magnitudes and the trend with age are consistent with theoretical and other estimates of the viscosity variation in the shallow upper mantle. Convective models can therefore explain the uplift and observed anomalies at midplate swells.

Robinson, E. M.↗

Correlation of Fracture Behavior With Microstructure in Friction Stir Welded, and Spin Formed AI-Li 2195 Domes

Single-piece, spin-formed domes manufactured from friction stir welded (FSW) plates of Al-Li alloy 2195 have the potential to reduce the cost of fabricating cryogenic propellant tanks. Mechanical properties in the completed domes can be related directly to the final material condition and the microstructures developed. However, these new fabrication techniques have resulted in unexpected material challenges, such as abnormal grain growth in the weld nugget and the propensity for fracture in the adjacent thermo-mechanically affected zone (TMAZ). In this study, the microstructure and texture transformations within the TMAZ are related to fracture location in the vicinity of the weldment. The texture variations in the TMAZ are caused primarily by the varying amounts of shear deformation introduced during the FSW process. Grain morphology and microtexture characteristics are examined as a function of location in the TMAZ via electron backscatter diffraction (EBSD). A strong correlation between fracture location and the presence of texture banding in the TMAZ is observed. The fracture path tends to follow a distinct region of low Taylor Factor (TF) grains.

Tayon, Wesley A.↗

Elastic-plastic models for multi-site damage

This paper presents recent developments in advanced analysis methods for the computation of stress site damage. The method of solution is based on the p-version of the finite element method. Its implementation was designed to permit extraction of linear stress intensity factors using a superconvergent extraction method (known as the contour integral method) and evaluation of the J-integral following an elastic-plastic analysis. Coarse meshes are adequate for obtaining accurate results supported by p-convergence data. The elastic-plastic analysis is based on the deformation theory of plasticity and the von Mises yield criterion. The model problem consists of an aluminum plate with six equally spaced holes and a crack emanating from each hole. The cracks are of different sizes. The panel is subjected to a remote tensile load. Experimental results are available for the panel. The plasticity analysis provided the same limit load as the experimentally determined load. The results of elastic-plastic analysis were compared with the results of linear elastic analysis in an effort to evaluate how plastic zone sizes influence the crack growth rates. The onset of net-section yielding was determined also. The results show that crack growth rate is accelerated by the presence of adjacent damage, and the critical crack size is shorter when the effects of plasticity are taken into consideration. This work also addresses the effects of alternative stress-strain laws: The elastic-ideally-plastic material model is compared against the Ramberg-Osgood model.

Actis, Ricardo L.↗

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗

The accommodation of relative motion at depth on the San Andreas fault system in California

Plate motion below the seismogenic layer along the San Andreas fault system in California is assumed to form by aseismic slip along a deeper extension of the fault or may result from lateral distribution of deformation below the seismogenic layer. The shallow depth of California earthquakes, the depth of the coseismic slip during the 1906 San Francisco earthquake, and the presence of widely separated parallel faults indicate that relative motion is distributed below the seismogenic zone, occurring by inelastic flow rather than by aseismic slip on discrete fault planes.

Prescott, W. H.↗

Laminar to Turbulence Transition in Boundary Layers due to Tripping Devices

Direct numerical simulations (DNS)and linear stability analysis were performed to identify the mechanisms by which two-and three-dimensional trips promote early transition in subsonic boundary layers over a flat plate. Investigations were conducted for two boundary layer transition trip configurations: one is a two-dimensional rectangular-shaped rod and the other is a three-dimensional zigzag tape. Reynolds numbers based on the trip heights are 683 and 300 for the two-and three-dimensional trips, respectively. Simulations with the two-dimensional trip showed that the flow separates at the top of the trip and forms a long recirculation zone downstream. However, the flow remains steady in the simulation without any external disturbances. Linear stability analysis showed that the inflectional profile in the recirculation zone is strongly unstable to frequencies in the range of 100-300 Hz. Simulations with the external disturbances forced at the frequency of 200 Hz showed that disturbances grow strongly inside the recirculation zone as observed in the Klebanoff1 experiment.

Transition↗

Macroscale property assessment and indentation characteristics of thick section friction stir welded AA 5083

The spatial gradients in microstructure have been proven to be effective in optimizing the performance of components, and several techniques have been developed to achieve this microstructure. Nevertheless, the local microstructural modification methods inevitably result in the formation of gradient microstructure leading to a variation in the property. Herein this work systematically investigates the effect of gradient microstructure formed during thick section friction stir weld Al5083 alloy on its mechanical properties. A novel macro-indentation technique, profilometer-based indentation plastometry (PIP), is utilized to capture the variation in the mechanical properties in the feedstock (rolled plate) and weld region. The feedstock exhibited a gradient microstructure owing to different stress states during rolling. Additionally, the stirring of the tool resulted in a complex material flow pattern producing a microstructure gradient in the weld region. The aspect ratio of the grains was identified as the primary factor causing variation in indentation response in the feedstock. In contrast, variation in the grain size in the weld region resulted in property variation. Overall, the stir zone has a lower yield strength (158±4MPa) than the base material (173±3MPa). In addition, microstructure heterogeneity in the stir zone resulted in lower elongation than the base material.

36 MATERIALS SCIENCE↗

The effect of turbulence on pollutant formation in a tubular burner

The role of turbulence in pollutant formation was investigated both experimentally and analytically with the objective of understanding the important mechanisms of a fairly basic level. Preliminary measurements of the cold-flow turbulence characteristics downstream of three perforated plate flame holders, of varying solidity ratio, were made. In the combustion experiment, measurements of the concentration distributions of CO, NO(x), HC, and CO2, downstream of the same flame holders, were made. The combustor configuration was tubular and constant-area, and the fuel was premixed, prevaporized propane. The experimental results were modeled by a one-dimensional analysis in which transport phenomena were neglected, and more successfully, by a quasi-one-dimensional analysis containing recirculation zones and turbulent transport effects.

Robinson, G. F.↗

Fracture of cylindrical and spherical shells containing a crack.

Fatigue and fracture of cylindrical and spherical shells containing a through crack and subjected to internal pressure or torsion are considered. The stress intensity factor ratios giving the effect of curvature are obtained as functions of a dimensionless shell parameter. By using the conventional plastic strip model the plastic zone size around the crack tip and the crack opening displacement are calculated. The calculated COD values are shown to be in good agreement with the experimental results. The fracture criterion of critical COD is verified by using the results of the burst tests in titanium and aluminum alloy cryogenic pressure vessels. Modified fatigue crack propagation models taking into account the bending effect in shells are introduced and are applied to the analysis of experimental data obtained from flat plates, and cylindrical shells under axial tension, internal pressure, and torsion. Finally, the paper includes the effect of humidity on the crack growth rate and the effect of load biaxiality on the rupture strength.

Erdogan, F.↗

Possible role of crustal flexure in the initial detachment of extensional allochthons

The existence of low-angle normal faults indicates that the ratio of shear stress (TAU) to normal stress (sigma sub N) needed to cause slip on faults is substantially less than would be predicted based on experimental data. Because the tensional strength of rock at a large scale is exceedingly low, the upper plate of a low-angle normal fault cannot be pulled down the fault ramp, but must be driven down it by its own weight. The active or recently active Sevier Desert detachment fault in western Utah dips regionally at 12 deg. The radio of shear stress to normal stress due to the weight of the upper plate on a 12 deg dipping fault surface is 0.2. In contrast, laboratory experiments indicate that slip on fracture surfaces occurs with almost all rock types when (tau/sigma) reaches values of 0.6 to 0.85, corresponding to normal-fault dips of 30 deg to 40 deg. Seismological data indicate that low deviatoric stresses are associated with movement on faults of other geometrics and are not unique to low-angle normal faults. It thus appears that approximately planar fault zones with surface areas of hundreds to thousands of square kilometers have different mechanical properties than would be predicted based on laboratory studies of fractured rock. Modeling of stresses indicates that deviatoric stresses greater than 5kb exist and are sustainable in oceanic lithosphere, and that failure occurs when tau/sigma sub N approaches 0.6 to 0.85.

Spencer, J. E.↗

The economic payoff for a state-of-the-art high-efficiency flat-plate crystalline silicon solar cell technology

In 1986 during the flat-plate solar array project, silicon solar cells 4.0 sq cm in area were fabricated at the Jet Propulsion Laboratory (JPL) with a conversion efficiency of 20.1 percent (AM1.5-global). Sixteen cells were processed with efficiencies measuring 19.5 percent (AM1.5 global) or better. These cells were produced using refined versions of conventional processing methods, aside from certain advanced techniques that bring about a significant reduction in a major mechanism (surface recombination) that limits cell efficiency. Wacker Siltronic p-type float-zone 0.18-ohm-cm wafers were used. Conversion efficiencies in this range have previously been reported by other researchers, but generally on much smaller (0.5 vs. 4.0 cm) devices which have undergone sophisticated and costly processing steps. An economic analysis is presented of the potential payoffs for this approach, using the Solar Array Manufacturing Industry Costing Standards (SAMICS) methodology. The process sequence used and the assumptions made for capturing the economies of scale are presented.

Bickler, Donald B.↗

Dilution jet mixing program

Parametric tests were conducted to quantify the mixing of opposed rows of jets (two-sided injection) in a confined cross flow. Results show that jet penetrations for two sided injections are less than that for single-sided injections, but the jet spreading rates are faster for a given momentum ratio and orifice plate. Flow area convergence generally enhances mixing. Mixing characteristics with asymmetric and symmetric convergence are similar. For constant momentum ratio, the optimum S/H(0) with in-line injections is one half the optimum value for single sided injections. For staggered injections, the optimum S/H(0) is twice the optimum value for single-sided injection. The correlations developed predicted the temperature distributions within first order accuracy and provide a useful tool for predicting jet trajectory and temperature profiles in the dilution zone with two-sided injections.

Srinivasan, R.↗

Theoretical and experimental separation dynamics in capillary zone electrophoresis

The mathematical model of Bier et al. (1983) is used in a computer aided analysis of the conditions in capillary zone electrophoresis (ZE) under which sample zones migrate noninteractively with the carrier electrolyte. The monitoring of sample zones with a capillary analyzer that features both on-line conductivity and UV detection at the end of the separation trough is discussed. Data from a ZE analysis of a 5-component mixture are presented, and it is noted that all five components can be monitored via their conductivity change if enough sample is present. It is suggested from the results that the concentration ratio of background buffer to sample should be a minimum of 100:1 to effectively apply the plate concept to ZE.

Thormann, Wolfgang↗

Constraints on continental accretion from sedimentation

Heat loss in the ancient Earth was discussed assuming that classical sea floor spreading was the only mechanism. This may be expressed as faster spreading or longer total ridge length. These have important implications as to the size and number of cratonic plates in the distant past, the degree to which they are flooded, the kinds of sediments and volcanics that would be expected, and the amount of recycling of continental material taking place. The higher proportion of marine sedimentary rocks and oceanic volcanics in the Archean, and the relative paucity of evaporites and continental volcanics may in part be due to smaller cratonic blocks. A model was developed of the percentage of continental flooding which utilizes round continents and a constant width of the zone of flooding. This model produces a reasonable good fit to the percentage of flooding on the present day continents.

Abbott, Dallas↗

Development of an accelerator-based neutron source to prototype Mo-99 production, part I: A liquid LBE windowless target

In this article, Molybdenum-99 (Mo-99)’s decay product, technetium-99 (Tc-99 m), is one of the most critical isotopes for medical diagnostics. To provide U.S. domestic supply of Mo-99 without using high-enriched uranium (HEU), a subcritical uranium target assembly (UTA) is irradiated by an accelerator-based neutron source to create Mo-99 through fission. This study discusses the development of the accelerator-based neutron source. The high-energy electrons from the accelerator irradiate a liquid lead-bismuth eutectic (LBE) target to produce neutrons. Part I of this work focuses on numerical and experimental analysis towards the development of a liquid LBE windowless target. Unlike the existing windowless targets in literature, the current design creates a vertical free surface for a beam to irradiate. First, a hydrodynamic analysis of the LBE windowless target is performed. Simplified analytical calculations are assisted by 2D computational fluid dynamics (CFD) simulations to design the target, with the focus on eliminating recirculation zones and avoiding cavitation. With the optimized geometry, the experimental study is performed to investigate the flow hydrodynamics using liquid LBE. The experiments (1) compare pressure drop in the system to correlation predictions; (2) visualize the free surface liquid LBE flow from the beam view; (3) validate the LBE flow profile using temperature sensitive paint from the side view; and (4) validate the liquid LBE film thickness using gamma densitometer measurements. Second, the power handling capability of the designed windowless target is investigated. The divider plate in the current design is susceptible to overheating due to the thin LBE film in front. As LBE erosion and corrosion is likely to occur at an LBE velocity of 2.0 m/s and temperature above 500 °C, a power limit of 10 kW of beam power was established to prevent this corrosion from occurring, which is calculated by a Nusselt number correlation. The divider plate surface temperature at 10 kW agrees well with the 3D CFD simulation results. Part I demonstrates the fundamental physics in liquid LBE windowless target design and associated testing. A companion paper, Part II will demonstrate how to couple this windowless target into the Mo-99 production system, including an accelerator system operating under an ultra-high vacuum and the UTA cooled by water at room temperature.

43 PARTICLE ACCELERATORS↗

Reaction Kernel Structure of a Slot Jet Diffusion Flame in Microgravity

Diffusion flame stabilization in normal earth gravity (1 g) has long been a fundamental research subject in combustion. Local flame-flow phenomena, including heat and species transport and chemical reactions, around the flame base in the vicinity of condensed surfaces control flame stabilization and fire spreading processes. Therefore, gravity plays an important role in the subject topic because buoyancy induces flow in the flame zone, thus increasing the convective (and diffusive) oxygen transport into the flame zone and, in turn, reaction rates. Recent computations show that a peak reactivity (heat-release or oxygen-consumption rate) spot, or reaction kernel, is formed in the flame base by back-diffusion and reactions of radical species in the incoming oxygen-abundant flow at relatively low temperatures (about 1550 K). Quasi-linear correlations were found between the peak heat-release or oxygen-consumption rate and the velocity at the reaction kernel for cases including both jet and flat-plate diffusion flames in airflow. The reaction kernel provides a stationary ignition source to incoming reactants, sustains combustion, and thus stabilizes the trailing diffusion flame. In a quiescent microgravity environment, no buoyancy-induced flow exits and thus purely diffusive transport controls the reaction rates. Flame stabilization mechanisms in such purely diffusion-controlled regime remain largely unstudied. Therefore, it will be a rigorous test for the reaction kernel correlation if it can be extended toward zero velocity conditions in the purely diffusion-controlled regime. The objectives of this study are to reveal the structure of the flame-stabilizing region of a two-dimensional (2D) laminar jet diffusion flame in microgravity and develop a unified diffusion flame stabilization mechanism. This paper reports the recent progress in the computation and experiment performed in microgravity.

Takahashi, F.↗

Mars 2001 Lander Mission: Measurement Synergy Through Coordinated Operations Planning And Implementation

The 2001 Mars Surveyor Program Mission includes an orbiter with a gamma ray spectrometer and a multispectral thermal imager, and a lander with an extensive set of instrumentation, a robotic arm, and the Marie Curie Rover. The Mars 2001 Science Operations Working Group (SOWG) is a subgroup of the Project Science Group that has been formed to provide coordinated planning and implementation of scientific observations, particularly for the landed portion of the mission. The SOWG will be responsible for delivery of a science plan and, during operations, generation and delivery of conflict-free sequences. This group will also develop an archive plan that is compliant with Planetary Data System (PDS) standards, and will oversee generation, validation, and delivery of integrated archives to the PDS. In this report we cover one element of the SOWG planning activities, the development of a plan that maximizes the scientific return from lander-based observations by treating the instrument packages as an integrated payload. Scientific objectives for the lander mission have been defined. They include observations focused on determining the bedrock geology of the site through analyses of rocks and also local materials found in the soils, and the surficial geology of the site, including windblown deposits and the nature and history of formation of indurated sediments such as duricrust. Of particular interest is the identification and quantification of processes related to early warm, wet conditions and the presence of hydrologic or hydrothermal cycles. Determining the nature and origin of duricrust and associated salts is -very important in this regard. Specifically, did these deposits form in the vadose zone as pore water evaporated from soils or did they form by other processes, such as deposition of volcanic aerosols? Basic information needed to address these questions includes the morphology, topography, and geologic context of landforms and materials exposed at the site, together with quantitative information on material mineralogy, chemistry, and physical properties (rock textures; soil grain size and shape distributions; degree and nature of soil induration; soil magnetic properties). The calibration targets provide radiometric and mineralogical control surfaces. The magnets allow observations of magnetic phases. Patch plates are imaged to determine adhesive and abrasive properties of soils. Coordinated mission planning is crucial for optimizing the measurement synergy among the packages included on the lander. This planning has already begun through generation of multi-sol detailed operations activities. One focus has been to develop a scenario to use the arm to dig a soil trench to a depth of tens of centimeters. The activity will be monitored through use of Pancam and RAC to ensure nominal operations and to acquire data to determine subsurface physical properties (e.g., angle of repose of trench walls). Pancam and Mini-TES observations would also provide constraints on mineralogy and texture for the walls and bottom of the trench during excavation. If desired, soils excavated at depth could be deposited on the surface and Mossbauer and APXS measurements could be acquired for these materials. Soil samples from various depths would be delivered to MECA for characterization of aqueous geochemistry and physical properties of soil grains, particularly size, shape, and hardness. These physical properties would be determined by optical and atomic force microscopy. When completed, detailed information of soil properties as a function of depth would be obtained. These various data sets would constrain our understanding of whether or not there are systematic variations in soil characteristics as a function of depth. These variations might be related, for example, to evaporative moisture losses and formation of salt deposits, thereby indicating water transport processes occurred fairly recently. Many other value-added measurement scenarios are being developed. For example, characterizing the nature and dynamics of dust deposition will be done using MIP/DART to provide deposition rates, Pancam and RAC imaging of lander and rover surfaces to extrapolate these measurements to other areas, and a variety of measurements to determine if the bulk loose soil has the same characteristics as dust that accumulates during the mission. Bedrock geology of the site is primarily an APEX-focus setting, mineralogy, and texture, and APXS data to be we interest will be to determine the extent to which rock hydrothermal processes, given that APEX is the precursor 4 and 2005 rover missions. Additional information is contained in the original.

Arvidson, R.↗