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NASA NTRS2008

Method for the growth of large low-defect single crystals

A method and the benefits resulting from the product thereof are disclosed for the growth of large, low-defect single-crystals of tetrahedrally-bonded crystal materials. The process utilizes a uniquely designed crystal shape whereby the direction of rapid growth is parallel to a preferred crystal direction. By establishing several regions of growth, a large single crystal that is largely defect-free can be grown at high growth rates. This process is particularly suitable for producing products for wide-bandgap semiconductors, such as SiC, GaN, AlN, and diamond. Large low-defect single crystals of these semiconductors enable greatly enhanced performance and reliability for applications involving high power, high voltage, and/or high temperature operating conditions.

Powell, J. Anthony↗

NASA NTRS2009

Developing NDE Techniques for Large Cryogenic Tanks

The Shuttle and Constellation Programs require very large cryogenic ground storage tanks in which to store liquid oxygen and hydrogen. The existing LC-39 pad tanks, which will be passed onto Constellation, are 40 years old and have received minimal refurbishment or even inspection, because they can only be temperature cycled a few times before being overhauled (a costly operation in both time and dollars). Numerous questions exist on the performance and reliability of these old tanks which could cause a major Program schedule disruption. Consequently, with the passing of the first two tanks to Constellation to occur this year, there is growing awareness that NDE is needed to detect problems early in these tanks so that corrective actions can be scheduled when least disruptive. Time series thermal images of two sides of the Pad B LH2 tank have been taken over multiple days to demonstrate the effects of environmental conditions to the solar heating of the tank and therefore the effectiveness of thermal imaging.

Parker, Don↗

NASA NTRSDate not supplied

Towards Gbps Downlinks from Low-Cost Active Phased Arrays

Spacecraft performing science missions use high-directivity antennas to quickly downlink large amounts of collected data. Movement required to keep gimbaled reflector antennas trained on target receivers can impart blockages or vibrations which perturb precision science instruments. Recent manufacturing advances have made Ka-band electronically-steered antenna arrays a cost-effective option to mitigate these challenges, but only if these devices can be proven to deliver comparable quality of service. In this work we present a hardware and software architecture for high-rate links using an active phased array-based terminal in a 1U (10cm cube) form factor. Over-the-air tests in an antenna range characterize two key features of the architecture: high-order (32APSK and above) modulations and dual carriers. We calculate an optimal modulation-dependent input power backoff from array saturation and perform orbital simulations of the link at this operating point. We conclude that reliable links with rates in excess of 1Gbps are possible with current-generation hardware.

Adam Gannon↗

DOE OSTI2012

Market-Based Indian Grid Integration Study Options: Preprint

The Indian state of Gujarat is forecasting solar and wind generation expansion from 16% to 32% of installed generation capacity by 2015. Some states in India are already experiencing heavy wind power curtailment. Understanding how to integrate variable generation (VG) into the grid is of great interest to local transmission companies and India's Ministry of New and Renewable Energy. This paperdescribes the nature of a market-based integration study and how this approach, while new to Indian grid operation and planning, is necessary to understand how to operate and expand the grid to best accommodate the expansion of VG. Second, it discusses options in defining a study's scope, such as data granularity, generation modeling, and geographic scope. The paper also explores how Gujarat'smethod of grid operation and current system reliability will affect how an integration study can be performed.

14 SOLAR ENERGY↗

DOE OSTI2012

Light ion source for proton/deuteron production at CEA Saclay for the Spiral2 project

The production of rare radioactive ion beam (RIB) far from the valley of stability is one of the final purposes of the Spiral2 facility in Caen. The RIB will be produced by impinging a deuteron beam onto a carbon sample to produce a high neutron flux, which will interact with a uranium target. The primary deuteron beam is produced by an ion source based on ECR plasma generation. The deuteron source and the low energy beam transport (LEBT) has been assembled and tested at CEA Saclay. Diagnostics from other laboratories were implemented on the LEBT in order to characterize the deuteron beam produced and compare it to the initial simulations. The ion source has been based on a SILHI-type source, which has demonstrated good performances in pulsed and continuous mode, and also a very good reliability on long term operation. The 5 mA of deuteron beam required at the RFQ entrance is extracted from the plasma source at the energy of 40 kV. After a brief description of the experimental set-up, this article reports on the first beam characterization experiments.

43 PARTICLE ACCELERATORS↗

NASA NTRS2003

Structural Mechanics and Dynamics Branch

The 2002 annual report of the Structural Mechanics and Dynamics Branch reflects the majority of the work performed by the branch staff during the 2002 calendar year. Its purpose is to give a brief review of the branch s technical accomplishments. The Structural Mechanics and Dynamics Branch develops innovative computational tools, benchmark experimental data, and solutions to long-term barrier problems in the areas of propulsion aeroelasticity, active and passive damping, engine vibration control, rotor dynamics, magnetic suspension, structural mechanics, probabilistics, smart structures, engine system dynamics, and engine containment. Furthermore, the branch is developing a compact, nonpolluting, bearingless electric machine with electric power supplied by fuel cells for future "more electric" aircraft. An ultra-high-power-density machine that can generate projected power densities of 50 hp/lb or more, in comparison to conventional electric machines, which generate usually 0.2 hp/lb, is under development for application to electric drives for propulsive fans or propellers. In the future, propulsion and power systems will need to be lighter, to operate at higher temperatures, and to be more reliable in order to achieve higher performance and economic viability. The Structural Mechanics and Dynamics Branch is working to achieve these complex, challenging goals.

Stefko, George↗

DOE OSTI2020

Impact of undoped substrates on high performance silicon solar cells

Today's highest-efficiency silicon solar cells typically operate near the threshold between low-level and high-level injection. It is not well understood if pushing further into a regime in which the cell operating point is solidly in high-level injection at all times of the day has further benefits for the solar cell performance. From a reliability perspective, cells fabricated on lower doped silicon have a larger breakdown voltage. This advantage can affect the design of modules allowing higher voltages and a relaxation of the number of bypass diodes needed. In this project, we present a comprehensive assessment, both experimental and using simulation, of how bulk resistivity, light intensity, and operation temperature impact the performance of the silicon solar cell. This work incorporates a comprehensive device physics analysis assisted by numerical simulation. The source code is now available under General Public License (GPL3), and to further leverage the findings of this project and outreach people outside of the scientific community, we are working with www.pveducation.org (which receives >1 million visitors a year) to create interactive content using our simulation results. The simulation results indicate that high bulk resistivity wafers (>>10 Ωcm) require bulk Shockley-Read-Hall (SRH) lifetimes in the millisecond range to outperform wafers with standard bulk resistivities (<10 Ωcm). Additionally, above bulk resistivities of 10 Ωcm (the exact value depends on the bulk characteristics of the wafer), the cell efficiency is weakly dependent on the bulk resistivity. As a result, ingot manufactures may have an opportunity to further reduce wafer cost by growing higher resistivity ingots that are more tolerant to resistivity variations. This project is particularly relevant today, as solar cell architectures with improved surface passivation and milliseconds lifetimes wafers are commercially available, leveraging potential benefits of using higher bulk resistivities. Outside of interdigitated back contact (IBC) cell, reported studies on high resistivity silicon (>100 Ωcm) are very limited. To the best of our knowledge, this project provides for the first-time experimental insight on solar cells fabricated on wafers with bulk resistivities up to several thousand Ωcm, delivering a comprehensive vision of their performance under real-world temperature and light intensity operation conditions. We manufactured and characterized solar cells with bulk resistivities in the range of 1 Ωcm to >15k Ωcm. Under standard testing conditions (STC), we measured solar cells efficiencies over 20% over the entire range of bulk resistivities, using our baseline cell processing. To evaluate the cell performance in real-world operation conditions, the solar cells were measured at different temperatures (25-80°C) and at different light intensities (0.1-1 suns). The measurements show that the bulk resistivity does not impact the solar cell response to temperature and light intensity. Similar thermal coefficients (TC) were measured for standard and high bulk resistivities, and they are comparable with the TC values reported in the literature for standard bulk resistivities <10 Ωcm. After light soaking, the solar cell didn’t show signs of light-induced degradation (LID). This result was expected since n-type float zone (FZ) wafers were used in this work, i.e. low traces of boron and low concentration of oxygen (oxygen is typically found in the seed end of Czochralski (CZ) ingots). We measured for high bulk resistivities (>10 Ωcm) extremely high breakdown voltages (>1000V). In conclusion, the insight provided by this project can positively impact the levelized cost of energy (LCOE) of the photovoltaic systems through its effect on cell and ingot manufacturing yield, silicon cell power output, and module reliability.

14 SOLAR ENERGY↗

NASA NTRS1990

Worldwide differential GPS for Space Shuttle landing operations

Worldwide differential Global Positioning System (WWDGPS) is viewed as an effective method of offering continuous high-quality navigation worldwide. The concept utilizes a network with as few as 33 ground stations to observe most of the error sources of GPS and provide error corrections to users on a worldwide basis. The WWDGPS real-time GPS tracking concept promises a threefold or fourfold improvement in accuracy for authorized dual-frequency users, and in addition maintains an accurate and current ionosphere model for single-frequency users. A real-time global tracking network also has the potential to reverse declarations of poor health on marginal satellites, increasing the number of satellites in the constellation and lessening the probability of GPS navigation outage. For Space Shuttle operations, the use of WWDGPS-aided P-code equipment promises performance equal to or better than other current landing guidance systems in terms of accuracy and reliability. This performance comes at significantly less cost to NASA, which will participate as a customer in a system designed as a commercial operation serving the global civil navigation community.

Loomis, Peter V. W.↗

DOE OSTI2011

Reliability of EUCLIDIAN: An autonomous robotic system for image-guided prostate brachytherapy

Purpose: Recently, several robotic systems have been developed to perform accurate and consistent image-guided brachytherapy. Before introducing a new device into clinical operations, it is important to assess the reliability and mean time before failure (MTBF) of the system. In this article, the authors present the preclinical evaluation and analysis of the reliability and MTBF of an autonomous robotic system, which is developed for prostate seed implantation. Methods: The authors have considered three steps that are important in reliability growth analysis. These steps are: Identification and isolation of failures, classification of failures, and trend analysis. For any one-of-a-kind product, the reliability enhancement is accomplished through test-fix-test. The authors have used failure mode and effect analysis for collection and analysis of reliability data by identifying and categorizing the failure modes. Failures were classified according to severity. Failures that occurred during the operation of this robotic system were considered as nonhomogenous Poisson process. The failure occurrence trend was analyzed using Laplace test. For analyzing and predicting reliability growth, commonly used and widely accepted models, Duane's model and the Army Material Systems Analysis Activity, i.e., Crow's model, were applied. The MTBF was used as an important measure for assessing the system's reliability. Results: During preclinical testing, 3196 seeds (in 53 test cases) were deposited autonomously by the robot and 14 critical failures were encountered. The majority of the failures occurred during the first few cases. The distribution of failures followed Duane's postulation as well as Crow's postulation of reliability growth. The Laplace test index was -3.82 (<0), indicating a significant trend in failure data, and the failure intervals lengthened gradually. The continuous increase in the failure occurrence interval suggested a trend toward improved reliability. The MTBF was 592 seeds, which implied that several prostate seed implantation cases would be possible without encountering any critical failure. The shape parameter for the MTBF was 0.3859 (<1), suggesting a positive reliability growth of this robotic system. At 95% confidence, the reliability for deposition of 65 seeds was more than 90%. Conclusions: Analyses of failure mode strongly indicated a gradual improvement of reliability of this autonomous robotic system. High MTBF implied that several prostate seed implant cases would be possible without encountering any critical failure.

62 RADIOLOGY AND NUCLEAR MEDICINE↗

NASA NTRS2019

Advanced Optical Techniques for Sensing and Imaging in Harsh Environments

Advances in aircraft propulsion technologies require new techniques for performance evaluation of aircraft components and subsystems as well as reliable in-flight control and health management. Those components and subsystems operate in harsh environments and for a proper operation these environments should be constantly monitored to obtain the designed performance of the engine. Optical techniques due to their immunity to electromagnetic radiation, chemical stability, and other unique features pose to meet the ever increasing requirements of the industry.The presentation will address applications of advanced optical techniques for both for sensing and imaging. In the process we will address fiber optics Bragg temperature sensors that were developed at NASA Glenn Research Center and tested at NASA Armstrong Flight Research Center as well as other advanced techniques for sensing and imaging in harsh environments. The presentation will also include discussion on various applications of presented techniques and proposed directions for future development.

Imaging↗

NASA NTRS2010

Space Shuttle Main Engine (SSME) Reliability and Analysis Evolution

The Space Shuttle Main Engine (SSME) is a large thrust class, reusable, staged combustion cycle rocket engine employing liquid hydrogen and liquid oxygen propellants. A cluster of three SSMEs is used on every space shuttle mission to propel the space shuttle orbiter vehicle into low earth orbit. Development of the SSME began in the early 70 s and the first flight of the space shuttle occurred in 1981. Today, the SSME has accrued over one million seconds of ground test and flight operational time, launching 129 space shuttle missions. Given that the SSME is used to launch a manned vehicle, its reliability must be commensurate for the task. At the same time, the SSME is a high performance, high power density engine which traditionally does not lend itself towards high reliability. Furthermore, throughout its history, the SSME operational envelope has been explored and expanded leading to several major test failures. Hence, assessing the reliability of the SSME throughout its history has been a challenging undertaking. This paper provides a review and discussion of SSME reliability assessment techniques and results over its history. Basic reliability drivers such as engine design, test program, major failures, redesigns and upgrades will also be discussed.

Stephens, Walter E.↗

DOE OSTI2018

Chapter 8: Managing Safety Risk by Cell Manufacturers from the book Electrochemical Power Sources: Fundamentals, Systems, and Applications: Li-Battery Safety

Durability, reliability and safety are closely related in battery operation, requiring proper design to assure performance. To attain these properties are challenging and their issues of concerns need to be addressed in a coherent, holistic approach. For cell manufacturers, battery safety is about proper cell design. To implement effective safety measures, key is to engage failure mode and effect analysis in a sufficiently quantitative manner to understand cause-and-consequence relationship through advanced diagnostic and prognostic analyses to derive adequate cell design metrics to facilitate safe cell design. A key aspect of safety, not often discussed in the literature, is how to address it in the full context of electrochemical, thermal and mechanical balance. It is also important to realize that only when we can characterize the degree of tolerance and resilience to abuse, we are mature to know how to design a safe battery for operation.

25 ENERGY STORAGE↗

DOE OSTI2018

Managing Safety Risk by Cell Manufacturers

25 ENERGY STORAGE↗

DOE OSTI2014

Raytheon's next generation compact inline cryocooler architecture

Since the 1970s, Raytheon has developed, built, tested and integrated high performance cryocoolers. Our versatile designs for single and multi-stage cryocoolers provide reliable operation for temperatures from 10 to 200 Kelvin with power levels ranging from 50 W to nearly 600 W. These advanced cryocoolers incorporate clearance seals, flexure suspensions, hermetic housings and dynamic balancing to provide long service life and reliable operation in all relevant environments. Today, sensors face a multitude of cryocooler integration challenges such as exported disturbance, efficiency, scalability, maturity, and cost. As a result, cryocooler selection is application dependent, oftentimes requiring extensive trade studies to determine the most suitable architecture. To optimally meet the needs of next generation passive IR sensors, the Compact Inline Raytheon Stirling 1-Stage (CI-RS1), Compact Inline Raytheon Single Stage Pulse Tube (CI-RP1) and Compact Inline Raytheon Hybrid Stirling/Pulse Tube 2-Stage (CI-RSP2) cryocoolers are being developed to satisfy this suite of requirements. This lightweight, compact, efficient, low vibration cryocooler combines proven 1-stage (RS1 or RP1) and 2-stage (RSP2) cold-head architectures with an inventive set of warm-end mechanisms into a single cooler module, allowing the moving mechanisms for the compressor and the Stirling displacer to be consolidated onto a common axis and in a common working volume. The CI cryocooler is a significant departure from the current Stirling cryocoolers in which the compressor mechanisms are remote from the Stirling displacer mechanism. Placing all of the mechanisms in a single volume and on a single axis provides benefits in terms of package size (30% reduction), mass (30% reduction), thermodynamic efficiency (>20% improvement) and exported vibration performance (≤25 mN peak in all three orthogonal axes at frequencies from 1 to 500 Hz). The main benefit of axial symmetry is that proven balancing techniques and hardware can be utilized to null all motion along the common axis. Low vibration translates to better sensor performance resulting in simpler, more direct mechanical mounting configurations, eliminating the need for convoluted, expensive, massive, long lead damping hardware.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Flat TBPS Integration Testing for the CMS Outer Tracker Upgrade

The upcoming High-Luminosity (HL) LHC will significantly increase luminosity, introducing more demanding operating conditions for the CMS detector. To meet these challenges, CMS is undergoing major upgrades, including a complete replacement of its tracking detector. This poster presents recent integration testing efforts conducted at Fermilab on the Flat Tracker Barrel with pixel-strip (PS) modules integration test stand, a subcomponent of the outer tracker located in the central barrel region. In this region, PS modules are mounted on structures that provide mechanical support and cooling, called planks. The testing focuses on validating the integrated system’s thermal and electrical performance. Results from these tests will be discussed, highlighting their importance for ensuring reliable tracker operation in the HL-LHC era.

Salazar Segovia, Itzelli [UC, Davis]↗

DOE OSTI2019

Use of Thermistor Temperature Sensors for Cyber-Physical System Security

The last few decades have seen a large proliferation in the prevalence of cyber-physical systems. This has been especially highlighted by the explosive growth in the number of Internet of Things (IoT) devices. Unfortunately, the increasing prevalence of these devices has begun to draw the attention of malicious entities which exploit them for their own gain. What makes these devices especially attractive is the various resource constraints present in these devices that make it difficult to add standard security features. Therefore, one intriguing research direction is creating security solutions out of already present components such as sensors. Physically Unclonable Functions (PUFs) are one potential solution that use intrinsic variations of the device manufacturing process for provisioning security. In this work, we propose a novel weak PUF design using thermistor temperature sensors. Our design uses the differences in resistance variation between thermistors in response to temperature change. To generate a PUF that is reliable across a range of temperatures, we use a response-generation algorithm that helps mitigate the effects of temperature variation on the thermistors. We tested the performance of our proposed design across a range of environmental operating conditions. From this we were able to evaluate the reliability of the proposed PUF with respect to variations in temperature and humidity. We also evaluated the PUF’s uniqueness using Monte Carlo simulations.

Internet of Things (IoT)↗

DOE OSTI2021

Cloud Droplet Measurement System for the ARM Tethered Balloon System (TBS) Field Campaign Report

The Mesa Photonics' cloud droplet measurement system (CDMS) performs in situ measurement of droplet size distribution and droplet number density in clouds. These characteristics are important cloud microphysical properties that are critical input parameters for atmospheric models and are also useful for proper calibration and validation of performance of other atmospheric measurement instrumentation. This small campaign was the first project (out of two) that involved integration of the CDMS into the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility’s tethered balloon system (TBS) and its initial testing at the ARM Southern Great Plains (SGP) atmospheric observatory. The follow-up campaign (AFC07016) involved testing of the CDMS under relevant conditions at the third ARM Mobile Facility (AMF3) at Oliktok Point, Alaska and making in situ measurements in clouds. The goal of this small field campaign was to deploy the CDMS on the ARM TBS, demonstrate its integrity and compatibility with the TBS, and test the wireless telecommunication system in preparation for subsequent in-cloud measurements at ARM’s North Slope of Alaska (NSA) observatory at Utqiagvik (formerly Barrow). The specific technical objectives included: (1) Integration of the Mesa Photonics' CDMS into the ARM TBS, (2) testing of the wireless telecommunication system of the CDMS, (3) evaluating the data acquisition software and image processing algorithms especially under high-background-illumination conditions, and (4) testing the ruggedness of the instrument's optical alignment and other performance characteristics. All objectives have been successfully met. The mounting hardware was designed and built mostly at Sandia National Laboratories (SNL), which allowed reliable mounting of the CDMS on the TBS and co-locating the CDMS with other instruments. The field tests were performed by the principal investigator (PI) in collaboration with the TBS operational crew led by D. Dexheimer. The field testing demonstrated good compatibility of the CDMS with the TBS. During the TBS flights, the crew did not experience any operational issues with the CDMS. The instrument demonstrated reliable operational characteristics, including sufficient battery life and good thermal management. The wireless telecommunication system has been successfully tested at TBS flight altitudes of up to 1000 m. During all flights, the CDMS raw data were wirelessly transmitted to the ground station and processed in real time. The ruggedness of the instrument's optical alignment was evaluated by performing calibration of the CDMS (using Mesa Photonics' fixed-size monodisperse droplet generator) before and after the campaign. The calibration was stable within the instrument's measurement precision. In summary, the campaign demonstrated good compatibility of the Mesa Photonics' CDMS with the ARM TBS. The flight tests confirmed the mechanical integrity of the CDMS and stability of its optical layout, as well as reliability of the wireless telecommunication system. Successful completion of this campaign provided a solid basis for the next campaign (AFC07016, November 2020), that involved testing of the CDMS during in-cloud TBS flights at AMF3 at Oliktok Point.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2016

Performance tests of helium circulator under abnormal cooling conditions - 18523

Helium circulator is one of the key equipment of High-temperature Gas-cooled Reactor Pebble-bed Module (HTR-PM) and the unique rotating equipment of primary loop. It transports heat generated by fission reactions from reactor core to steam generator by forcing helium circulating in primary loop. As the study on the characteristics of helium circulator in HTGR was limited and the advanced designs integrated with many new technologies, a prototype of helium circulator was manufactured. It was supported by Active Magnetic Bearings (AMBs), and was assembled in a pressure vessel. The prototype was tested in Engineering Test Facility - Helium Circulator (ETF-HC), which is a full scale, rated flow rate and power, engineering test loop. Although performance tests under normal operation condition were successfully fulfilled, the complete features and performance still need further verification, especially for abnormal cooling conditions. Thus performance tests under abnormal cooling operation conditions were carried out. Tests such as temporary coolant loss of motor and AMBs cooler and abnormal high-temperature cooling water condition were fulfilled. All performance tests results showed that helium circulator met the entire requirement of HTR-PM plant under abnormal cooling conditions and validated its safety and reliability. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗