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NASA NTRS2003

Status of the Node 3 Regenerative Environmental Cpntrol& Life Support System Water Recovery & Oxygen Generation Systems

NASA s Marshall Space Flight Center is providing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for flight on the lnternational Space Station s (ISS) Node 3 element. The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems lnternational (HSSSI), while the UPA and PSM are being designed and manufactured in-house by MSFC. The assemblies are currently in the manufacturing and test phase and are to be completed and integrated into flight racks this year. This paper gives an overview of the technologies and system designs, technical challenges encountered and solved, and the current status.

Carrasquillo, Robyn L.↗

NASA NTRS2004

Status of the Node 3 Regenerative ECLSS Water Recovery and Oxygen Generation Systems

NASA's Marshall Space Flight Center is providing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for flight on the International Space Station's (ISS) Node 3 element. The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems International (HSSSI), while the UPA and PSM are being designed and manufactured in-house by MSFC. The assemblies are completing the manufacturing phase and are in various stages of ORU and system level testing, to be followed by integration into the flight racks. This paper gives a current status, along with technical challenges encountered and lessons learned.

Carrasquillo, Robyn L.↗

NASA NTRS2011

Apollo 13 Case Study

The dramatic journey of the crippled Apollo 13 vehicle has been heavily documented and popularized. Many people know there was an explosion in the service module which caused the vehicle to lose its oxygen supply. Less well known is the set of circumstances which led to the explosion. This paper examines the manufacturing, processing and testing history of oxygen tank #2, detailing the additive effects which caused the oxygen to ignite and to overpressure the tank.

Anderson, Brenda Lindley↗

NASA NTRS2011

A Case Study of the Failure on Apollo 13: Based on TMX-65270, Report of Apollo 13 Review Board

Anderson, Brenda Lindley↗

NASA NTRS1979

Preserving Perishables (Dormavac)

A new commercial product that can preserve perishable commodities for weeks without freezing, so that they can be shipped fresh without the cost of air freight, has been developed by Grumman Corporation, Bethpage, Long Island, New York. The development benefited from the company's experience in developing the environmental control system for the Lunar Module, which delivered Apollo astronauts to the surface of the moon. Called Dormavac, the system provides a commodity-preserving environment within an aluminum container that can be transported by truck, rail or ship. Dormavac creates a cold-but above freezing-environment with high relative humidity and very low air pressure. The saturated air minimizes commodity weight loss and the air is automatically changed several times an hour to flush away odors and harmful gases released by the commodities. According to company literature, Dormavac significantly extends the transportation life of perishables. For example, pork has a normal cold storage life of about seven days, beef two weeks and tomatoes three weeks; with Dormavac, pork remains fresh for three weeks, beef more than six weeks and tomatoes seven weeks or more. Dormavac is manufactured and marketed by Grumman Allied Industries, Woodbury, New York. In developing the system, Grumman Allied drew upon the technological resources of another company subsidiary, Grumman Aerospace. Engineers who had earlier worked on Lunar Module environmental control brought their know-how and experience to the Dormavac development.

Source record↗

DOE OSTI2016

Modulation of PEDOT:PSS pH for efficient inverted perovskite solar cells with reduced potential loss and enhanced stability

Inverted p-i-n perovskite solar cells (PVSCs) using PEDOT:PSS as the hole-transporting layer (HTL) is one of the most widely adopted device structures thus far due to its facile processability and good compatibility for high throughput manufacturing processes. However, most of the PEDOT:PSS-based CH 3 NH 3 PbI 3 PVSCs reported to date suffered an inferior open-circuit voltage (V OC ) (0.88-0.95 V) compared to that (1.05-1.12 V) obtained for common CH 3 NH 3 PbI 3 PVSCs, revealing a severe potential loss issue. Herein, we describe a simple method to alleviate this problem by tuning the pH value of PEDOT:PSS with a mild base, imidazole. Accompanied by the pH modulation, the blended imidazole concurrently tailors the surface texture and electronic properties of PEDOT:PSS to promote the quality and crystallization of the perovskite film deposited on top of it and enable better energy-level alignment at this corresponding interface. Consequently, the PVSC using this modified PEDOT:PSS HTL yields an enhanced power conversion efficiency (PCE) of 15.7% with an enlarged V OC of 1.06 V and improved long-term stability. Lastly, these outperform the pristine device showing a PCE of 12.7% with a much smaller V OC of 0.88 V and unsatisfactory environmental stability.

14 SOLAR ENERGY↗

DOE OSTI2023

High-density SSiC 3D-printed Lattices for Compact HTHP Aero-engine Recuperators

The proposed project utilizes advanced ceramic-based 3D-printing technology to develop light, low-cost, ultra-compact, high-temperature high-pressure (HTHP) heat exchangers (HX) for the harsh oxidizing environment of aircraft gas-turbine engines. Typical 3D printing technologies (powder bed or lithographic techniques) cannot produce large high-density, monolithic ceramic material with intricate internal features and channels required for high-temperature, high-pressure recuperators. Furthermore, typical 3D printing technologies are not yet economical for large high-density components. A high-density material is required for hermeticity, high-temperature strength, and oxidation, corrosion, and wear resistance. The team has invented an extrusion-based additive manufacturing technology (referred to as robocasting) and developed processing techniques to tailor composition and rheological mix properties for rapid 3D printing of high-density alumina and SiC parts. The goal of the proposed project is to use robocasting technology to demonstrate commercializable high-density 3D-printed ceramic HX modules with high durability and quality, thereby reducing the risk of thermo-mechanical failure under extreme environments. In addition, the proposed project improves the quality of the ceramic 3D-printing process over a large printed area and HTHP operating conditions. Ceramic 3D printing technology also provides a means to create advanced topologies that are unobtainable with conventional manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

United States Nuclear Manufacturing Infrastructure Assessment

This report provides a review and assessment of the existing U.S. infrastructure capabilities to manufacture on a commercial scale, the major components and unique materials required by the various U.S. designs for advanced nuclear reactors and small modular reactors (SMRs). The approach was to compare the needs of SMRs and advanced reactors against the capability of U.S. manufacturers to ascertain gaps that could inhibit U.S. industrial support for deployment of SMRs or advanced reactors. This report focused on the reactor plant designs being developed by NuScale Power (the NuScale Power Module), TerraPower (both the Traveling Wave Reactor and the Molten Chloride Fast Reactor to a limited extent), and X-energy (the Xe-100). To gather the information, MPR visited each of these companies and selected candidate suppliers to tour their facilities and conduct in-person interviews. Information was also obtained by telephone interviews, internet research, and literature review of technical reports. The overarching conclusion from this study is that the U.S. has existing capability or can readily develop capability to support and sustain most, but not all, aspects of commercial deployment of advanced reactors and SMRs. The greatest concerns for capability gaps in the U.S. infrastructure for supply of components for SMRs and advanced reactors are associated with reactor pressure vessels, steam generators, and fuel fabrication. Foreign vendors can supply reactor pressure vessels and steam generators. Issues with fuel fabrication are associated with uranium enrichment and development of fabrication methods for the innovative fuel concepts planned for advanced reactors. The technical capabilities of U.S. manufacturers appear satisfactory with the possible exceptions noted above. However, the capacity of the existing U.S. manufacturing infrastructure may be insufficient for a high rate of construction. Manufacturers contacted as part of this study indicated a willingness to expand capacity if sufficient orders are in place. The review of U.S. infrastructure included a detailed review of capabilities in many different processes including forging, tube drawing, machining, fabrication, and testing. In addition, MPR researched the advanced manufacturing processes for additive manufacturing (i.e., 3D printing) and powder metallurgy - hot isostatic pressing. Reactor plant designers and candidate suppliers are planning to rely on traditional processes for the initial plants. If advanced manufacturing processes are developed and accepted by the nuclear industry, these processes may be used in the future. In the immediate term, ongoing research (much of which is funded by DOE) is necessary to develop and refine advanced manufacturing methods. This report includes several recommendations for DOE that will advance deployment of SMRs and advanced reactors from a manufacturing perspective and other areas identified during the course of this project.

36 MATERIALS SCIENCE↗

DOE OSTI2014

SU-E-CAMPUS-T-05: Validation of High-Resolution 3D Patient QA for Proton Pencil Beam Scanning and IMPT by Polymer Gel Dosimetry

Purpose: Validation of high-resolution 3D patient QA for proton pencil beam scanning and IMPT by polymer gel dosimetry. Methods: Four BANG3Pro polymer gel dosimeters (manufactured by MGS Research Inc, Madison, CT) were used for patient QA at the Robert's Proton Therapy Center (RPTC, Philadelphia, PA). All dosimeters were sealed in identical thin-wall Pyrex glass spheres. Each dosimeter contained a set of markers for 3D registration purposes. The dosimeters were mounted in a consistent and reproducible manner using a custom build holder. Two proton pencil beam scanning plans were designed using Varian Eclipse™ treatment planning system: 1) A two-field intensity modulated proton therapy (IMPT) plan and 2) one single field uniform dose (SFUD) plan. The IMPT fields were evaluated as a composite plan and individual fields, the SFUD plan was delivered as a single field plan.Laser CT scanning was performed using the manufacturer's OCTOPUS-IQ axial transmission laser CT scanner using a 1 mm slice thickness. 3D registration, analysis, and OD/cm to absorbed dose calibrations were perfomed using DICOM RT-Dose and CT files, and software developed by the manufacturer. 3D delta index, a metric equivalent to the gamma tool, was used for dose comparison. Results: Very good agreement with single IMPT fields and with SFUD was obtained. Composite IMPT fields had a less satisfactory agreement. The single fields had 3D delta index passing rates (3% dose difference, 3 mm DTA) of 98.98% and 94.91%. The composite 3D delta index passing rate was 80.80%. The SFUD passing rate was 93.77%. Required shifts of the dose distributions were less than 4 mm. Conclusion: A formulation of the BANG3Pro polymer gel dosimeter, suitable for 3D QA of proton patient plans is established and validated. Likewise, the mailed QA analysis service provided by the manufacturer is a practical option when required resources are unavailable. We fully disclose that the subject of this research regards a production of MGS Research, Inc.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

WE-D-17A-04: Magnetically Focused Proton Irradiation of Small Volume Targets

Purpose: To explore the advantages of magnetic focusing for small volume proton irradiations and the potential clinical benefits for radiosurgery targets. The primary goal is to create narrow elongated proton beams of elliptical cross section with superior dose delivery characteristics compared to current delivery modalities (eg, collimated beams). In addition, more general beam shapes are also under investigation. Methods: Two prototype magnets consisting of 24 segments of samarium-cobalt (Sm2Co17) permanent magnetic material adhered into hollow cylinders were manufactured for testing. A single focusing magnet was placed on a positioning track on our Gantry 1 treatment table and 15 mm diameter proton beams with energies and modulation relevant to clinical radiosurgery applications (127 to 186 MeV, and 0 to 30 mm modulation) were delivered to a terminal water tank. Beam dose distributions were measured using a PTW diode detector and Gafchromic EBT2 film. Longitudinal and transverse dose profiles were analyzed and compared to data from Monte Carlo simulations analogous to the experimental setup. Results: The narrow elongated focused beam spots showed high elliptical symmetry indicating high magnet quality. In addition, when compared to unfocused beams, peak-to-entrance depth dose ratios were 11 to 14% larger (depending on presence or extent of modulation), and minor axis penumbras were 11 to 20% smaller (again depending on modulation) for focused beams. These results suggest that the use of rare earth magnet assemblies is practical and could improve dose-sparing of normal tissue and organs at risk while delivering enhanced dose to small proton radiosurgery targets. Conclusion: Quadrapole rare earth magnetic assemblies are a promising and inexpensive method to counteract particle out scatter that tends to degrade the peak to entrance performance of small field proton beams. Knowledge gained from current experiments will inform the design of a prototype treatment nozzle that incorporates similar focusing magnets. This project was sponsored in part by funding from the Department of Defense (DOD# W81XWH-BAA-10-1)

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

Ultrasonic Characterization of Ethylene Vinyl Acetate (EVA) Crosslinking for Quality Assurance and Lamination Process Control (US-Xlink)

Module makers strive to cut lamination processing times to enhance production throughput and reduce costs. If overdone, this might lead to poor EVA quality due to incomplete EVA crosslinking and a large concentration of potentially harmful reactants. Those deficiencies are frequently missed during production quality testing as initially their impact on power output is small. Additionally, the crosslinking agent is frequently inhomogeneously dispersed across the EVA foils such that local destructive characterization procedures such as differential scanning calorimetry (DSC), Soxhlet extraction, swelling methods, or mechanical tests provide only a limited amount of information. However, these defects and inhomogeneities can become considerably more important during field operation, dramatically reducing long-term power yield, and increasing LCOE. Examples of typical long-term module degradation modes relating to poor lamination process conditions include cell breakage, corrosion of the metallization, delamination, and local quality deficiencies. To provide reliable material characterization in a manufacturing setting, we devised a non-destructive technology that uses ultrasound to evaluate the quality of interface adhesion and the degree of crosslinking. As a calibration reference, DSC measurements were employed. Although the potential of ultrasonic approaches for this purpose has already been noted, those previous methods were generally limited to local qualitative measurements. Furthermore, variations in EVA thickness and temperature had a substantial impact on them. The solution we propose solves these limitations by employing ultrasonic absorption rather than relying solely on sound velocity data.

14 SOLAR ENERGY↗

NASA NTRS1989

Modularity in robotic systems

Most robotic systems today are designed one at a time, at a high cost of time and money. This wasteful approach has been necessary because the industry has not established a foundation for the continued evolution of intelligent machines. The next generation of robots will have to be generic, versatile machines capable of absorbing new technology rapidly and economically. This approach is demonstrated in the success of the personal computer, which can be upgraded or expanded with new software and hardware at virtually every level. Modularity is perceived as a major opportunity to reduce the 6 to 7 year design cycle time now required for new robotic manipulators, greatly increasing the breadth and speed of diffusion of robotic systems in manufacturing. Modularity and its crucial role in the next generation of intelligent machines are the focus of interest. The main advantages that modularity provides are examined; types of modules needed to create a generic robot are discussed. Structural modules designed by the robotics group at the University of Texas at Austin are examined to demonstrate the advantages of modular design.

Tesar, Delbert↗

NASA NTRS2014

Investigation into the Use of the Concept Laser QM System as an In-Situ Research and Evaluation Tool

The NASA Marshall Space Flight Center (MSFC) is using a Concept Laser Fusing (Cusing) M2 powder bed additive manufacturing system for the build of space flight prototypes and hardware. NASA MSFC is collecting and analyzing data from the M2 QM Meltpool and QM Coating systems for builds. This data is intended to aide in understanding of the powder-bed additive manufacturing process, and in the development of a thermal model for the process. The QM systems are marketed by Concept Laser GmbH as in-situ quality management modules. The QM Meltpool system uses both a high-speed near-IR camera and a photodiode to monitor the melt pool generated by the laser. The software determines from the camera images the size of the melt pool. The camera also measures the integrated intensity of the IR radiation, and the photodiode gives an intensity value based on the brightness of the melt pool. The QM coating system uses a high resolution optical camera to image the surface after each layer has been formed. The objective of this investigation was to determine the adequacy of the QM Meltpool system as a research instrument for in-situ measurement of melt pool size and temperature and its applicability to NASA's objectives in (1) Developing a process thermal model and (2) Quantifying feedback measurements with the intent of meeting quality requirements or specifications. Note that Concept Laser markets the system only as capable of giving an indication of changes between builds, not as an in-situ research and evaluation tool. A secondary objective of the investigation is to determine the adequacy of the QM Coating system as an in-situ layer-wise geometry and layer quality evaluation tool.

Bagg, Stacey↗

DOE OSTI2019

The impact of thermoelectric leg geometries on thermal resistance and power output

Thermoelectric devices enable direct, solid-state conversion of heat to electricity and vice versa. Rather than designing the shape of thermoelectric units or legs to maximize this energy conversion, the cuboid shape of these legs has instead remained unchanged in large part because of limitations in the standard manufacturing process. However, the advent of additive manufacturing (a technique in which freeform geometries are built up layer-by-layer) offers the potential to create unique thermoelectric leg geometries designed to optimize device performance. This work explores this new realm of novel leg geometry by simulating the thermal and electrical performance of various leg geometries such as prismatic, hollow, and layered structures. The simulations are performed for two materials, a standard bismuth telluride material found in current commercial modules and a higher manganese silicide material proposed for low cost energy conversion in high-temperature applications. The results include the temperature gradient and electrical potential developed across individual thermoelectric legs as well as thermoelectric modules with 16 legs. Even simple hollow and layered leg geometries result in larger temperature gradients and higher output powers than the traditional cuboid structure. As a result, the clear dependence of thermal resistance and power output on leg geometry provides compelling motivation to explore additive manufacturing of thermoelectric devices.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

Precursor Engineering of All-Inorganic Perovskite Absorber and Rapid Photonic Annealing for Large-Area Highly Stable Perovskite Solar Modules

Currently the all-inorganic perovskites were prepared by toxic dimethylformamide (DMF) as a main solvent, and small-area PSCs were prepared by a simple spin-coating method followed by lengthy thermal annealing. All these issues limited the commercialization of these PSCs. Therefore, it is necessary to develop an eco-friendly all-inorganic perovskite ink that can be coated over large areas at low temperatures followed by rapid annealing for the scale-up manufacturing with high compatibility to the industrial scale sheet-to-sheet or roll-to-roll processes.

14 SOLAR ENERGY↗

DOE OSTI2021

Morphological landscapes from high content imaging reveal cytokine priming strategies that enhance mesenchymal stromal cell immunosuppression

Abstract Successful clinical translation of mesenchymal stromal cell (MSC) products has not been achieved in the United States and may be in large part due to MSC functional heterogeneity. Efforts have been made to identify “priming” conditions that produce MSCs with consistent immunomodulatory function; however, challenges remain with predicting and understanding how priming impacts MSC behavior. The purpose of this study was to develop a high throughput, image‐based approach to assess MSC morphology in response to combinatorial priming treatments and establish morphological profiling as an effective approach to screen the effect of manufacturing changes (i.e., priming) on MSC immunomodulation. We characterized the morphological response of multiple MSC lines/passages to an array of Interferon‐gamma (IFN‐γ) and tumor necrosis factor‐⍺ (TNF‐⍺) priming conditions, as well as the effects of priming on MSC modulation of activated T cells and MSC secretome. Although considerable functional heterogeneity, in terms of T‐cell suppression, was observed between different MSC lines and at different passages, this heterogeneity was significantly reduced with combined IFN‐γ/TNF‐⍺ priming. The magnitude of this change correlated strongly with multiple morphological features and was also reflected by MSC secretion of immunomodulatory factors, for example, PGE2, ICAM‐1, and CXCL16. Overall, this study further demonstrates the ability of priming to enhance MSC function, as well as the ability of morphology to better understand MSC heterogeneity and predict changes in function due to manufacturing.

Andrews, Seth H.↗

DOE OSTI2015

SU-D-304-02: Magnetically Focused Proton Irradiation of Small Field Targets

Purpose: To investigate the use of magnetic focusing for small field proton irradiations. It is hypothesized that magnetic focusing will provide significant dose distribution benefits over standard collimated beams for fields less than 10 mm diameter. Methods: Magnets consisting of 24 segments of radiation hard samarium-cobalt adhered into hollow cylinders were designed and manufactured. Two focusing magnets were placed on a positioning track on our Gantry 1 treatment table. Proton beams with energies of 127 and 157 MeV, 15 and 30 mm modulation, and 8 mm initial diameters were delivered to a water tank using single-stage scattering. Depth dose distributions were measured using a PTW PR60020 diode detector and transverse profiles were measured with Gafchromic EBT3 film. Monte Carlo simulations were also performed - both for comparison with experimental data and to further explore the potential of magnetic focusing in silica. For example, beam spot areas (based on the 90% dose contour) were matched at Bragg depth between simulated 100 MeV collimated beams and simulated beams focused by two 400 T/m gradient magnets. Results: Preliminary experimental results show 23% higher peak to entrance dose ratios and flatter spread out Bragg peak plateaus for 8 mm focused beams compared with uncollimated beams. Monte Carlo simulations showed 21% larger peak to entrance ratios and a ∼9 fold more efficient dose to target delivery compared to spot-sized matched collimated beams. Our latest results will be presented. Conclusion: Our results suggest that rare earth focusing magnet assemblies could reduce skin dose and beam number while delivering dose to nominally spherical radiosurgery targets over a much shorter time compared to unfocused beams. Immediate clinical applications include those associated with proton radiosurgery and functional radiosurgery of the brain and spine, however expanded treatment sites can be also envisaged.

60 APPLIED LIFE SCIENCES↗