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NASA NTRSDate not supplied

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Sustainable Electric Aviation

All-electric and hybrid electric aerovehicle concepts face numerous technical barriers prior to their introduction into the consumer marketplace in order to meet sustainable aviation goals. One of the primary barriers to overcome is developing an energy dense storage system capable of meeting the rigorous aerospace safety and performance criteria. Additionally, the electric aviation market requires that the batteries be fabricated in a sustainable manner with materials that are readily available and abundant within the U.S. to ensure there are no supply chain issues during manufacturing. The performance metrics to enable electric aviation are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for safe operation of commercial electric aerovehicles. The SABERS concept proposes a battery that meets the key performance criteria through development of a solid-state architecture battery utilizing high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. The hybrid cathode has been developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte has been used as a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed into a serial stacking configuration to enable dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150 °C which provides the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. This poster summarizes recent results from battery component optimization to scale-up production of full SABERS pouch cells.

Urban Air Mobility (UAM) Vehicles↗

NASA NTRSDate not supplied

Solid-State Architecture Batteries for Enhanced Rechargeability and Safety (SABERS) Beyond Li-Ion: Technology to Enable Next-Generation Sustainable Electric

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The primary barrier to overcome is developing an energy storage system that meets rigorous aerospace safety and performance criteria. The performance metrics for eVTOL vehicles are at least two times greater than those of electric ground vehicles. Furthermore, inherently non-flammable batteries are essential for the safe operation of commercial electric aero vehicles. The SABERS concept proposes a battery that meets the critical performance criteria by developing a solid-state architecture battery utilizing a high-capacity sulfur-selenium cathode and lithium metal anode. The combination of sulfur and selenium offers a balanced energy-to-power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This hybrid cathode will be developed using NASA-patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. A solid-state electrolyte will be used as a safe, non-flammable replacement for the highly flammable liquid organic electrolytes currently in SOA lithium-ion batteries. This solid-state lithium-sulfur/selenium cell will be designed in a serial stacking configuration to enable the dense packaging of the battery cells. The serial stacking configuration is termed a bipolar stack, which has the advantages of reducing overall cell weight, simplifying the interfaced connections for the cell, and minimizing the cooling requirements. Lastly, the optimization of battery components will occur through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a fully solid-state battery with operational temperatures up to 150°C, providing the required energy density, discharge rates, and inherent safety to meet the strict aerospace mission performance criteria. The SABERS team employed novel materials development, computational modeling, and design-of-experiments (DOE) optimization studies in their research. This presentation will show the results of these studies and demonstrate a feasible path for solid-state cells with a specific energy greater than 400 Wh/kg to enable electric aircraft.

Computational Modeling↗

NASA NTRS1997

Microfabricated Ice-Detection Sensor

Knowledge of ice conditions on important aircraft lift and control surfaces is critical for safe operation. These conditions can be determined with conventional ice-detection sensors, but these sensors are often expensive, require elaborate installation procedures, and interrupt the airflow. A micromachined, silicon-based, flush-mounted sensor which generates no internal heat has been designed, batch fabricated, packaged, and tested. The sensor is capable of distinguishing between an ice-covered and a clean surface. It employs a bulk micromachined wafer with a 7 micrometer-thick, boron-doped, silicon diaphragm which serves as one plate of a parallel-plate capacitor. This is bonded to a second silicon wafer which contains the fixed electrodes, one to drive the diaphragm by application of a voltage, the other to measure the deflection by a change in capacitance. The diaphragm sizes ranged from 1x1 mm to 3x3 mm, and the gap between parallel-plate capacitors is 2 micrometers. A 200 V d.c. was applied to the driving electrode which caused the capacitance to increase approximately 0.6pf, from a nominal capacitance of 0.6pf, when the surface was ice free. After the sensor was cooled below the freezing point of water, the same voltage range was applied to the drive electrode. The capacitance increased by the same amount. Then a drop of water was placed over the diaphragm and allowed to freeze. This created an approximately 2mm-thick ice layer. The applied 200V d.c. produced no change in capacitance, confirming that the diaphragm was locked to the ice layer. Since the sensor uses capacitive actuation, it uses very little power and is an ideal candidate for inclusion in a wireless sensing system.

DeAnna, Russell G.↗

NASA NTRS1991

Evaluation of advanced lubricants for aircraft applications using gear surface fatigue tests

Surface pitting fatigue life tests were conducted with five lubricants, using spur gears made from a single lot of consumable-electrode vacuum melted (CVM) AISI 9310 steel. The gears were case carbonized and hardened to a Rockwell c-60 and finish ground. The gear pitch diameter was 8.89 cm. The lot of gears was divided into five groups, each of which was tested with a different lubricant. The test lubricants can be classified as synthetic polyol-esters with various viscosities and additive packages. Test conditions included bulk gear temperature of 350 K, a maximum Hertz stress of 1.71 GPa (248 ksi) at the pitch line, and a speed of 10,000 RPM. The lubricant with a viscosity that provided a specific film thickness greater than one and with an additive package produced far greater gear surface fatigue lives than lubricants with a viscosity that provided specific film thickness less than one. A low viscosity lubricant with an additive package produced gear surface fatigue lives equivalent to a similar base stock lubricant with 30 percent higher viscosity, but without an additive package. Lubricants with the same viscosity and similar additive packages gave equivalent gear surface fatigue lives.

Townsend, Dennis P.↗

NASA NTRS1991

Evaluation of advanced lubricants for aircraft applications using gear surface fatigue tests

Townsend, Dennis P.↗

NASA NTRS1999

Experimental Investigation of Pool Boiling Heat Transfer Enhancement in Microgravity in the Presence of Electric Fields

In boiling high heat fluxes are possible driven by relatively small temperature differences, which make its use increasingly attractive in aerospace applications. The objective of the research is to develop ways to overcome specific problems associated with boiling in the low gravity environment by substituting the buoyancy force with the electric force to enhance bubble removal from the heated surface. Previous studies indicate that in terrestrial applications nucleate boiling heat transfer can be increased by a factor of 50, as compared to values obtained for the same system without electric fields. The goal of our research is to experimentally explore the mechanisms responsible for EHD heat transfer enhancement in boiling in low gravity conditions, by visualizing the temperature distributions in the vicinity of the heated surface and around the bubble during boiling using real-time holographic interferometry (HI) combined with high-speed cinematography. In the first phase of the project the influence of the electric field on a single bubble is investigated. Pool boiling is simulated by injecting a single bubble through a nozzle into the subcooled liquid or into the thermal boundary layer developed along the flat heater surface. Since the exact location of bubble formation is known, the optical equipment can be aligned and focused accurately, which is an essential requirement for precision measurements of bubble shape, size and deformation, as well as the visualization of temperature fields by HI. The size of the bubble and the frequency of bubble departure can be controlled by suitable selection of nozzle diameter and mass flow rate of vapor. In this approach effects due to the presence of the electric field can be separated from effects caused by the temperature gradients in the thermal boundary layer. The influence of the thermal boundary layer can be investigated after activating the heater at a later stage of the research. For the visualization experiments a test cell was developed. All four vertical walls of the test cell are transparent, and they allow transillumination with laser light for visualization experiments by HI. The bottom electrode is a copper cylinder, which is electrically grounded. The copper block is heated with a resistive heater and it is equipped with 6 thermocouples that provide reference temperatures for the measurements with HI. The top electrode is a mesh electrode. Bubbles are injected with a syringe into the test cell through the bottom electrode. The working fluids presently used in the interferometric visualization experiments, water and PF 5052, satisfy requirements regarding thermophysical, optical and electrical properties. A 30kV power supply equipped with a voltmeter allows to apply the electric field to the electrodes during the experiments. The magnitude of the applied voltage can be adjusted either manually or through the LabVIEW data acquisition and control system connected to a PC. Temperatures of the heated block are recorded using type-T thermocouples, whose output is read by a data acquisition system. Images of the bubbles are recorded with 35mm photographic and 16mm high-speed cameras, scanned and analyzed using various software packages. Visualized temperature fields HI allows the visualization of temperature fields in the vicinity of bubbles during boiling in the form of fringes. Typical visualized temperature distributions around the air bubbles injected into the thermal boundary layer in PF5052 are shown. The temperature of the heated surface is 35 C. The temperature difference for a pair of fringes is approximately 0.05 C. The heat flux applied to the bottom surface is moderate, and the fringe patterns are regular. In the image a bubble penetrating the thermal boundary layer is visible. Because of the axial symmetry of the problem, simplified reconstruction techniques can be applied to recover the temperature field. The thermal plume developing above the heated surface for more intensive heating is shown. The temperature distribution in the liquid is clearly 3D, and tomographic techniques have to be applied to recover the temperature distribution in such a physical situation. A sequence of interferometric images showing the temperature distribution around the rising bubble, recorded with a high-speed camera is shown. Again, the temperature distribution is 3D, and a more complex approach to the evaluation, the tomographic reconstruction has to be taken. Measurement of the temperature distribution from the fringe pattern temperature distributions that yield important information regarding heat transfer are determined. Two algorithms that allow the quantitative evaluation of interferometric fringe patterns and the reconstruction of temperature fields during boiling have been developed at the Heat Transfer Laboratory of the Johns Hopkins University. In the first algorithm the bubble is assumed to be axially symmetrical, which significantly reduces the computational effort for quantifying the temperature distribution around the bubble. For this purpose the thermal boundary layer around the bubble is divided into equidistant concentric shells, and the refractive index is assumed to be constant in each of the shells. Since large temperature gradients are expected in the vicinity of the bubble during boiling, the deflection of the light beam cannot be neglected in boiling experiments. Since the exit angle of the light beam is known, this allows to account for the deflections and phase shifts outside the boundary layer (in the bulk fluid and in the windows of the test cell). Three dimensional temperature distributions in the vicinity of the bubble are reconstructed using tomographic techniques. In tomography, the measurement volume is sliced into 2D planes. In the present study these planes are parallel to the heated surface. The objective is to determine the values of the field parameter of interest in form of the field function in these 2D planes. The field parameter is the change of the refractive index of the liquid in the measurement volume caused by temperature changes. By superimposing data for many 2D planes recorded at the same time instant, the 3D temperature distribution in the measurement volume is recovered.

Herman, Cila↗

NASA NTRS2017

Transparent Conductive Ink for Additive Manufacturing

NASA analyzes, tests, packages, and fabricates electrical, electronic, and electromechanical (EEE) parts. Nanotechnology is listed in NASA's Technology Roadmap as a key area to invest for further development.1 This research project focused on using nanotechnology to improve electroluminescent lighting in terms of additive manufacturing and to increase energy efficiency. Specifically, this project's goal was to produce a conductive but transparent printable ink that can be sprayed on any surface for use as one of the electrodes in electroluminescent device design. This innovative work is known as thick film dielectric electroluminescent (TDEL) technology. TDEL devices are used for "backlighting, illumination, and identification due to their tunable color output, scalability, and efficiency" (I.K. Small, T.D. Rolin, and A.D. Shields, "3D Printed Electroluminescent Light Panels," NASA Fiscal Year 2017 Center Innovation Fund Proposal, unpublished data, 2017). These devices use a 'front-to-back' printing method, where the substrate is the transparent layer, and the dielectric and phosphor are layered on top. This project is a first step in the process of creating a 3D printable 'back-to-front' electroluminescent device. Back-to-front 3D-printed devices are beneficial because they can be printed onto different substrates and embedded in different surfaces, and the substrate is not required to be transparent, all because the light is emitted from the top surface through the transparent conductor. Advances in this area will help further development of printing TDEL devices on an array of different surfaces. Figure 1 demonstrates the layering of the two electrodes that are aligned in a parallel plate capacitor structure (I.K. Small, T.D. Rolin, and A.D. Shields, "3D Printed Electroluminescent Light Panels," NASA Fiscal Year 2017 Center Innovation Fund Proposal, unpublished data, 2017). Voltage is applied across the device, and the subsequent electron excitation results in light emission at the top layer.

Patlan, X. J.↗

DOE OSTI2024

Surface water geochemistry along St. Louis River Estuary (Duluth/Superior, MN/WI)

This dataset is aimed at understanding changes in surface water chemistry associated with urbanization in the Great Lakes region. Surface water chemistry including cations, anions, organic and inorganic carbon, and nitrogen were collected from six locations along St. Louis River – a freshwater estuary entering Lake Superior (Duluth/Superior, MN/WI). The Duluth/Superior, MN/WI metropolitan area is the largest port on the United States side of Lake Superior. Samples were collected near different land uses every two weeks from late July 2023 to the onset of ice cover in November 2023. Water samples were analyzed using In-Situ AquaTroll 500 Multiparameter Sonde with Ammonium Ion Selective Electrode and Chlorophyll-a sensor (unfiltered), METTLER TOLEDO FiveEasy Plus FP20 and METTLER TOLEDO LE407 probe (unfiltered); HACH DR300 Pocket Colorimeter Iron FerroVer (filtered 0.22 μm in field); Shimadzu TOC-L Total Organic Carbon Analyzer with TNM-L Total Nitrogen Unit (filtered 0.22 μm in field); Agilent 8900 triple quadrupole ICP-MS (ICP-QQQ) (filtered 0.22 μm in field); and Dionex ICS-6000 HPIC System (filtered 0.22 μm in field).The data package is comprised of 5 files. dd.csv contains the description of columns in Geochemistry_LSNERR_water.csv and Sampling_sites.csv. flmd.csv contains descriptions of each file in the dataset. README.txt contains description of the dataset structure and file content. Geochemistry_LSNERR_water.csv contains geochemistry data for six sampling locations along the St. Louis River. Sampling_sites.csv contains latitude and longitude coordinates for each of the six sampling site locations along the St. Louis River.This data has not been previously published.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2003

Mars Surveyor Program '01 Mars Environmental Compatibility Assessment wet chemistry lab: a sensor array for chemical analysis of the Martian soil

The Mars Environmental Compatibility Assessment (MECA) instrument was designed, built, and flight qualified for the now canceled MSP (Mars Surveyor Program) '01 Lander. The MECA package consisted of a microscope, electrometer, material patch plates, and a wet chemistry laboratory (WCL). The primary goal of MECA was to analyze the Martian soil (regolith) for possible hazards to future astronauts and to provide a better understanding of Martian regolith geochemistry. The purpose of the WCL was to analyze for a range of soluble ionic chemical species and electrochemical parameters. The heart of the WCL was a sensor array of electrochemically based ion-selective electrodes (ISE). After 20 months storage at -23 degrees C and subsequent extended freeze/thawing cycles, WCL sensors were evaluated to determine both their physical durability and analytical responses. A fractional factorial calibration of the sensors was used to obtain slope, intercept, and all necessary selectivity coefficients simultaneously for selected ISEs. This calibration was used to model five cation and three anion sensors. These data were subsequently used to determine concentrations of several ions in two soil leachate simulants (based on terrestrial seawater and hypothesized Mars brine) and four actual soil samples. The WCL results were compared to simulant and soil samples using ion chromatography and inductively coupled plasma optical emission spectroscopy. The results showed that flight qualification and prolonged low-temperature storage conditions had minimal effects on the sensors. In addition, the analytical optimization method provided quantitative and qualitative data that could be used to accurately identify the chemical composition of the simulants and soils. The WCL has the ability to provide data that can be used to "read" the chemical, geological, and climatic history of Mars, as well as the potential habitability of its regolith.

Non-NASA Center↗

DOE OSTI2026

GPU-Accelerated Analytic Simulation of Sparse Ionization Signal Formation in Pixelated Projection Detector

This paper presents a GPU-accelerated simulation package, TRED, for next-generation neutrino detectors with pixelated charge readout, leveraging community-driven software ecosystems to ensure adaptability and extensibility. We introduce two generic contributions: (i) an effective-charge representation based on Gaussian quadrature rules, in which the linear- interpolation factors for the field response inside each voxel are absorbed into the effective charge, and (ii) a sparse, block- binned tensor representation that enables efficient FFT-based computation of induced signals on readout electrodes for sparsely activated detector volumes. The former captures structure inside a voxel without dense sampling, while the latter achieves low memory usage and scalable runtime, as demonstrated in bench- mark studies. The underlying data representation is applicable to large-scale detectors and to other computational problems involving sparse activity.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1989

A programmable CCD driver circuit for multiphase CCD operation

A programmable CCD (charge-coupled device) driver circuit was designed to drive CCDs in multiphased modes. The purpose of the drive electronics is to operate developmental CCD imaging arrays for NASA's tiltable moderate resolution imaging spectrometer (MODIS-T). Five objectives for the driver were considered during its design: (1) the circuit drives CCD electrode voltages between 0 V and +30 V to produce reasonable potential wells, (2) the driving sequence is started with one input signal, (3) the driving sequence is started with one input signal, (4) the circuit allows programming of frame sequences required by arrays of any size, (5) it produces interfacing signals for the CCD and the DTF (detector test facility). Simulation of the driver verified its function with the master clock running up to 10 MHz. This suggests a maximum rate of 400,000 pixels/s. Timing and packaging parameters were verified. The design uses 54 TTL (transistor-transistor logic) chips. Two versions of hardware were fabricated: wirewrap and printed circuit board. Both were verified functionally with a logic analyzer.

Ewin, Audrey J.↗

NASA NTRS1984

Special Test Methods for Batteries

Various methods are described for measuring heat generation in primary and secondary batteries as well as the specific heat of batteries and cell thermal conductance. Problems associated with determining heat generation in large batteries are examined. Special attention is given to monitoring temperature gradients in nickel cadmium cells, the use of auxiliary electrodes for conducting tests on battery charge control, evaluating the linear sweep of current from charge to discharge, and determining zero current voltage. The fast transient behavior of batteries in the microsecond range, and the electrical conductance of nickel sinters in the thickness direction are also considered. Mechanical problems experienced in the vibration of Ni-Cd batteries and tests to simulate cyclic fatigue of the steel table connecting the plates to the comb are considered. Methods of defining the distribution of forces when cells are compressed during battery packaging are also explored.

Gross, S.↗

NASA NTRS1990

Primary lithium cell life studies

One solution for providing a truly independent power source is to package, within the critical subsystem element, a primary battery that can remain dormant for time periods as long as the mission life, which can be 10-15 years, maximum. When primary power from the spacecraft solar array/battery system is interrupted, the backup battery system, which is connected through a diode to the power input line, would automatically support the load to avoid a power interruption to the critical load for a time period long enough to ensure that ground control could access the satellite and correct the anomaly by sending appropriate commands to the spacecraft. Critical subsystems identified for the application are telemetry and command circuits, volatile computer memory, attitude control circuits, and some critical payloads. Due to volume packaging and weight restrictions that exist on most spacecraft, coupled with the long storage periods required, lithium cell technology was selected for the backup power source. Because of the high energy density (200-400 Wh/kg), long shelf life, and load capability, soluble cathode primary lithium technology was chosen. The most important lithium cell properties that require detail characterization for this application are capacity loss, shelf life, and the voltage delay mechanism. These are functions of storage time and temperature. During storage, a passive film builds up on the lithium electrode. The film protects the lithium electrode from progressive capacity decay but requires time to break down when a load is applied. This phenomenon results in a depressed voltage during the period of film breakdown which can last from fractions of a second to minutes.

Capulli, John↗

DOE OSTI2022

Performance degradation in proton-conducting ceramic fuel cell and electrolyzer stacks

Proton-conducting ceramics are emerging as enabling materials for efficient electrochemical electricity generation, energy storage, and fuels synthesis. In this work, we present longer-term degradation results for protonic-ceramic fuel cells and electrolyzers based on a BaCe 0.4 Zr 0.4 Y 0.1 Yb 0.1 O 3-δ (BCZYYb) electrolyte. The cells are packaged within unit-cell stacks, including metallic interconnects, current collectors, sealing glasses and gaskets. Durability is found to be superior in protonic-ceramic electrolyzers in comparison to fuel cells. Operating conditions have a large impact on degradation rates; better stability is found at fuel-cell operating temperatures above 600 °C, and electrolyzer steam feeds below 20%. Here, we find that both fuel-cell and electrolyzer degradation is greatly reduced via the introduction of a gadolinium-doped ceria interlayer between the electrolyte and the air–steam electrode. Fuel-cell degradation falls to 1.2% khr –1 under methane fuel at 600 °C; electrolyzer degradation is reduced to 1% khr –1 at 550 °C and 50% steam. Further analyses of electrochemical impedance spectroscopy and distribution of relaxation times provide insight to root processes and degradation phenomena in protonic electroceramics.

25 ENERGY STORAGE↗

NASA NTRS2005

Modifications of Fabrication of Vibratory Microgyroscopes

A micromachining process for the fabrication of vibratory microgyroscopes from silicon wafers, and aspects of the microgyroscope design that are inextricably linked with the fabrication process, have been modified in an effort to increase production yields from perspectives of both quantity and quality. Prior to the modifications, the effective production yield of working microgyroscopes was limited to one or less per wafer. The modifications are part of a continuing effort to improve the design and increase production yields to more than 30 working microgyroscopes per wafer. A discussion of pertinent aspects of the unmodified design and the unmodified fabrication process is prerequisite to a meaningful description of the modifications. The design of the microgyroscope package was not conducive to high yield and rapid testing of many microgyroscopes. One of the major impediments to high yield and testing was found to lie in vibration- isolation beams around the four edges of each microgyroscope, which beams were found to be unnecessary for achieving high resonance quality factors (Q values) characterizing the vibrations of petallike cantilevers. The fabrication process included an 8- m-deep plasma etch. The purpose of the etch was to create 8- m vertical gaps, below which were to be placed large gold evaporated electrodes and sensing pads to drive and sense resonant vibrations of the "petals." The process also included a step in which bridges between dies were cut to separate the dies. The etched areas must be kept clean and smooth (free of debris and spikes), because any object close to 8 m high in those areas would stop the vibrations. However, it was found that after the etch, there remained some spikes with heights that were, variously, almost as high or as high as the etch depth. It also was found that the cutting of bridges created silicon debris, some of which lodged in the 8- m gaps and some of which landed on top of the petals. The masses added to the petals by the debris altered resonance frequencies and/or Q values to unacceptable degrees. Hence, the spikes and the debris have been conjectured to cause most of the observed malfunctions of newly fabricated microgyroscopes. Another pertinent aspect of the unmodified design and process was the fabrication of electrodes and the 8- m capacitance gap on a 500- m-thick wafer, and the fabrication of a 3-mm-thick baseplate from another wafer. It was necessary to bond these wafers to each other in an assembly step that was later found to be superfluous in that it could be eliminated by a suitable modification of the design.

Bae, Sam Y.↗

DOE OSTI2021

Damage Modeling of Solid Oxide Fuel Cells Accounting for Redox Effects

This work applies a multiscale mechanistic damage model developed for brittle ceramics and implemented in commercial finite element (FE) packages via user subroutines to study progressive damage in solid oxide fuel cells (SOFC) subjected to thermomechanical loading under normal operating and shutdown conditions including redox effects. The damage model captures the micromechanics of stiffness reduction due to material porosity change and microcracking and integrates the as-obtained stiffness reduction law into a continuum damage mechanics (CDM) formulation for the evolution of microcracks up to fracture. The volumetric “swelling” that occurs during redox is treated in constitutive modeling similarly to thermal expansion, but swelling strains are irreversible. Furthermore, this damage model was first validated through predictions of strength and stress-strain response for the SOFC electrode materials. Next, it has been applied to predict the potential for degradation in a generic planar SOFC stack with large active area cells. Multicell stack models were simulated in both co-flow and counter-flow configurations. In addition, a constant temperature redox cycle was also simulated to capture overall cell electrode damage due to volumetric swelling of the nickel (Ni)-based anode in the anode-supported cells.

25 ENERGY STORAGE↗

DOE OSTI2023

Comparison of Machine Learning Algorithms for Natural Gas Identification with Mixed Potential Electrochemical Sensor Arrays

Mixed-potential electrochemical sensor arrays consisting of indium tin oxide (ITO), La 0.87 Sr 0.13 CrO 3 , Au, and Pt electrodes can detect the leaks from natural gas infrastructure. Algorithms are needed to correctly identify natural gas sources from background natural and anthropogenic sources such as wetlands or agriculture. We report for the first time a comparison of several machine learning methods for mixture identification in the context of natural gas emissions monitoring by mixed potential sensor arrays. Random Forest, Artificial Neural Network, and Nearest Neighbor methods successfully classified air mixtures containing only CH 4 , two types of natural gas simulants, and CH 4 +NH 3 with >98% identification accuracy. The model complexity of these methods were optimized and the degree of robustness against overfitting was determined. Finally, these methods are benchmarked on both desktop PC and single-board computer hardware to simulate their application in a portable internet-of-things sensor package. The combined results show that the random forest method is the preferred method for mixture identification with its high accuracy (>98%), robustness against overfitting with increasing model complexity, and had less than 10 ms training time and less than 0.1 ms inference time on single-board computer hardware.

03 NATURAL GAS↗

NASA NTRS2000

Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes

A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.

Wintucky, Edwin G.↗