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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 865 records · Page 48

Deep Space Test Bed for Radiation Studies

A key factor affecting the technical feasibility and cost of missions to Mars or the Moon is the need to protect the crew from ionizing radiation in space. Some analyses indicate that large amounts of spacecraft shielding may be necessary for crew safety. The shielding requirements are driven by the need to protect the crew from Galactic cosmic rays (GCR). Recent research activities aimed at enabling manned exploration have included shielding materials studies. A major goal of this research is to develop accurate radiation transport codes to calculate the shielding effectiveness of materials and to develop effective shielding strategies for spacecraft design. Validation of these models and calculations must be addressed in a relevant radiation environment to assure their technical readiness and accuracy. Test data obtained in the deep space radiation environment can provide definitive benchmarks and yield uncertainty estimates of the radiation transport codes. The two approaches presently used for code validation are ground based testing at particle accelerators and flight tests in high-inclination low-earth orbits provided by the shuttle, free-flyer platforms, or polar-orbiting satellites. These approaches have limitations in addressing all the radiation-shielding issues of deep space missions in both technical and practical areas. An approach based on long duration high altitude polar balloon flights provides exposure to the galactic cosmic ray composition and spectra encountered in deep space at a lower cost and with easier and more frequent access than afforded with spaceflight opportunities. This approach also results in shorter development times than spaceflight experiments, which is important for addressing changing program goals and requirements.

Adams, James H.↗

Computational Modeling Develops Ultra-Hard Steel

Glenn Research Center's Mechanical Components Branch developed a spiral bevel or face gear test rig for testing thermal behavior, surface fatigue, strain, vibration, and noise; a full-scale, 500-horsepower helicopter main-rotor transmission testing stand; a gear rig that allows fundamental studies of the dynamic behavior of gear systems and gear noise; and a high-speed helical gear test for analyzing thermal behavior for rotorcraft. The test rig provides accelerated fatigue life testing for standard spur gears at speeds of up to 10,000 rotations per minute. The test rig enables engineers to investigate the effects of materials, heat treat, shot peen, lubricants, and other factors on the gear's performance. QuesTek Innovations LLC, based in Evanston, Illinois, recently developed a carburized, martensitic gear steel with an ultra-hard case using its computational design methodology, but needed to verify surface fatigue, lifecycle performance, and overall reliability. The Battelle Memorial Institute introduced the company to researchers at Glenn's Mechanical Components Branch and facilitated a partnership allowing researchers at the NASA Center to conduct spur gear fatigue testing for the company. Testing revealed that QuesTek's gear steel outperforms the current state-of-the-art alloys used for aviation gears in contact fatigue by almost 300 percent. With the confidence and credibility provided by the NASA testing, QuesTek is commercializing two new steel alloys. Uses for this new class of steel are limitless in areas that demand exceptional strength for high throughput applications.

Source record↗

Low-Torque Seal Development

The EcoTurn Class K production prototypes have passed all AAR qualification tests and received conditional approval. The accelerated life test on the second set of seals is in progress. Due to the performance of the first set, no problems are expected.The seal has demonstrated superior performance over the HDL seal in the test lab with virtually zero torque and excellent contamination exclusion and grease retention.

Lattime, Scott B.↗

The Behavior of Environmentally Friendly Corrosion Preventative Compounds in an Aggressive Coastal Marine Environment

The shift to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. The CPCs, while a temporary protective coating, must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different soft film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. The CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing . The initial results for the fifteen CPC systems are reported : Key words: corrosion preventive compound, CPC, spaceport, environmentally friendly, atmospheric exposure, marine, carbon steel, aluminum alloy, galvanic corrosion, wire on bolt.

Montgomery, Eliza L.↗

Environmentally Friendly Corrosion Preventative Compounds for Ground Support Structures

The need to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. CPCs are used as temporary protective coatings and must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different oily film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing. The results for the fifteen CPC systems are presented in this paper.

Montgomery Eliza L.↗

Mitigation and Diagnosis of Pin-Hole Formation in Polymer Electrolyte Membrane Fuel Cells

In this work, we implement a calendering technique to flatten stray fibers within the gas diffusion media, thereby mitigating pin-hole formation in the hot-pressed MEAs. We have investigated the influence of calendering on the long-term durability for several types of gas diffusion electrodes (GDEs) using a combined chemical and mechanical accelerated stress test (AST). The calendered MEAs demonstrate an average AST lifetime improvement of 77% relative to the as-fabricated MEAs.

AMR↗

Prediction of Climate-Specific Degradation Rate for Photovoltaic Encapsulant Discoloration

Encapsulant discoloration is a well-known field degradation mode of crystalline-silicon photovoltaic modules, particularly in the hot climate zones. The discoloration rate is influenced by several weathering factors, such as UV light, module temperature, and humidity, as well as the permeability of oxygen into the module. Here, a rate dependence model employing the modified Arrhenius equations to predict the degradation rate for encapsulant discoloration in different climates is presented. Two modeling approaches are introduced, which utilize the field and accelerated UV testing degradation data in conjunction with the field meteorological data to determine the acceleration factor for encapsulant browning. A novel method of accelerated UV stress testing at three simultaneous module temperatures in a single environmental chamber test run is implemented to estimate the activation energy for browning. The test was performed on three field-retrieved modules to capture the wear-out failure mechanism. The degradation in short-circuit current Isc rather than maximum power is used as a decisive parameter for the discoloration analysis. Furthermore, the developed model has been used to predict the Isc degradation rate for the Arizona field characterized by a hot and dry climate and is validated against the field-measured value. It has also been applied to other climate types, e.g., the cold and dry climate of New York.

14 SOLAR ENERGY↗

Environmental exposure effects on composite materials for commercial aircraft

The data base for composite materials' properties as they are affected by the environments encountered in operating conditions, both in flight and at ground terminals is expanded. Absorbed moisture degrades the mechanical properties of graphite/epoxy laminates at elevated temperatures. Since airplane components are frequently exposed to atmospheric moisture, rain, and accumulated water, quantitative data are required to evaluate the amount of fluids absorbed under various environmental conditions and the subsequent effects on material properties. In addition, accelerated laboratory test techniques are developed are reliably capable of predicting long term behavior. An accelerated environmental exposure testing procedure is developed, and experimental results are correlated and compared with analytical results to establish the level of confidence for predicting composite material properties.

Gibbons, M. N.↗

Evaluation and modeling of the potential effects of a module manufacturing anomaly

Photovoltaic lifetime predictions are in great demand, but are exceedingly difficult to achieve with uncertainties small enough to be useful. During the construction of photovoltaic modules, small unplanned variability in materials or processes can have profound effects on module durability. Thus, continual monitoring of production quality is needed. In the subject production run, module quality, as monitored by damp heat testing, revealed a subset of modules that were prone to higher degradation rates. An assessment of the potential long-term power loss and mitigation strategies was needed. To do this, modules were exposed to variable levels of humidity and temperature with periodic monitoring. The analysis takes into account the kinetics of the degradation and the spatially and temporally varying humidity content within the module during accelerated stress testing. This is an important aspect for extrapolating laboratory results to field exposure because moisture ingress is diffusion limited in most laboratory module tests but not limited in these fielded modules. This analysis predicted that although a solder flux induce degradation mechanism is significant in accelerated stress test, this is probably an artifact of a process with a very large acceleration factor that is not likely to be significant for deployed modules. The degradation mechanism affected a limited area around the tabbing helping to minimize the effect. Furthermore, three years after the system was commissioned, the fielded modules indeed show no significant power loss.

14 SOLAR ENERGY↗

Correction for Metastability in the Quantification of PID in Thin-Film Module Testing

A fundamental change in the analysis for the accelerated stress testing of thin-film modules is proposed, whereby power changes due to metastability and other effects that may occur due to the thermal history are removed from the power measurement that we obtain as a function of the applied stress factor. In this work, initial thermal treatment of the module is performed before application of the independent variable stress of system voltage so that any temperature-dependent processes (e.g., diffusion) that affect the module power are largely activated beforehand. Secondly, the power of reference modules normalized to an initial state-undergoing the same thermal and light exposure history but without the applied stress factor such as humidity or voltage bias-is subtracted from that of the stressed modules. For better understanding and appropriate application in standardized tests, the method is demonstrated and discussed for potential-induced degradation testing in view of the paralleloccurring but unrelated physical mechanisms that can lead to confounding power changes in the module.

14 SOLAR ENERGY↗

Bunch Extinction Measurements at PIP-II Injector Test Facility

The PIP2 particle accelerator is a new upgrade to the Fermilab accelerator complex, featuring an 800-MeV H-superconducting linear accelerator that will inject the beam into the present Fermilab Booster. A test accelerator known as PIP-II Injector Test (PIP2IT) has been built to validate the concept of the front-end of such a machine. One of the paramount challenges of PIP2IT was to validate the bunch by bunch chopping system in the Medium Energy Beam Transport (MEBT). This paper aims to present the direct extinction measurements at PIP2IT and their analysis. These measurements have been taken by two Resistive Wall Current Monitors (RWCM) and recorded by a high bandwidth oscilloscope.

43 PARTICLE ACCELERATORS↗

Characterization of Interconnects

Combined-accelerated stress testing (C-AST) simultaneously combines stress factors of the natural environment (including UV radiation, temperature, humidity, electrical current, and external mechanical force) into a single test that requires fewer modules, fewer chambers, and makes it possible to discover weaknesses in new designs that are not known a-priori. C-AST reduces risk, accelerates time to market, and improves bankability by reducing costly overdesign using test levels not exceeding those seen in the natural environment. This project seeks to evaluate strengths and weaknesses of modern cell interconnect designs with combined-accelerated stress testing (C-AST) to screen multiple climates along with finite element and failure analysis to determine the potential for a 50-year life. Supporting this, we seek to develop methods of characterization to assess the degradation of interconnects, enable predictive rate models with material forensics and FEA and show C-AST's ability to find interconnect failures and benchmark it relative to other accelerated stress test methods like temperature cycling and cyclic dynamic mechanical loading. Examples of modern interconnect designs covered are Canadian Solar Hetero Technology ribbon enabling closer cell interconnections, SmartWire (eg. Meyer-Berger technology), and shingled cells with new interconnect materials.

C-AST↗

Understanding and Overcoming Water-induced Interfacial Degradation in Si Modules (Final Technical Report)

Moisture ingress is an established issue for photovoltaic module durability. Durability studies probing moisture effects typically evaluate performance losses at the module level, attributing global power losses to the overall humidity condition of the test environment while leaving local module behavior unknown. This project successfully develops an in situ short-wave infrared probe of moisture content in PV modules with demonstrated detection limits better than 100 ppm in EVA-encapsulated Al-BSF and PERC architectures (66 µg/cm3) and applicability across the range of terrestrial conditions. Combining this optical moisture quantification method (water reflectometry detection, WaRD) with peel testing of interfaces, biased photoluminescence imaging of performance, and first principles computation, we correlate module moisture content and cell performance over the course of accelerated damp heat tests. By performing multi-level humidity and thermal accelerated testing over thousands of hours (0, 65 and 85% RH and 25, 65, and 85°C), we are able to attribute effects of individual environmental stresses and the dependence on module architecture. Using first-principles computational chemistry, we find that the decomposition of EVA to acetic acid (Norrish II) is thermodynamically preferred over a pathway to acetaldehyde (Norrish I), elucidating the underlying chemistry of encapsulant degradation. We also find it is likely that water segregates to the stable interfaces of the cell, especially the SiNx/EVA interface. We find that moisture is strongly correlated with reduction in adhesion at the interfaces of the cells, particularly at Ag fingers. We show uniquely that the peel strength required to delaminate the encapsulant from the front of the cell depends not only on the exposure to a high heat and humid environment, but also to the moisture content during the mechanical testing, indicating an important interaction between when mechanical stresses are faced in terms of the moisture content of the module and its durability. We find that the background sheet resistance (that is, the sheet resistance rise not attributable to finger interruptions or cracks) is substantially higher in the backsheet mini-modules vs glass-glass packages when humidity and temperature are faced. This increase in power loss due to the background resistance increase over time in damp heat in glass-backsheet modules resulted in ~3-4% larger decrease in relative PCE compared to glass-glass modules. In glass-backsheet modules, the effect of the moisture dose alone is comparable or greater than that of the combined temperature and water term, suggesting that glass-backsheet modules are overall more susceptible to moisture induced performance loss. Finally, we show that thin film PV modules are amenable to WaRD measurement, based on the ability to detect moisture in POE encapsulants or in the cell stack itself. The ease of WaRD measurement and its few requirements on the bill of materials should enable broad applicability of this technique for studying the effects of moisture in PV.

14 SOLAR ENERGY↗

Ultrasonic and optical evaluation of surgical implant materials and devices. A durability study of pericardial bioprostheses

Laser Doppler Anemometry (LDA) and accelerated fatigue testing were used in an attempt to assess the durability of two cardiac value bioprostheses. The LDA system was used to monitor the function of the cardiac valves over time. This was done through flow characterization in an aortic flow chamber, designed to closely simulate in vivo conditions, both in the near vicinity (sinuses of valsalva region) and also somewhat downstream (aortic region) from the values. The accelerated fatigue tester was operated by opening and closing the valves at a rate of 1300 R.P.M., about 18 x the normal rate. The results from the two test valves indicate a definite change in the flow characteristics downstream from the valve after certain accelerated test intervals. The high velocity cross-sectional flow area seems to increase over time in use, causing a decrease in the peak velocity. The tissue became more flaccid in certain areas, and tears were apparent at about 9.4 million cycles for the Ionescu-Shiley valve and at 24 million cycles for the Carpentier-Edwards valve. The use of Doppler ultrasound as a technique for monitoring the function of bioprostheses over time in vivo is also discussed.

Schuster, P. R.↗

Long-Term Reliability of High Speed SiGe/Si Heterojunction Bipolar Transistors

Accelerated lifetime tests were performed on double-mesa structure Si/Si0.7Ge0.3/Si npn heterojunction bipolar transistors, grown by molecular beam epitaxy, in the temperature range of 175C-275C. Both single- and multiple finger transistors were tested. The single-finger transistors (with 5x20 micron sq m emitter area) have DC current gains approximately 40-50 and f(sub T) and f(sub MAX) of up to 22 GHz and 25 GHz, respectively. The multiple finger transistors (1.4 micron finger width, 9 emitter fingers with total emitter area of 403 micron sq m) have similar DC current gain but f(sub T) of 50 GHz. It is found that a gradual degradation in these devices is caused by the recombination enhanced impurity diffusion (REID) of boron atoms from the p-type base region and the associated formation of parasitic energy barriers to electron transport from the emitter to collector layers. This REID has been quantitatively modeled and explained, to the first order of approximation, and the agreement with the measured data is good. The mean time to failure (MTTF) of the devices at room temperature is estimated from the extrapolation of the Arrhenius plots of device lifetime versus reciprocal temperature. The results of the reliability tests offer valuable feedback for SiGe heterostructure design in order to improve the long-term reliability of the devices and circuits made with them. Hot electron induced degradation of the base-emitter junction was also observed during the accelerated lifetime testing. In order to improve the HBT reliability endangered by the hot electrons, deuterium sintered techniques have been proposed. The preliminary results from this study show that a deuterium-sintered HBT is, indeed, more resistant to hot-electron induced base-emitter junction degradation. SiGe/Si based amplifier circuits were also subjected to lifetime testing and we extrapolate MTTF is approximately 1.1_10(exp 6) hours at 125iC junction temperature from the circuit lifetime data.

Ponchak, George E.↗

Mechanisms of nitrogen heterocycle influence on turbine fuel stability

Lewis bases were extracted from a Utah COED syncrude via ligand exchange. Addition of this extract to Jet A at levels as low as 5 ppm N produced deterioration of stability in both JFTOT and accelerated storage tests (7 days at 394 K with 13:1air to fuel ratio). Comparable effects on Jet A stability were obtained by addition of pyridine and quinoline, while pyrrole and indole were less detrimental at the same concentration level. The weight of deposit produced accelerated storage tests was found to be proportional to the concentration of added nitrogen compound. Over the narrow temperature range accessible with the experimental method, Arrhenius plots obtained by assuming specific rate to be proportional to the weight of material deposited in seven days exhibit greater slopes in the presence of those nitrogen compounds producing the greater deposition rates. It is shown that despite variation in appearance the elemental composition and spectral characteristics of the deposits are unaffected by addition of the nitrogen compounds. The linearity of the Arrhenius plots and of a plot of Arrhenius slope versus intercept for all the compounds suggests a constancy of mechanism over the range of temperature and heterocycles studied.

Daniel, S. R.↗

Highly Stable Anion Exchange Membranes for High-Voltage Redox-Flow Batteries

In this work, multiple polymer backbones were screened for oxidation resistance and multiple chemistries were explored for tethering tris(2,4,6-trimethylphenyl)phosphonium (9MeTTP + ) to the selected polymer backbones. A new tethering strategy through brominated 9MeTTP+ cation was developed and used to obtain the desired 9MeTTP + -functionalized polysulfone (PSf) and hexafluoro polybenzimidazole (F 6 PBI) polymer. The crosslinked 9MeTTP+-functionalized hexafluoro polybenzimidazole (9MeTTP-F 6 PBI) polymer demonstrated excellent oxidation stability that met the go-no-go milestone of the first year. However, large-scale bromination inevitably involved multi-bromination products, which led to polymer crosslinking in the next tethering. A new synthesis strategy with diiodobutane as linker was developed to overcome the crosslinking problem. The prepared 9MeTTP + -F 6 PBI membrane without crosslinking showed only 3.58% water uptake and less than 1 mS/cm OH - conductivity in water at 20°C, possibly due to the hydrophobic 9MeTTP + cation. In order to improve the conductivity, hydrophilic tris(2,4,6-trimethoxylphenyl)phosphonium (9MeOTTP+) cation was tethered to an F 6 PBI backbone, and a 9MeOTTP + -F 6 PBI PTFE reinforced membrane was prepared with 17.4% water uptake to increase the mechanical strength and durability in cerium (IV) solution. A 9MeOTTP+-F 6 PBI PTFE reinforced membrane had less than 20% conductivity loss during an accelerated stability test in 0.5 M cerium (IV) and 1.3 M HClO 4 at 55°C for 100 hours. Moreover, a 9MeOTTP + -F 6 PBI PTFE reinforced membrane had more than double the lifetime of commercial FAS-30 and FAB-PK-130 AEMs during an accelerated stability test in 0.5 M cerium (IV) and 1.3 M HClO 4 at 55°C. Low area specific resistance (ASR) of a 9MeOTTP + -F 6 PBI PTFE reinforced membrane in the sulfuric acid system was also achieved due to the high acid doping ability of the polymer structure. The cationic 9MeOTTP + -F 6 PBI PTFE reinforced membrane shows a cerium (IV) permeability that is 27-fold lower than that of Nafion 212. Excellent voltage and energy efficiencies with a 9MeOTTP + -F 6 PBI PTFE reinforced membrane were demonstrated in an all-vanadium redox flow battery (VRFB).

25 ENERGY STORAGE↗