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DOE OSTI2018

An improved three-point bending test method for the investigation of nanosecond laser dicing of ultrathin Si dies with Cu stabilization layer

Highlights: • A selective chemical etching method has been developed for removal of metallization layers on ultrathin Si dies for three-point bending test. • The complex elastoplastic stress distribution in the die is simplified to an elastic stress distribution. • The die sidewall fracture strength can be determined using the standard three-point bending tensile stress equation. • The characteristic fracture strengths of ultrathin Si dies were correlated to the laser-induced microstructures of the die sidewall. - Abstract: The sidewall fracture strength of ultrathin Si dies with frontside and backside metallization layers cannot be determined directly from three-point bending (3PB) test. The complex 3PB elastoplastic stress distribution makes it difficult to determine the die sidewall fracture strength by analytical method or finite element analysis due to various theoretical and practical constraints. In this work, a selective chemical etching method has been developed for complete removal of the frontside and backside metallization layers on the ultrathin die without affecting the critical microstructure and strength of the die sidewall induced by laser dicing. By removing all the metallization layers on the die, the complex 3PB elastoplastic stress distribution is simplified to an elastic stress distribution. This enables a straightforward calculation of the die sidewall fracture strength using the standard 3PB tensile stress equation for a homogeneous linear elastic material with a rectangular cross section. Two chemical etchants were evaluated and found to be suitable but FeCl{sub 3} is preferred because of the much faster etching time. With this improved 3PB test method, the effect of nanosecond laser dicing on ultrathin Si dies with backside Cu layer was investigated. The die frontside and backside characteristic fracture strengths of ultrathin Si dies with varying backside Cu thickness were determined and correlated to TEM analyses of the compositions and microstructures at the fracture origins.

36 MATERIALS SCIENCE↗

DOE OSTI2022

A Critical Review of the Circular Economy for Lithium-Ion Batteries and Photovoltaic Modules: Status, Challenges, and Opportunities

To meet net-zero emissions and cost targets for power production, recent analysis indicates that photovoltaic (PV) capacity in the United States could exceed 1 TW by 2050 alongside comparable levels of energy storage capacity, mostly from batteries. For comparison, the total U.S. utility-scale power capacity from all energy sources in 2020 was 1.2 TW (EIA 2022), of which solar satisfied approximately 3% (DOE 2021). With such massive scales of deployment, questions have arisen regarding issues of material supply for manufacturing, end-of-life management of technologies, environmental impacts across the life cycle, and economic costs to both individual consumers and society at large. A set of solutions to address these issues center on the development of a circular economy - shifting from a take-make-waste linear economic model to one that retains the value of materials and products as long as possible, recovering materials at end of life to recirculate back into the economy. With limited global experience, scholars and practitioners have begun to investigate circular economy pathways, focusing on applying novel technologies and analytical methods to fast-growing sectors like renewable energy. This critical review aims to synthesize the growing literature to identify key insights, gaps, and opportunities for research and implementation of a circular economy for two of the leading technologies that enable the transition to a renewable energy economy: solar PV and lithium-ion batteries (LIBs). We apply state-of-the-science systematic literature review procedures to critically analyze over 3,000 publications on the circular economy of solar PV and LIBs, categorizing those that pass a series of objective screens in ways that can illuminate the current state of the art, highlight existing impediments to a circular economy, and recommend future technological and analytical research. We conclude that while neither PV nor LIB industries have reached a circular economy, they are both on a path towards increased circularity. Based on our assessment of the state of current literature and scientific understanding, we recommend research move beyond its prior emphasis on recycling technology development to more comprehensively investigate other CE strategies, more holistically consider economic, environmental and policy aspects of CE strategies, increase leveraging of digital information systems that can support acceleration towards a CE, and to continue to study CE-related aspects of LIB and PV markets.

circular economy↗

NASA NTRS2003

A new method to evaluate human-robot system performance

One of the key issues in space exploration is that of deciding what space tasks are best done with humans, with robots, or a suitable combination of each. In general, human and robot skills are complementary. Humans provide as yet unmatched capabilities to perceive, think, and act when faced with anomalies and unforeseen events, but there can be huge potential risks to human safety in getting these benefits. Robots provide complementary skills in being able to work in extremely risky environments, but their ability to perceive, think, and act by themselves is currently not error-free, although these capabilities are continually improving with the emergence of new technologies. Substantial past experience validates these generally qualitative notions. However, there is a need for more rigorously systematic evaluation of human and robot roles, in order to optimize the design and performance of human-robot system architectures using well-defined performance evaluation metrics. This article summarizes a new analytical method to conduct such quantitative evaluations. While the article focuses on evaluating human-robot systems, the method is generally applicable to a much broader class of systems whose performance needs to be evaluated.

Space Flight/instrumentation↗

NASA NTRS2001

Advanced Methods for Aircraft Engine Thrust and Noise Benefits: Nozzle-Inlet Flow Analysis

Three connected sub-projects were conducted under reported project. Partially, these sub-projects are directed to solving the problems conducted by the HU/FM&AL under two other NASA grants. The fundamental idea uniting these projects is to use untraditional 3D corrugated nozzle designs and additional methods for exhaust jet noise reduction without essential thrust lost and even with thrust augmentation. Such additional approaches are: (1) to add some solid, fluid, or gas mass at discrete locations to the main supersonic gas stream to minimize the negative influence of strong shock waves forming in propulsion systems; this mass addition may be accompanied by heat addition to the main stream as a result of the fuel combustion or by cooling of this stream as a result of the liquid mass evaporation and boiling; (2) to use porous or permeable nozzles and additional shells at the nozzle exit for preliminary cooling of exhaust hot jet and pressure compensation for non-design conditions (so-called continuous ejector with small mass flow rate; and (3) to propose and analyze new effective methods fuel injection into flow stream in air-breathing engines. Note that all these problems were formulated based on detailed descriptions of the main experimental facts observed at NASA Glenn Research Center. Basically, the HU/FM&AL Team has been involved in joint research with the purpose of finding theoretical explanations for experimental facts and the creation of the accurate numerical simulation technique and prediction theory for solutions for current problems in propulsion systems solved by NASA and Navy agencies. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analysis for advanced aircraft and rocket engines. The F&AL Team uses analytical methods, numerical simulations, and possible experimental tests at the Hampton University campus. We will present some management activity and theoretical numerical simulation results obtained by the FM&AL Team in the reporting period in accordance with the schedule of the work.

Morgan, Morris H.↗

NASA NTRS2007

Aerospace Toxicology and Microbiology

Toxicology dates to the very earliest history of humanity with various poisons and venom being recognized as a method of hunting or waging war with the earliest documentation in the Evers papyrus (circa 1500 BCE). The Greeks identified specific poisons such as hemlock, a method of state execution, and the Greek word toxos (arrow) became the root of our modern science. The first scientific approach to the understanding of poisons and toxicology was the work during the late middle ages of Paracelsus. He formulated what were then revolutionary views that a specific toxic agent or "toxicon" caused specific dose-related effects. His principles have established the basis of modern pharmacology and toxicology. In 1700, Bernardo Ramazzini published the book De Morbis Artificum Diatriba (The Diseases of Workers) describing specific illnesses associated with certain labor, particularly metal workers exposed to mercury, lead, arsenic, and rock dust. Modern toxicology dates from development of the modern industrial chemical processes, the earliest involving an analytical method for arsenic by Marsh in 1836. Industrial organic chemicals were synthesized in the late 1800 s along with anesthetics and disinfectants. In 1908, Hamilton began the long study of occupational toxicology issues, and by WW I the scientific use of toxicants saw Haber creating war gases and defining time-dosage relationships that are used even today.

James, John T.↗

DOE OSTI2020

Analytical Study to Use the Excess Digester Gas of Wastewater Treatment Plants

This study presents an analytical method that can be used to enhance the power production rate and the energy-saving at wastewater treatment plants. The digester used at wastewater treatment plants produces digester gas by anaerobic digestion, with which biofuel production can be achieved. Biofuels can be used to meet some of the energy requirements of the wastewater treatment facility through combined heat and power (CHP) gas engines (cogeneration). Using micro gas turbine (MGT), a CHP technology can be introduced in wastewater treatment plants (WWTPs). The combination of MGTs and absorption chillers is a promising technology as it produces electricity, heating, and cooling simultaneously. The study demonstrated how the waste heat of MGTs could be used to drive absorption chillers. In this analytical study, a detailed technical and economic analysis is provided on the trigeneration system, i.e., the integration of MGTs and absorption chillers driven by waste digester gas of the wastewater treatment plants. It can meet the heating and cooling demands of the plants, which promote the reduction of utility costs. The technology presented is also useful for other thermal energy users.

09 BIOMASS FUELS↗

NASA NTRS1998

Inverse Compton Scattering in Mildly Relativistic Plasma

We investigated the effect of inverse Compton scattering in mildly relativistic static and moving plasmas with low optical depth using Monte Carlo simulations, and calculated the Sunyaev-Zel'dovich effect in the cosmic background radiation. Our semi-analytic method is based on a separation of photon diffusion in frequency and real space. We use Monte Carlo simulation to derive the intensity and frequency of the scattered photons for a monochromatic incoming radiation. The outgoing spectrum is determined by integrating over the spectrum of the incoming radiation using the intensity to determine the correct weight. This method makes it possible to study the emerging radiation as a function of frequency and direction. As a first application we have studied the effects of finite optical depth and gas infall on the Sunyaev-Zel'dovich effect (not possible with the extended Kompaneets equation) and discuss the parameter range in which the Boltzmann equation and its expansions can be used. For high temperature clusters (k(sub B)T(sub e) greater than or approximately equal to 15 keV) relativistic corrections based on a fifth order expansion of the extended Kompaneets equation seriously underestimate the Sunyaev-Zel'dovich effect at high frequencies. The contribution from plasma infall is less important for reasonable velocities. We give a convenient analytical expression for the dependence of the cross-over frequency on temperature, optical depth, and gas infall speed. Optical depth effects are often more important than relativistic corrections, and should be taken into account for high-precision work, but are smaller than the typical kinematic effect from cluster radial velocities.

Molnar, S. M.↗

DOE OSTI2017

Plant iTRAQ-based proteomics

We present a simple one-pot extraction protocol, which rapidly isolates hydrophyllic metabolites, lipids, and proteins from the same pulverized plant sample. Also detailed is a global plant proteomics sample preparation method utilizing iTRAQ multiplexing reagents that enables deep proteome coverage due to the use of HPLC fractionation of the peptides prior to mass spectrometric analysis. We have successfully used this protocol on several different plant tissues (e.g., roots, stems, leaves) from different plants (e.g., sorghum, poplar, Arabidopsis, soybean), and have been able to successfully detect and quantify thousands of proteins. Multiplexing strategies such as iTRAQ and the bioinformatics strategy outlined here, ultimately provide insight into which proteins are significantly changed in abundance between two or more groups (e.g., control, perturbation). Our bioinformatics strategy yields z-score values, which normalize the expression data into a format that can easily be cross-compared with other expression data (i.e., metabolomics, transcriptomics) obtained from different analytical methods and instrumentation.

60 APPLIED LIFE SCIENCES↗

NASA NTRS1991

Flow analysis and design optimization methods for nozzle afterbody of a hypersonic vehicle

This report summarizes the methods developed for the aerodynamic analysis and the shape optimization of the nozzle-afterbody section of a hypersonic vehicle. Initially, exhaust gases were assumed to be air. Internal-external flows around a single scramjet module were analyzed by solving the three dimensional Navier-Stokes equations. Then, exhaust gases were simulated by a cold mixture of Freon and Argon. Two different models were used to compute these multispecies flows as they mixed with the hypersonic airflow. Surface and off-surface properties were successfully compared with the experimental data. In the second phase of this project, the Aerodynamic Design Optimization with Sensitivity analysis (ADOS) was developed. Pre and post optimization sensitivity coefficients were derived and used in this quasi-analytical method. These coefficients were also used to predict inexpensively the flow field around a changed shape when the flow field of an unchanged shape was given. Starting with totally arbitrary initial afterbody shapes, independent computations were converged to the same optimum shape, which rendered the maximum axial thrust.

Baysal, Oktay↗

DOE OSTI2015

Organically bound tritium analysis in environmental samples

Organically bound tritium (OBT) has become of increased interest within the last decade, with a focus on its behaviour and also its analysis, which are important to assess tritium distribution in the environment. In contrast, there are no certified reference materials and no standard analytical method through the international organization related to OBT. In order to resolve this issue, an OBT international working group was created in May 2012. Over 20 labs from around the world participated and submitted their results for the first intercomparison exercise results on potato (Sep 2013). The samples, specially-prepared potatoes, were provided in March 2013 to each participant. Technical information and results from this first exercise are discussed here for all the labs which have realised the five replicates necessary to allow a reliable statistical treatment. The results are encouraging as the increased number of participating labs did not degrade the observed dispersion of the results for a similar activity level. Therefore, the results do not seem to depend on the analytical procedure used. From this work an optimised procedure can start to be developed to deal with OBT analysis and will guide subsequent planned OBT trials by the international group.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2021

A Review of Nuclear Forensics: 2016-2020

The study of nuclear forensics harkens back to the Manhattan Project-era, when scientists first started to analyze the debris from the 1945 Trinity test. Political turmoil stemming from the Cold War and the rehabilitation of Germany following WWII has led to new challenges in international security involving nuclear proliferation. Nuclear materials have, on occasion, been lost, misplaced, or stolen from former Soviet countries, and illicit materials have been interdicted all over the world. The National Technical Nuclear Forensics Center (NTNFC) was established in 2006, and has been at the forefront of drive to advance nuclear forensic capabilities in the United States. The ultimate goal of nuclear forensics is to examine nuclear and other radioactive materials using analytical techniques to determine origin and history of the material, particularly in the context of law enforcement investigations. Nuclear forensics can be divided into two parts: predetonation and post-detonation. Pre-detonation forensics, as the name implies, is the investigation of a nuclear material or weapon that has not been detonated or involved in an explosion, whereas postdetonation forensics is the study of activation or fission products in debris or the environment following the use of a nuclear or radiological dispersal device (RDD). Both parts require a number of analytical chemical and radiochemical techniques to determine identification of the material. Many advancements in analytical techniques, including rapidity, sample size, and forensic signatures have been made in recent years. The analytical methods that can be used in a nuclear forensic investigation, such as mass spectrometry and gamma spectroscopy, have been described in detail in previous reviews, including Straub et.al, and will not be explained here. This review will discuss recent publications (from 2016 to present) describing advancements of techniques such as radiochronometry, morphology, development of novel reference materials, and inter-laboratory collaborations for both pre- and post-detonation nuclear forensics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Mesoscale modeling and semi-analytical approach for the microstructure-aware effective thermal conductivity of porous polygranular materials

Here we established a comprehensive modeling approach for investigating the microstructure-aware effective thermal conductivity ($κ_{eff}$) for porous microstructures containing solid particles and gaseous pores. Our approach combines the mesoscale computational modeling framework and the semi-analytical method, allowing for efficient prediction of $κ_{eff}$ for realistic porous microstructures, while considering complicated microstructural thermal conduction pathways effectively in the prediction. We used the diffuse-interface mesoscale computational model to generate extensive simulated $κ_{eff}$ data for realistic digital representations of microstructures with wide ranges of porosity ($f_p$), thermal conductivity of the gas phase ($κ_g$), and thermal conductivity of the solid phase ($κ_s$). From the simulated data, we identified two property variation regimes for $κ_{eff}$: (1) a slow $κ_{eff}$ increase for $κ_s ~ κ_g$; and (2) a faster $κ_{eff}$ increase for $κ_s \gg κ_g$. To capture the key features of the relationship between the microstructure and $κ_{eff}$, we derived a semi-analytical model by introducing structure and intensification factors. The two new factors incorporate the calibrated effective contribution of the solid volume with $κ_s$ and additional interfacial effects into the prediction of $κ_{eff}$, respectively, allowing for consideration of parallel, serial, and interfacial conduction mechanisms effectively. Using the selected simulation data, we quantified key model parameters within the semi-analytical model and verified that the parameterized model exhibits excellent agreement with simulated $κ_{eff}$ for the entire range of the parameter space.

36 MATERIALS SCIENCE↗

NASA NTRS2021

Experimental and Computational Investigation of Flow Boiling in Microgravity

This study explores use of Computational Fluid Dynamics (CFD) to predict near-saturated flow boiling of FC-72 in microgravity. The computational method employs transient analysis to predict detailed interfacial behavior and heat transfer characteristics along a rectangular channel heated along two opposite walls. Predicted results are validated against experimental temperature measurements and high-speed video images captured during a series of parabolic aircraft maneuvers for three sets of operating conditions which include variations of both mass velocity and wall heat flux. The computational method is based on the multi-phase volume of fluid (VOF) model, which is combined with appropriate phase change and turbulence models, and accounts for both shear-lift force on bubbles and conjugate heat transfer along the heating walls. A key advantage of the CFD method is ability to capture details that are very difficult to measure experimentally, including detailed spatial variations of bubble shape, void fraction, mixture fluid temperature, liquid velocity, and vapor velocity, results for which are presented for each of the three test cases. Different flow regimes predicted along the heated length exhibit a number of dominant mechanisms including bubble nucleation, bubble growth, coalescence, vapor blankets, interfacial waviness, and residual liquid sub-layer, all of which agree well with experiment. Vapor velocity is shown to increase appreciably along the heated length because of increased void fraction, while liquid velocity experiences large fluctuations. Non-equilibrium effects are accentuated with increasing mass velocity, contributing minor deviations of fluid temperature from simulations compared to those predicted by the analytical method. Predicted wall temperature is fairly uniform in the middle of the heated length but increases in the entrance region, due to sensible heat transfer in the subcooled liquid, and decreases toward the exit, mostly because of flow acceleration resulting from increased void fraction.

two-phase cooling; flow boiling; CFD; microgravity↗

DOE OSTI2012

Stability Study for Ultra-Dilute Chemical Warfare Agent Standards

Ultra-dilute (10 ppm) chemical warfare agent (CWA) standards are being supplied to the Environmental Response Laboratory Network (ERLN) laboratories to allow the use of authentic standards to assist in analyses required in the aftermath of a terrorist attack with CWAs. It is critical for the ERLN laboratories to be able to work with authentic CWA standards to allow the unambiguous identification and quantification of CWAs. The ultra dilute standards are synthesized in-house for use in analytical method development by the ERLN laboratories. However, data regarding the long-term stability of the ultra-dilute standards are lacking. For this reason, a study was undertaken to monitor the concentrations of CWAs in ultra-dilute standards as a function of time, under normal conditions of storage and use. The data collected in such a study could then be used to estimate reliable holding times for the ultra-dilute standards.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2017

Characterization of Crystallographic Structures Using Bragg-Edge Neutron Imaging at the Spallation Neutron Source

Over the past decade, wavelength-dependent neutron radiography, also known as Bragg-edge imaging, has been employed as a non-destructive bulk characterization method due to its sensitivity to coherent elastic neutron scattering that is associated with crystalline structures. Several analysis approaches have been developed to quantitatively determine crystalline orientation, lattice strain, and phase distribution. In this study, we report a systematic investigation of the crystal structures of metallic materials (such as selected textureless powder samples and additively manufactured (AM) Inconel 718 samples), using Bragg-edge imaging at the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source (SNS). Firstly, we have implemented a phenomenological Gaussian-based fitting in a Python-based computer called iBeatles. Secondly, we have developed a model-based approach to analyze Bragg-edge transmission spectra, which allows quantitative determination of the crystallographic attributes. Moreover, neutron diffraction measurements were carried out to validate the Bragg-edge analytical methods. These results demonstrate that the microstructural complexity (in this case, texture) plays a key role in determining the crystallographic parameters (lattice constant or interplanar spacing), which implies that the Bragg-edge image analysis methods must be carefully selected based on the material structures.

47 OTHER INSTRUMENTATION↗

NASA NTRS2016

Monte Carlo Simulation of a Knudsen Effusion Mass Spectrometer Sampling System

Knudsen flow is easily simulated with a Monte Carlo method. In this study we develop a Visual Basic for Excel (VBA) code to simulate the molecular beam from a vaporizing solid. The system at NASA Glenn uses the restricted collimation method of Chatillon and colleagues, which consists of two apertures between the effusion cell and the ionizer. The diameter of the first aperture is smaller than the diameter of the effusion cell orifice, so the ionizer effectively only sees inside the effusion cell. The code is able to calculate the transmission coefficient through the cell orifice, through the cell orifice and the first aperture, and through the cell orifice and first and second aperatures. Calculated transmission coefficients through the cell orifice are compared to tabulated values to validate the code. Then transmission coefficients are calculated through the cell orifice and both apertures to the ionizer. This allows the geometry (aperture spacing and diameters) of the sampling system the sampling system to be optimized. Calculated transmission factors are also compared to literature values calculated via an analytic method.

Radke, Michael J.↗

NASA NTRS2020

An Overview of the Null-Field Method. II: Convergence and Numerical Stability

In this paper we provide an analysis of the convergence and numerical stability of the null-field method with discrete sources. We show that (i) if the null-field scheme is numerically stable then we can decide whether or not convergence can be achieved; (ii) if the null-field scheme is numerically unstable then we cannot draw any conclusion about the convergence issue; and (iii) the numerical stability is closely related to the property of a tangential system of radiating discrete sources to form a Riesz basis. Our numerical analysis indicates that for prolate spheroids and localized vector spherical wave functions, the null-field scheme is numerically unstable (this system of vector functions does not form a Riesz basis), while for distributed vector spherical wave functions, the numerical instability is not so pronounced (this system of discrete sources almost possesses the property of being a Riesz basis). We also describe an analytical method for computing the surface integrals in the framework of the conventional null-field method with localized vector spherical wave functions which increases the stability of the numerical scheme.

Null-field method↗

NASA NTRS1992

Resin transfer molding of textile preforms for aircraft structural applications

The NASA LaRC is conducting and supporting research to develop cost-effective fabrication methods that are applicable to primary composite aircraft structures. One of the most promising fabrication methods that has evolved is resin transfer molding (RTM) of dry textile material forms. RTM has been used for many years for secondary structures, but has received increased emphasis because it is an excellent method for applying resin to damage-tolerant textile preforms at low cost. Textile preforms based on processes such as weaving, braiding, knitting, stitching, and combinations of these have been shown to offer significant improvements in damage tolerance compared to laminated tape composites. The use of low-cost resins combined with textile preforms could provide a major breakthrough in achieving cost-effective composite aircraft structures. RTM uses resin in its lowest cost form, and storage and spoilage costs are minimal. Near net shape textile preforms are expected to be cost-effective because automated machines can be used to produce the preforms, post-cure operations such as machining and fastening are minimized, and material scrap rate may be reduced in comparison with traditional prepreg molding. The purpose of this paper is to discuss experimental and analytical techniques that are under development at NASA Langley to aid the engineer in developing RTM processes for airframe structural elements. Included are experimental techniques to characterize preform and resin behavior and analytical methods that were developed to predict resin flow and cure kinetics.

Hasko, Gregory H.↗