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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Antenna Measurements: Test & Analysis of the Radiated Emissions/Immunity of the NASA/Orion Spacecraft Dart Parachute Simulator & Prototype Capsule - The Crew Exploration Vehicle

For future NASA Manned Space Exploration of the Moon and Mars, a blunt body capsule, called the Orion Crew Exploration Vehicle (CEV), composed of a Crew Module (CM) and a Service Module (SM), with a parachute decent assembly is planned for reentry back to Earth. A Capsule Parachute Assembly System (CPAS) is being developed for preliminary prototype parachute drop tests at the Yuma Proving Ground (YPG) to simulate high-speed reentry to Earth from beyond Low-Earth-Orbit (LEO) and to provide measurements of position, velocity, acceleration, attitude, temperature, pressure, humidity, and parachute loads. The primary and secondary (backup) avionics systems on CPAS also provide mission critical firing events to deploy, reef, and release the parachutes in three stages (extraction, drogues, mains) using mortars and pressure cartridge assemblies. In addition, a Mid-Air Delivery System (MDS) is used to separate the capsule from the sled that is used to eject the capsule from the back of the drop plane. Also, high-speed and high-definition cameras in a Video Camera System (VCS) are used to film the drop plane extraction and parachute landing events. Intentional and unintentional radiation emitted from and received by antennas and electronic devices on/in the CEV capsule, the MDS sled, and the VCS system are being tested for radiated emissions/immunity (susceptibility) ~ (RE/RS). To verify Electromagnetic Compatibility (EMC) of the Orion capsule, Electromagnetic Interference (EMI) measurements are being made inside a semi-anechoic chamber at NASA/JSC on the components of the CPAS system. Measurements are made at 1m from the components-under-test (CUT). In addition, EMI measurements of the integrated CEV system are being made inside a hanger at YPG. These measurements are made in a complete circle, at 30◦ angles or less, around the Orion Capsule, the spacecraft system under-test (SUT). Near-field B-Dot probe measurements on the surface of the Orion capsule are being extrapolated outward to the 1m standard distance for comparison to the MIL-STD radiated emissions limit, and far-field hybrid antenna measurements at 3m are being extrapolated inward to the 1m distance for similar comparisons.

Norgard, John D.↗
NASA NTRSDate not supplied

Application of Advanced Earth Observations and Model Simulations to Improve Air Quality Monitoring in the Hindu-Kush-Himalayan Region

Air pollution is a serious environmental health concern in the Hindu Kush Himalayan (HKH) region of south-central Asia, as rapid industrialization and population growth have led to increased anthropogenic emissions from transportation, residential, industrial, energy, and biomass burning sources. Natural emissions from dust and forest fires are additional sources of air pollutants that can exacerbate air quality in the region. The combination of the complex pollutant mixtures and atmospherically stable weather conditions during the winter monsoon can visibility reductions and hazardous air quality from persistent haze episodes. The Kathmandu Valley is especially vulnerable to extreme haze issues due to the surrounding mountains that restrict air movement and retains pollutants in the atmosphere. This study uses state-of-the-art satellite observations and modeling capabilities in conjunction with ground-based networks to provide a comprehensive data toolkit for advancing air quality monitoring and forecasting decisions in the HKH region. The toolkit includes new generation satellite observations from the TROPOspheric Monitoring Instrument (TROPOMI), Geostationary Environment Monitoring Spectrometer (GEMS), and Advanced Meteorological Imager, which provide high spatiotemporal information on NO2, HCHO, SO2, O3, and aerosol optical depth (AOD). Particulate matter with diameters less than 2.5 micrometers (PM2.5) are derived from the satellite-retrieved AOD using ground-based observations and forecast model data. The satellite observations are also used to initialize and constrain forecast model systems designed for the HKH region. This talk will highlight the performance of the air quality toolkit for enhancing decision-making processes during exceptional air quality events in the region. Note: Presentation includes additional attachment of full presentation with sound and animation (best when viewed as slide show) with runtime of 15 min 32 secs

Aaron Naeger↗
DOE OSTI2018

Short-Pulse Photoneutron Production on Beryllium Using the Mercury Pulsed Power X-ray Source

An x-ray beam can produce neutrons using beryllium as a photoneutron converter because of the relatively low 9 Be(ɤ,n) reaction energy threshold. Previous photoneutron production simulations have focused on using a linear accelerator and heavy water to generate photoneutrons for potential medical therapies. This experimental work focused on creating a short, intense neutron pulse using the Mercury pulsed power machine at the U.S. Naval Research Laboratory, which fired a Bremsstrahlung photon beam with an energy endpoint of 4.8 MeV. Several independent detector systems were included in the experiment to measure both the characteristics of the x-ray pulse and resulting photoneutrons. We discovered the neutron pulse follows the time history of the x-ray pulse, enabling neutron pulses as short as 30 ns with less than 10% shot-to-shot variation. The approach offers a high-flux of neutrons with a higher end-point energy than using a heavy water converter. Previous experiments at Mercury have generated fission neutrons using a higher x-ray endpoint and 238 U(n,f). Results indicate that with an optimized diode and beryllium converter target design, neutron production could be further increased.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS2009

Liquid Oxygen/Liquid Methane Test Results of the RS-18 Lunar Ascent Engine at Simulated Altitude Conditions at NASA White Sands Test Facility

Tests were conducted with the RS-18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA's Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to ~122,000 ft (~37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. LO2 flow ranged from 5.9 - 9.5 lbm/sec (2.7 - 4.3 kg/sec), and LCH4 flow varied from 3.0 - 4.4 lbm/sec (1.4 - 2.0 kg/sec) during the RS-18 hot-fire test series. Propellant flow rate was measured using a coriolis mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup due to two-phase flow effects. Subsequent cold-flow testing demonstrated that the propellant manifolds must be adequately flushed in order for the coriolis flow meters to give accurate data. The coriolis flow meters were later shown to provide accurate steady-state data, but the turbine flow meter data should be used in transient phases of operation. Thrust was measured using three load cells in parallel, which also provides the capability to calculate thrust vector alignment. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes. All of these objectives were met with the RS-18 data and additional testing data from subsequent LO2/methane test programs in 2009 which included the first simulated-altitude pyrotechnic ignition demonstration of LO2/methane.

Melcher, John C., IV↗
DOE OSTI2022

Two-stage membrane-based process utilizing highly CO 2 -selective membranes for cost and energy efficient carbon capture from coal flue gas: A process simulation study

Membrane technology for CO 2 capture has become an attractive strategy due to its cost and energy efficiency and low materials costs. In the past decade, membrane-based process designs for post-combustion power plant CO 2 capture have been developed, utilizing existing highly CO 2 -permeable membranes with relatively low CO 2 /N 2 selectivity (<50), and have obtained reasonably economic carbon capture. However, few membrane-based process designs were proposed for moderate to highly CO 2 -selective membranes (CO 2 /N 2 selectivity of 50–300, and >300, respectively), which have vastly emerged in recent years, such as various facilitated transport membranes (FTMs). Herein, we proposed a two-stage membrane-base process design targeting economic carbon capture from coal-fired flue gas. This process design features the utilization of highly CO 2 -selective membranes for one-stage CO 2 enrichment to 95% dry-base purity in the first stage and recycle of the remaining CO 2 by a highly CO 2 -permeable membrane in the second stage, in order to achieve economic CO 2 capture with 90% capture rate and >95% CO 2 product purity. Through an integration-iteration membrane model and the Aspen Plus process simulation, a sensitivity study of operating pressures (feed and permeate pressures) and membrane properties (CO 2 permeance and CO 2 /N 2 selectivity) was conducted. Critical CO 2 /N 2 selectivity of 300–400 was found for the highly CO 2 -selctive membranes to meet the demand for cost and energy efficient results. The lowest possible membrane area of 4.8 × 10 5 m 2 and fractional energy of 19.3% were obtained, which is comparable to or even more attractive than reported membrane-based process designs. Here, this work provides a new membrane process design option for highly CO 2 -selective membranes and gives insights on the influence of membrane performance and operation condition.

42 ENGINEERING↗
DOE OSTI2022

Predictive modeling of a subcritical pulverized-coal power plant for optimization: Parameter estimation, validation, and application

As renewable power generation deployment increases, fossil fuel plants are increasingly required to operate more flexibly. Many coal-fired power plants were originally designed to operate at base load and do not operate optimally at partial load. Predictive first-principles plant-wide models can be employed to identify opportunities for flexibility improvements and diagnose low-load operating issues. This paper describes the application of the Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES) to model and optimize flexible power plant operations. The key benefits of using IDAES are that it provides an open-source, fully equation-oriented modeling framework for efficient modular model construction, reuse, and customization, together with a mathematical optimization framework leveraging powerful, state-of-the-art solvers. The process systems engineering workflow from predictive process simulation to parameter estimation, model validation, and plant optimization is applicable to a variety of existing and next-generation energy systems as well as other chemical and environmental processes. Here, to demonstrate this capability, a physics-based, steady-state model was developed to improve full- and part-load performance of the Escalante Generating Station, a 245 MWe (net) subcritical pulverized coal-fired power plant owned and operated by Tri-State Generation and Transmission Association. Specifically, sixty-nine model parameters were simultaneously estimated from several months of operating data enabling prediction of flow rates, temperatures, pressures, and steam quality throughout the plant. The validated model was leveraged by Escalante to reduce the minimum operating load from 90 MW to 50 MW by diagnosing a low-load water-hammer issue, enabling coal usage and emissions reductions during periods of low power demand. Additionally, opportunities for heat rate reduction (i.e., efficiency improvement) through a steeper sliding-pressure approach to load-following and optimization of other boiler operating variables were also identified and quantified. For example, a potential efficiency improvement of 0.7 percentage points was observed at half-load operation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

(U) The Effects of Impurities on Detonator Bridge Performance

The primary route for impurities to impact bridge performance is through an increase in resistivity leading to premature bridge burst resulting in both decreased burst time and burst current. Changes in burst time could increase timing error while a decrease in burst current could reduce the firing margin. The most consistent results may be achieved by the minimization of impurities. However, since complete elimination is not practical, a practical production specification approach is presented. Further, since specification limits should be based on performance, a practical approach to estimate and simulate the effects of impurities is also provided using the existing Davis Bridge Burst Model.

42 ENGINEERING↗
NASA NTRS1991

Experimental investigation of a solid rocket combustion simulator

The response of solid rocket motor materials to high-temperature corrosive gases is usually accomplished by testing the materials in a subscale solid rocket motor. While this imposes the proper thermal and chemical environment, a solid rocket motor does not provide practical features that would enhance systematic evaluations such as: the ability to throttle for margin testing, on/off capability, low test cost, and a low-hazards test article. Solid Rocket Combustion Simulators (SRCS) are being evaluated by NASA to test solid rocket nozzle materials and incorporate these essential practical features into the testing of rocket materials. The SRCS is designed to generate the thermochemical environment of a solid rocket. It uses hybrid rocket motor technology in which gaseous oxygen (Gox) is injected into a chamber containing a solid fuel grain. Specific chemicals are injected in the aft mixing chamber so that the gases entering the test section match the temperature and a non-dimensional erosion factor B' to insure similarity with a solid motor. Because the oxygen flow can be controlled, this approach allows margin testing, the ability to throttle, and an on/off capability. The fuel grains are inert which makes the test article very safe to handle. The objective of this work was to establish the baseline operating characteristics of a Labscale Solid Rocket Combustion Simulator (LSRCS). This included establishing the baseline burning rates of plexiglass fuels and the evaluation of a combustion instability for hydroxy-terminated polybutadyene (HTPB) propellants. The scope of the project included: (1) activation of MSFC Labscale Hybrid Combustion Simulator; (2) testing of plexiglass fuel at Gox ranges from 0.025 to 0.200 lb/s; (3) burning HTPB fuels at a Gox rate of 0.200 lb/s using four different mixing chamber configurations; and (4) evaluating the fuel regression and chamber pressure responses of each firing.

Frederick, Robert A., Jr.↗
NASA NTRS1993

Monte Carlo simulation of radiating reentry flows

The Direct Simulation Monte Carlo (DSMC) method is applied to a radiating, hypersonic, axisymmetric flow over a blunt body in the near continuum regime. The ability of the method to predict the flowfield radiation and the radiative heating is investigated for flow over the Project Fire II configuration at 11.36 kilometers per second at an altitude of 76.42 kilometers. Two methods that differ in the manner in which they treat ionization and estimate electronic excitation are employed. The calculated results are presented and compared with both experimental data and solutions where radiation effects were not included. Differences in the results are discussed. Both methods ignore self absorption and, as a result, overpredict measured radiative heating.

Taylor, Jeff C.↗
NASA NTRS1996

Time Varying Compensator Design for Reconfigurable Structures Using Non-Collocated Feedback

Analysis and synthesis tools are developed to improved the dynamic performance of reconfigurable nonminimum phase, nonstrictly positive real-time variant systems. A novel Spline Varying Optimal (SVO) controller is developed for the kinematic nonlinear system. There are several advantages to using the SVO controller, in which the spline function approximates the system model, observer, and controller gain. They are: The spline function approximation is simply connected, thus the SVO controller is more continuous than traditional gain scheduled controllers when implemented on a time varying plant; ft is easier for real-time implementations in storage and computational effort; where system identification is required, the spline function requires fewer experiments, namely four experiments; and initial startup estimator transients are eliminated. The SVO compensator was evaluated on a high fidelity simulation of the Shuttle Remote Manipulator System. The SVO controller demonstrated significant improvement over the present arm performance: (1) Damping level was improved by a factor of 3; and (2) Peak joint torque was reduced by a factor of 2 following Shuttle thruster firings.

Scott, Michael A.↗
NASA NTRS2014

Building the Fire Energetics and Emissions Research (FEER) Smoke Emissions Inventory Version 1.0

The Fire Energetics and Emissions Research (FEER) group's new coefficient of emission global gridded product at 1x1 resolution that directly relates fire readiative energy (FRE) to smoke aerosol release, FEERv1.0 Ce, made its public debut in August 2013. Since then, steps have been taken to generate corresponding maps and totals of total particulate matter (PM) emissions using different sources of FRE, and subsequently to simulate the resulting PM(sub 2.5) in the WRF-Chem 3.5 model using emission rates from FEERv1.0 as well as other standard biomass burning emission inventories. An flowchart of the FEER algorithm to calculate Ce is outlined here along with a display of the resulting emissions of total PM globally and also regionally. The modeling results from the WRF-Chem3.5 simulations are also shown.

particulate matter↗
NASA NTRS2015

3-D CFD Simulation and Validation of Oxygen-Rich Hydrocarbon Combustion in a Gas-Centered Swirl Coaxial Injector using a Flamelet-Based Approach

Injector design is a critical part of the development of a rocket Thrust Chamber Assembly (TCA). Proper detailed injector design can maximize propulsion efficiency while minimizing the potential for failures in the combustion chamber. Traditional design and analysis methods for hydrocarbon-fuel injector elements are based heavily on empirical data and models developed from heritage hardware tests. Using this limited set of data produces challenges when trying to design a new propulsion system where the operating conditions may greatly differ from heritage applications. Time-accurate, Three-Dimensional (3-D) Computational Fluid Dynamics (CFD) modeling of combusting flows inside of injectors has long been a goal of the fluid analysis group at Marshall Space Flight Center (MSFC) and the larger CFD modeling community. CFD simulation can provide insight into the design and function of an injector that cannot be obtained easily through testing or empirical comparisons to existing hardware. However, the traditional finite-rate chemistry modeling approach utilized to simulate combusting flows for complex fuels, such as Rocket Propellant-2 (RP-2), is prohibitively expensive and time consuming even with a large amount of computational resources. MSFC has been working, in partnership with Streamline Numerics, Inc., to develop a computationally efficient, flamelet-based approach for modeling complex combusting flow applications. In this work, a flamelet modeling approach is used to simulate time-accurate, 3-D, combusting flow inside a single Gas Centered Swirl Coaxial (GCSC) injector using the flow solver, Loci-STREAM. CFD simulations were performed for several different injector geometries. Results of the CFD analysis helped guide the design of the injector from an initial concept to a tested prototype. The results of the CFD analysis are compared to data gathered from several hot-fire, single element injector tests performed in the Air Force Research Lab EC-1 test facility located at Edwards Air Force Base.

Richardson, Brian↗
DOE OSTI2017

Historical and Projected Trends in Landscape Drivers Affecting Carbon Dynamics in Alaska

Modern climate change in Alaska has resulted in widespread thawing of permafrost, increased fire activity, and extensive changes in vegetation characteristics that have significant consequences for socio-ecological systems. Despite observations of the heightened sensitivity of these systems to change, there has not been a comprehensive assessment of factors that drive ecosystem changes throughout Alaska. In this paper, we present research that improves our understanding of the main drivers of the spatiotemporal patterns of carbon dynamics using in situ observations, remote sensing data, and an array of modeling techniques. In the last 60 years, Alaska has seen a large increase in mean annual air temperature (1.7 °C), with the greatest warming occurring over winter and spring. Warming trends are projected to continue throughout the 21st century and will likely result in landscape-level changes to ecosystem structure and function. Wetlands, mainly bogs and fens, which are currently estimated to cover 12.5% of the landscape, strongly influence exchange of methane between Alaska's ecosystems and the atmosphere and are expected to be affected by thawing permafrost and shifts in hydrology. Simulations suggest the current proportion of near-surface (within 1 m) and deep (within 5 m) permafrost extent will be reduced by 9–74% and 33–55% by the end of the 21st century, respectively. Since 2000, an average of 678,595 ha/yr was burned, more than twice the annual average during 1950–1999. The largest increase in fire activity is projected for the boreal forest, which could result in a reduction in late-successional spruce forest (8–44%) and an increase in early-succession deciduous forest (25–113%) that would mediate future fire activity and weaken permafrost stability in the region. Climate warming will also affect vegetation communities across arctic regions, where the coverage of deciduous forest could increase (223–620%), shrub tundra may increase (4–21%), and graminoid tundra might decrease (10–24%). Finally, this study sheds light on the sensitivity of Alaska's ecosystems to change that has the potential to significantly affect local and regional carbon balance, but more research is needed to improve estimates of land-surface and subsurface properties, and to better account for ecosystem dynamics affected by a myriad of biophysical factors and interactions.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2021

Extreme Ozone Loss Following Nuclear War Results in Enhanced Surface Ultraviolet Radiation

For the first time, we use a modern climate model with interactive chemistry including the effects of aerosols on photolysis rates to simulate the consequences of regional and global scale nuclear wars (injecting 5 and 150 Tg of soot respectively) for the ozone layer and surface ultraviolet (UV) light. For a global nuclear war, heating in the stratosphere, reduced photolysis, and an increase in catalytic loss from the Hox cycle cause a 15 year-long reduction in the ozone column, with a peak loss of 75% globally and 65% in the tropics. This is larger than predictions from the 1980s, which assumed large injections of nitrogen oxides (NOx),but did not include the effects of smoke. NOx from the fireball and the fires provide a small (5%) Increase to the global average ozone loss for the first few years. Initially, soot would shield the surface from UV-B, but UV Index values would become extreme: greater than 35in the tropics for 4years, and greater than 45during the summer in the southern polar regions for 3 years. For a regional war, global column ozone would be reduced by 25% with recovery taking 12 years. This is similar to previous simulations, but with a faster recovery time due to a shorter lifetime for soot in our simulations. In-line photolysis provides process specific action spectra enabling future integration with biogeochemistry models and allows output that quantifies the potential health impacts from changes in surface UV for this and other larger aerosol injections.

nuclear war↗
DOE OSTI2018

Development of Intelligent Monitoring System (IMS) Modules for the Aquistore CO 2 Storage Project

The monitoring data generated at a CO 2 storage site can quickly result in large amounts of data, often requiring significant labor- and time-intensive efforts to process and analyze before being able to make operational decisions. Implementing an intelligent monitoring system (IMS) can reduce the associated data-processing and analysis costs, which can thereby improve the efficiency of the monitoring process and enable real-time operational decision-making. The Energy & Environmental Research Center (EERC) has completed a 3-year project focused on developing an IMS comprising new workflows, algorithms, and a user interface for the automation and integration of geologic carbon dioxide (CO 2 ) storage site-monitoring and simulation data. The design for the IMS was based on using injection and monitoring data acquired from Aquistore, an operating CO 2 storage project. Managed by the Petroleum Technology Research Centre, the Aquistore Project is injecting CO 2 captured from SaskPower’s coal-fired Boundary Dam Power Station into a deep saline formation for geologic storage. Using data from the Aquistore Project provided a real-world basis to develop an IMS.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

CO 2 and Renewable Electricity into Chemicals: Formic Acid Production from Coal Flue Gas

Formic acid (FA) is an industrial chemical. It is used as a preservative for silage, as a digestive aid for animals, as a fluid for fracking, as a pharmaceutical intermediate and in leather tanning. The global formic acid market is valued at 777.4 million USD in 2020 and is expected to reach 851.8 million USD by the end of 2026. A new major formic acid application is the use of formic acid as a key feedstock for the bioprocessing industry. It has the potential to grow tremendously if we can lower the cost of formic acid production compared with the current fossil-fuel one. Recently, Dioxide Materials has developed a technology that can directly convert CO 2 to pure formic acid with a three-compartment CO 2 electrolyzer. However, the electrolyzer performance needs further improvement for the technology to be commercially viable. The major objective of this project is to develop the electrolyzer technology to enable formic acid as a feedstock for the bioprocessing industry to be economically manufactured from flue gas from a coal fired pilot plant. In particular, the project is to understand how to run the electrolyzer for the conversion of CO 2 into formic acid using flue gas from a coal fired power plant as a source of CO 2 . The work will include characterizing how the performance of the electrolyzer changes with low CO 2 concentration and impurities, developing new cell designs that can still operate with feedstocks with low CO 2 concentrations, testing simulated flue gas in the electrolyzer system and developing filters to remove any impurities that arise.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRSDate not supplied

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System↗
DOE OSTI2015

Low cost back contact heterojunction solar cells on thin c-Si wafers. Integrating laser and thin film processing for improved manufacturability

An interdigitated back contact (IBC) Si wafer solar cell with deposited a-Si heterojunction (HJ) emitter and contacts is considered the ultimate single junction Si solar cell design. This was confirmed in 2014 by both Panasonic and Sharp Solar producing IBC-HJ cells breaking the previous record Si solar cell efficiency of 25%. But manufacturability at low cost is a concern for the complex IBC-HJ device structure. In this research program, our goals were to addressed the broad industry need for a high-efficiency c-Si cell that overcomes the dominant module cost barriers by 1) developing thin Si wafers synthesized by innovative, kerfless techniques; 2) integrating laser-based processing into most aspects of solar cell fabrication, ensuring high speed and low thermal budgets ; 3) developing an all back contact cell structure compatible with thin wafers using a simplified, low-temperature fabrication process; and 4) designing the contact patterning to enable simplified module assembly. There were a number of significant achievements from this 3 year program. Regarding the front surface, we developed and applied new method to characterize critical interface recombination parameters including interface defect density Dit and hole and electron capture cross-section for use as input for 2D simulation of the IBC cell to guide design and loss analysis. We optimized the antireflection and passivation properties of the front surface texture and a-Si/a-SiN/a-SiC stack depositions to obtain a very low (< 6 mA/cm2) front surface optical losses (reflection and absorption) while maintaining excellent surface passivation (SRV<5 cm/s). We worked with kerfless wafer manufacturers to apply defect-engineering techniques to improve bulk minority-carrier lifetime of thin kerfless wafers by both reducing initial impurities during growth and developing post-growth gettering techniques. This led insights about the kinetics of nickel, chromium, and dislocations in PV-grade silicon and to achieving millisecond lifetimes in kerfless silicon materials. Laser fired contacts to n-Si were developed for the first time using a Al/Sb/Ti metal stack giving contact resistances < 5 mOhm-cm2 when fired through several different dielectric layers. A new 2 step laser+chemical etch isolation technique was developed using a sacrificial top coating which avoids laser damage to Si passivation. Regarding the heterojunction emitter, analysis of front FHJ (1D) and IBC (2D) cells with range of p-layer conditions found that a 2-stage high/low doped p-layer was optimum: the low doped region has lower defects giving higher Voc and the high doped region gave a better contact to the metal. A significant effort was spent studying the patterning process and its contribution to degradation of passivation and reproducibility. Several promising new cleaning, contact and deposition patterning and processing approaches were implemented leading to fabrication of several runs with cells having 19-20% efficiency which were stable over several months. This program resulted in the training and support of 12 graduate students, publication of 21 journal papers and 14 conference papers.

14 SOLAR ENERGY↗