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The paper discusses some of the lessons learned in research and development of high performance thermoelectric materials. Discussion is on optimizing existing thermoelectric materials and considerations for development of new materials.
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A set of convenient thermoelectric device solutions have been derived in order to capture a number of factors which are previously only resolved with numerical techniques. The concise conversion efficiency equations derived from governing equations provide intuitive and straight-forward design guidelines. These guidelines allow for better device design without requiring detailed numerical modeling. The analytical modeling accounts for factors such as i) variable temperature boundary conditions, ii) lateral heat transfer, iii) temperature variable material properties, and iv) transient operation. New dimensionless parameters, similar to the figure of merit, are introduced including the device design factor, fin factor, thermal diffusivity factor, and inductance factor. These new device factors allow for the straight-forward description of phenomenon generally only captured with numerical work otherwise. As an example a device design factor of 0.38, which accounts for thermal resistance of the hot and cold shoes, can be used to calculate a conversion efficiency of 2.28 while the ideal conversion efficiency based on figure of merit alone would be 6.15. Likewise an ideal couple with efficiency of 6.15 will be reduced to 5.33 when lateral heat is accounted for with a fin factor of 1.0.
The measurement of Seebeck coefficient and electrical resistivity are critical to the investigation of all thermoelectric systems. Therefore, it stands that the measurement uncertainty must be well understood to report ZT values which are accurate and trustworthy. A detailed uncertainty analysis of the ZEM-3 measurement system has been performed. The uncertainty analysis calculates error in the electrical resistivity measurement as a result of sample geometry tolerance, probe geometry tolerance, statistical error, and multi-meter uncertainty. The uncertainty on Seebeck coefficient includes probe wire correction factors, statistical error, multi-meter uncertainty, and most importantly the cold-finger effect. The cold-finger effect plagues all potentiometric (four-probe) Seebeck measurement systems, as heat parasitically transfers through thermocouple probes. The effect leads to an asymmetric over-estimation of the Seebeck coefficient. A thermal finite element analysis allows for quantification of the phenomenon, and provides an estimate on the uncertainty of the Seebeck coefficient. The thermoelectric power factor has been found to have an uncertainty of +9-14 at high temperature and 9 near room temperature.
Traditional silicon germanium high temperature thermoelectrics have potential for improvements in figure of merit via nano-structuring with a silicide phase. A second phase of nano-sized silicides can theoretically reduce the lattice component of thermal conductivity without significantly reducing the electrical conductivity. However, experimentally achieving such improvements in line with the theory is complicated by factors such as control of silicide size during sintering, dopant segregation, matrix homogeneity, and sintering kinetics. Samples are prepared using powder metallurgy techniques; including mechanochemical alloying via ball milling and spark plasma sintering for densification. In addition to microstructural development, thermal stability of thermoelectric transport properties are reported, as well as couple and device level characterization.
The Mars Science Laboratory (MSL) rover was launched on an Atlas V on November 26, 2011. Preparations were carried out prior to launch in order to closeout the spacecraft's complex heat rejection system (HRS), which consists of two mechanically pumped CFC-11 fluid loops. The first HRS loop, onboard the Curiosity rover, was fully integrated, filled with CFC-11, and successfully operated prior to launch pad operations; however, the second thermal loop, called the cruise HRS loop, required final mechanical and thermal integration activities to occur while on the launch pad in order to accommodate the last minute installation of the rover's Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) power source. In order to prevent overheating of propellant tanks and critical avionics equipment buried deep within the spacecraft's aeroshell, the MMRTG needed to be pre-cooled using a separate non-flight mechanically pumped fluid loop prior to and during the final closeout and subsequent startup of the flight loop. This paper outlines the various steps that took place to safely install the MMRTG while carefully transitioning from the pre-cooling operation to the final startup and operation of the flight cruise HRS loop. Temperature data of the launch pad thermal transition from the ground support loop activity to the final flight loop operation is presented. Some background development of the ground support loop and lessons learned are also discussed. This successful launch pad integration activity required a close-knit coordination between NASA KSC, JPL, the Department of Energy, Idaho National Labs, Pratt and Whitney Rocketdyne Inc., Teledyne Technologies Inc., ULA, and Advanced Thermal Sciences Corp.
After 39 years of continuous operation in space, the output of the Voyager 1 & 2 spacecraft Radioisotope Thermoelectric Generator (RTG) power systems has decreased to the point where managing the power margin and maintaining thermal control has become increasingly difficult. As the total power dissipation in the bus has decreased, propellant line temperatures and margin above minimum Allowable Flight Temperature (AFT) have decreased, creating risk of the hydrazine freezing (at 1.6°C). This is further complicated by the lack of existing thermal models that can be used to assess propellant tank and line temperatures. In 2014, an effort was begun to create a Voyager spacecraft thermal model for that purpose. A steady-state Thermal Desktop model has been created from scratch over the past two years. Applied Sciences Laboratory (ASL) started the initial thermal model development under contract to Jet Propulsion Laboratory (JPL). The effort relied primarily on archived manufacturing drawings, limited documentation, interviews of senior engineers who worked on the Voyager design and implementation, and the experience of the Voyager Flight Operations team. Data from the Voyager System Thermal Vacuum (STV) tests is no longer available, making it necessary to correlate the model to more recent flight data and small in-flight tests. Correlation was achieved to within ±5°C for a hot case and a cold case (both data sets from 2014). However, the flight system has very few temperature sensors directly on propellant lines. Therefore, the task remains to determine how best to use the model, in conjunction with flight data, to make sure the Voyagers can continue to fly successfully.
INL has evaluated and refurbished General Purpose Heat Source (GPHS) Radioisotope Thermoelectric Generator (RTG) Flight Unit 5 (GPHS-RTG F5R or F5R) that was defueled in 2005. The generator has passed all the INL internal reviews, an end item data package has been delivered to NASA and is ready fueling for a mission. NASA requested a user’s guide for F5R with enough detail for a prospective mission proposal. This report documents the development of the power prediction model used in the user’s guide. The prediction evaluated the thermoelectric “burn-in” and the graceful degradation modes of the missions and developed a thermal inventory dependent equation that predicts the power that matches Galileo, Cassini, and PNH within a three-standard deviation of ±1%. This prediction is only valid for the 30 VDC load voltage of these missions.
INL has evaluated and refurbished General Purpose Heat Source (GPHS) Radioisotope Thermoelectric Generator (RTG) Flight Unit 5 (GPHS-RTG F5R or F5R) that was defueled in 2005. The generator has passed all the INL internal reviews, an end item data package has been delivered to NASA and is ready fueling for a mission. NASA requested a user’s guide for F5R with enough detail for a prospective mission proposal. This report documents the development of the power prediction model used in the user’s guide. The prediction evaluated the thermoelectric “burn-in” and the graceful degradation modes of the missions and developed a thermal inventory dependent equation that predicts the power that matches Galileo, Cassini, and PNH within a three-standard deviation of ±1%. This prediction is only valid for the 30 VDC load voltage of these missions.
Radioisotope Thermoelectric Generators (RTGs) were extensively used in past space missions with great success. An improved generation of RTGs employing a new lightweight, modular heat source is being built by the DOE for NASA launches in 1986. More advanced modular RTGs which promise power-to-weight ratios of over 8.8 watts(e)/kg (4 watts(e)/lb) are currently under development by the DOE and could be flight-ready within five years. Dynamic Isotope Power Systems (DIPS) which offer 18-20% conversion efficiencies were demonstrated by the DOE in ground tests. DIPS would be useful for several military missions requiring power in the low-kilowatt range. These systems could also be brought to flight readiness by the DOE following receipt of firm user requirements.
Under NASA's Project Prometheus, the Nuclear Systems Program, the Jet Propulsion Laboratory, Pratt & Whitney Rocketdyne, and Teledyne Energy Systems have teamed with a number of universities, under the Segmented Thermoelectric Multicouple Converter (STMC) program, to develop the next generation of advanced thermoelectric converters for space reactor power systems. Work on the STMC converter assembly has progressed to the point where the lower temperature stage of the segmented multicouple converter assembly is ready for laboratory testing and the upper stage materials have been identified and their properties are being characterized. One aspect of the program involves mission application studies to help define the potential benefits from the use of these STMC technologies for designated NASA missions such as the lunar base power station where kilowatts of power are required to maintain a permanent manned presence on the surface of the moon. A modular 50 kWe thermoelectric power station concept was developed to address a specific set of requirements developed for this mission. Previous lunar lander concepts had proposed the use of lunar regolith as in-situ radiation shielding material for a reactor power station with a one kilometer exclusion zone radius to minimize astronaut radiation dose rate levels. In the present concept, we will examine the benefits and requirements for a hermetically-sealed reactor thermoelectric power station module suspended within a man-made lunar surface cavity. The concept appears to maximize the shielding capabilities of the lunar regolith while minimizing its handling requirements. Both thermal and nuclear radiation levels from operation of the station, at its 100-m exclusion zone radius, were evaluated and found to be acceptable. Site preparation activities are reviewed and well as transport issues for this concept. The goal of the study was to review the entire life cycle of the unit to assess its technical problems and technology needs in all areas to support the development, deployment, operation and disposal of the unit.
Bonding process, bond failure mechanisms, and braze and shoe system for lead telluride thermoelectric materials in power generation devices
Radioisotope thermoelectric generator with lead telluride converter, discussing intact reentry and impact capability, refractory construction and reliability
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Radioisotope thermoelectric generators (RTGs) running off the radioisotope Pu238 are the current standard in deep space probe power supplies. While reliable, these generators are very inefficient, operating at only approx.7% efficiency. As an alternative, more efficient radioisotope thermionic emission generators (RTIGs) are being explored. Like RTGs, current RTIGs concepts use exotic materials for the emitter, limiting applicability to space and other niche applications. The high demand for long-lasting mobile power sources would be satisfied if RTIGs could be produced inexpensively. This work focuses on exposing several common materials, such as Al, stainless steel, W, Si, and Cu, to elevated temperatures under vacuum to determine the efficiency of each material as inexpensive replacements for thermoelectric materials.
Tailoring the solar absorptivity (alpha(sub s)) and thermal emissivity (epsilon(sub T)) of materials constitutes an innovative approach to solar energy control and energy conversion. Numerous ceramic and metallic materials are currently available for solar absorbance/thermal emittance control. However, conventional metal oxides and dielectric/metal/dielectric multi-coatings have limited utility due to residual shear stresses resulting from the different coefficient of thermal expansion of the layered materials. This research presents an alternate approach based on nanoparticle-filled polymers to afford mechanically durable solar-absorptive and thermally-emissive polymer nanocomposites. The alpha(sub s) and epsilon(sub T) were measured with various nano inclusions, such as carbon nanophase particles (CNPs), at different concentrations. Research has shown that adding only 5 wt% CNPs increased the alpha(sub s) and epsilon(sub T) by a factor of about 47 and 2, respectively, compared to the pristine polymer. The effect of solar irradiation control of the nanocomposite on solar energy conversion was studied. The solar irradiation control coatings increased the power generation of solar thermoelectric cells by more than 380% compared to that of a control power cell without solar irradiation control coatings.
The Apollo Lunar Surface Experiments Package (ALSEP) measures lunar physical and environmental characteristics and transmits the data to receiving stations on earth. The data are used to derive information on the composition and structure of the moon. The electrical power subsystem generates and conditions all the electrical power for operations of the ALSEP system. The power source for the ALSEP is the Systems for Nuclear Auxiliary Power (SNAP) Radioisotope Thermoelectric Generator (RTG). The generator produces electricity by thermoelectric conversion. The radioactive isotope plutonium 238 is used as the energy source for the SNAP-27. By April 1, 1970, the SNAP-27 RTG had produced more than 230 kWh of continuous and stable power for the ALSEP.-