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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 145 records · Page 8

Landsat Legacy

The Landsat resources survey system spawned a number of companies engaged in commercial applications of remote sensing, among them International Imaging Systems (I2S). With initial NASA assistance, I2S has provided remote sensing hardware and software to several foreign countries, developed meteorological analysis systems, medical diagnostic software and scanning equipment for government and commercial use. Latest product is an advanced image-based photogrammetric system employing digital technology - not optical or mechanical systems - to generate terrain elevation data and other processing functions. Called PRI2SM, it compensates automatically for topographic relief displacement, is cheaper, faster, and easier to use and maintain. Company product line includes four major areas: image processing equipment for Earth Resources Management; meteorological analysis systems; satellite ground processing systems; and digital photogrammetric mapping systems.

Source record↗

Application of a Heat Integrated Post-combustion CO 2 Capture System with Hitachi Advanced Solvent into Existing Coal-Fired Power Plant (Final Technical Report)

The goal of this final project report is to comprehensively summarize the work conducted on project DE-FE0007395. In accordance with the Project Management Plan (PMP), Revision F dated 5/10/2019, and Statement of Project Objectives (SOPO) within, the University of Kentucky (UK) Center for Applied Energy Research (CAER) (Recipient) has successfully demonstrated a unique, versatile CO 2 capture system (CCS) using a heat integrated process combined with two-stage stripping for process intensification, heat recovery and demineralized (DM) water generation. This project involved the design, fabrication, installation, testing of and data analysis from the UK CAER 0.7 MWe small pilot scale CO2 capture process installed at Kentucky Utilities (KU) E.W. Brown Generating Station in Harrodsburg, KY. During each of the four project Budget Periods (BPs), UK CAER met all project deliverables, all project milestones, with National Energy Technology Laboratory (NETL) approved adjustments made to the campaign long-term hours during BP4. The CCS was constructed in modular skids. Two solvent campaigns were initially conducted; the first with a 30 wt% monoethanolamine (MEA) as a baseline, and the second with the Hitachi H3-1 advanced solvent. Additional tests were performed with two advanced solvents including CAER and Proprietary Solvent C. Short-period testing with a higher concentration of 40 wt% MEA was conducted to evaluate the potential saving with high alkalinity. From the various solvent campaigns, unique aspects of the UK CAER CCS technology, as well as its flexibility and versatility were experimentally validated and demonstrated. With respect to solvent evaluation efforts in identifying candidates with significant operational and capital cost savings potential, performance of solvents were evaluated to determine the energy requirements for regeneration; environmental impacts from secondary emissions and degradation products; degradation rates, solvent make-up rates and stability. The assessments were done from parametric tests that determined optimum operating conditions for the individual solvents to maximize process efficiency and minimize the parasitic load of the power plant, and from long term campaigns (1000 hours for 30 wt% MEA and 1000 hours for H3-1) which collectively informed the techno-economic analyses (TEA) of the process. The long term campaigns included corrosion studies which used three types of metal coupons in different sections of the process: (absorber, primary stripper, lean carbon-loaded and rich carbon loaded flow streams in process) to mimic heat and flow dynamics process equipment were exposed to. The estimated corrosion rates were used to elucidate corrosion mechanisms and to further guide process material selection for potential capital cost savings.

gas separation↗

Pyrotechnic hazards classification and evaluation program. Phase 2, segment 3: Test plan for determining hazards associated with pyrotechnic manufacturing processes

A comprehensive test plan for determining the hazards associated with pyrotechnic manufacturing processes is presented. The rationale for each test is based on a systematic analysis of historical accounts of accidents and a detailed study of the characteristics of each manufacturing process. The most hazardous manufacturing operations have been determined to be pressing, mixing, reaming, and filling. The hazard potential of a given situation is evaluated in terms of the probabilities of initiation, communication, and transition to detonation (ICT). The characteristics which affect the ICT probabilities include the ignition mechanisms which are present either in normal or abnormal operation, the condition and properties of the pyrotechnic material, and the configuration of the processing equipment. Analytic expressions are derived which describe the physical conditions of the system, thus permitting a variety of processes to be evaluated in terms of a small number of experiments.

Source record↗

Improved Gamma-and X-Ray Pinhole Camera

Electronic additions increase image quality. Digital image-processing equipment electronically performs functions of S1 and D2 improving resolution and adding capability for image storage and further processing. System useful in nuclear medicine or radioisotope imaging, tomography and nuclear industry.

Yin, L. I.↗

Making Highly Pure Glass Rods

Proposed quasi-containerless method for making glass rods or fibers minimizes contact between processing equipment and product. Method allows greater range of product sizes and shapes than achieved in experiments on containerless processing. Molten zone established in polycrystalline rod. Furnace sections separated, and glass rod solidifies between them. Clamp supports solid glass as it grows in length. Pulling clamp rapidly away from melt draws glass fiber. Fiber diameter controlled by adjustment of pulling rate.

Naumann, R. J.↗

Ad-Mat: Adaptations of Mature Manufacturing Strategies for Accelerated Redox Flow Battery Deployment

The concept of the Ad-Mat approach is to leverage existing adjacent markets across a broad scope of technologies in order to reduce the manufacturing learning curve and ultimately accelerate redox flow battery (RFB) deployment at scale. Lithium-ion batteries (LIBs) are currently the dominant energy storage technology, and they came to technological maturity under unique market conditions when there was no meaningful competition in the consumer electronic and electric vehicle (EV) space. Today, alternative chemistries that may be technologically better-suited for long-duration storage applications are experiencing a high barrier to entry. This is in large part due to the substantial bias towards the scaled-up production and supply chain that now exists for LIBs. In the case of RFBs in particular, numerous analyses have suggested that RFBs should theoretically have a much lower system cost than LIBs - however, this relies on a mature and competitive manufacturing landscape, which has been extremely challenging to achieve for both flow batteries and other LIB competitors. At the moment, LIB alternatives tend to have isolated small-scale manufacturing pathways, which preclude the economies of scale that would be required to compete with the mature LIB industry. In the present state of the industry, niche manufacturing tools and approaches have evolved to support each alternative technology, such that there is substantial replication and duplication in effort. Continuing to pursue a strategy of isolated manufacturing processes/approaches for each LIB-alternative may never allow for at-scale deployment. In order for RFBs to meaningfully compete with LIBs in the realm of LDES, a new disruptive approach based on cross-industry learning and coordination is needed - and this is exactly what our Ad-Mat concept aims to tackle. In this re-envisioned manufacturing landscape, tools and processes from mature industries can be adapted and deployed across the range of alternative energy storage technologies. Adapting tools, equipment, processes, and industrial learning from mature industries to meet the technological requirements of RFBs would open new markets for existing OEMs in adjacent industries, would prevent unnecessary duplication and re-development, would improve efficiency across the manufacturing chain, and would ultimately support reduced costs and accelerated deployment of RFBs at scale.

adaptive manufacturing↗

High density circuit technology, part 3

Dry processing - both etching and deposition - and present/future trends in semiconductor technology are discussed. In addition to a description of the basic apparatus, terminology, advantages, glow discharge phenomena, gas-surface chemistries, and key operational parameters for both dry etching and plasma deposition processes, a comprehensive survey of dry processing equipment (via vendor listing) is also included. The following topics are also discussed: fine-line photolithography, low-temperature processing, packaging for dense VLSI die, the role of integrated optics, and VLSI and technology innovations.

Wade, T. E.↗

TDRSS S-shuttle unique receiver equipment

Beginning with STS-9, the Tracking and Date Relay Satellite system (TDRSS) will start providing S- and Ku-band communications and tracking support to the Space Shuttle and its payloads. The most significant element of this support takes place at the TDRSS White Sands Ground Terminal, which processes the Shuttle return link S- and Ku-band signals. While Ku-band hardware available to other TDRSS users is also applied to Ku-Shuttle, stringent S-Shuttle link margins have precluded the application of the standard TDRSS S-band processing equipment to S-Shuttle. It was therfore found necessary to develop a unique S-Shuttle Receiver that embodies state-of-the-art digital technology and processing techniques. This receiver, developed by Motorola, Inc., enhances link margins by 1.5 dB relative to the standard S-band equipment and its bit error rate performance is within a few tenths of a dB of theory. An overview description of the Space Shuttle Receiver Equipment (SSRE) is presented which includes the presentation of block diagrams and salient design features. Selected, measured performance results are also presented.

Weinberg, A.↗

Optimization of edge bead removal (EBR) process to enhance defect reduction in optical lithography

Defect reduction remains a critical objective in the integrated circuit manufacturing process, particularly within the highly re-entrant lithography modules where minimizing defects is crucial. Defects at the wafer edge can contaminate lithography modules and downstream processing equipment, leading to redistribution onto the wafer surface and adversely affecting overall device yield. A persistent challenge in the resist coating process is the formation of resist edge beads, driven by the strong Van der Waals attraction of excess photoresist (PR) to itself and the underlying substrate. The edge bead removal (EBR) process is a standard cleaning step designed to eliminate these edge beads and prevent potential contamination. Here, in this study, we identify the sources of EBR induced defects and additional EBR process encroachment toward edge patterning during the EBR cleaning process. This study provides a comprehensive study aimed at optimizing the EBR cleaning process to effectively eliminate EBR-induced defects, thereby enhancing overall device yield. Specifically, we identify three primary defects induced by the EBR cleaning process: rainbow-type, finger-shaped, and teardrop-type defects. Our experimental study reveals that in addition to EBR rinse time, PR cast time is crucial parameters contributing to the formation of these defects. By properly optimizing the PR cast time and EBR rinse time, we were able to remove nearly 100 % of dense clusters of defects that were easily visible even at low magnification optical microscopy throughout the wafer edge. We observed that shorter PR casting times shows edge defects caused by inefficient EBR process because of insufficient time for PR to fully settle causing superfluous PR to continue flowing toward wafer edge during EBR clearing step, leading to partial removal of PR at the wafer edge and the formation of rainbow defects. Proper optimization of both PR casting time and EBR chemistries dispense time is essential to resolve these defects, ensuring efficient EBR cleaning process and improved overall device yield.

42 ENGINEERING↗

State-of-the-art in Manufacturing Pyrochemical Processing Crucibles

Engineers at Los Alamos National Laboratory have been purifying plutonium through pyrochemical processing for many years. The harsh environments involved with the pyrochemical processes include high temperatures (700-900 °C), molten salts and reactive metals (MgCl 2 , PuCl 3 , NaCl-KCl, CaCl 2 , Pu, Ca), and chlorine gas. Because of these corrosive conditions, designing and developing the pyrochemical processing equipment has always been an intriguing technical challenge. In this article I focus on the design and development of the pyrochemical processing crucible for the electrorefining (ER) process, applying design for manufacturability principles throughout the process. I review the current crucible design and electrorefining process and explore possibilities of making the crucible as one part, building the anode and cathode into the crucible, and various material of construction improvements. Materials of construction that should be reviewed further include alumina, silicon nitride, and a tantalum carbon alloy. I briefly review the application of three-dimensional (3D) printing to the process of producing the ER crucible, including thermoplastic 3D printing and mechanical property concerns. I finish by summarizing current plans and possibilities of improving the ER crucible.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Powder Processing of High Temperature Cermets and Carbides at Marshall Space Flight Center

The Materials and Processing Laboratory at NASA Marshall Space Flight Center is developing Powder Metallurgy (PM) processing techniques for high temperature cermet and carbide material consolidation. These new group of materials would be utilized in the nuclear core for Nuclear Thermal Rockets (NTR). Cermet materials offer several advantages for NTR such as retention of fission products and fuels, better thermal shock resistance, hydrogen compatibility, high thermal conductivity, and high strength. Carbide materials offer the highest operating temperatures but are sensitive to thermal stresses and are difficult to process. To support the effort, a new facility has been setup to process refractory metal, ceramic, carbides and depleted uranium-based powders. The facility inciudes inert atmosphere glove boxes for the handling of reactive powders, a high temperature furnace, and powder processing equipment used for blending, milling, and sieving. The effort is focused on basic research to identify the most promising compositions and processing techniques. Several PM processing methods including Cold and Hot Isostatic Pressing are being evaluated to fabricate samples for characterization and hot hydrogen testing.

Salvail, Pat↗

Roles of the ground and flight crew in Apollo operations.

The functions performed by ground personnel and flight crews of Apollo missions are reviewed, covering vehicle systems operation and management, Saturn launch vehicle, command-service and lunar modules, lunar rover, communication relay unit and ground-commanded TV assembly. Details of the flight path, scientific experiments, photographic equipment and crew health monitoring are also discussed in terms of these functions. The coordinated combination of large numbers of experts and data processing equipment on the ground with the crew's capabilities to operate the spacecraft and exercise on-the-spot judgements is viewed as the backbone of the successful fulfillment of Apollo missions.

Wolfer, B. M.↗

Assessment of the Performance of Hydrofluoroolefins, Hydrochlorofluoroolefins, and Halogen-Free Foam Blowing Agents in Cellular Plastic Foams

Oak Ridge National Laboratory has conducted a literature search to identify relevant information available on alternative materials and technologies that are proposed for foam blowing agents applications. For comparison, similar information was collected for available hydrofluorocarbons (HFC), hydrofluoroolefin (HFO), and hydrochlorofluoroolefins (HCFO) materials. The publicly available literature was analyzed and assessed for technical accuracy for each alternative, and a gap analysis was conducted to understand if additional studies are required to fully assess the viability of an alternative. In assessing these alternatives, this project focused on relevant performance and safety attributes. The performance attributes collected include insulation value per unit thickness, which impacts energy usage of buildings and insulated equipment such as refrigerators. We also assessed the impact of blowing agents on foam mechanical properties and flammability characteristics, and the ability of current processing equipment and techniques to utilize these alternatives. Diffusion of blowing agents through foam cells and its impact on foam aging was also examined. The applications covered in this study are spray foam, boardstock, panels, and appliances. Some of the most relevant findings are summarized below.

36 MATERIALS SCIENCE↗

Bi-Modal Model for Neutron Emissions from PuO{sub 2} and MOX Holdup

The measurement of uranium and plutonium holdup in plants during process activity and for decommissioning is important for nuclear safeguards and material control. The amount of plutonium and uranium holdup in glove-boxes, pipes, ducts, and other containers has been measured for several decades using both neutron and gamma-ray techniques. For the larger containers such as hot cells and glove-boxes that contain processing equipment, the gamma-ray techniques are limited by self-shielding in the sample as well as gamma absorption in the equipment and associated shielding. The neutron emission is more penetrating and has been used extensively to measure the holdup for the large facilities such as the MOX processing and fabrication facilities in Japan and Europe. In some case the totals neutron emission rates are used to determine the holdup mass and in other cases the coincidence rates are used such as at the PFPF MOX fabrication plant in Japan. The neutron emission from plutonium and MOX has 3 primary source terms: 1) Spontaneous fission (SF) from the plutonium isotopes, 2) The (α,n) reactions from the plutonium alpha particle emission reacting with the oxygen and other impurities, and 3) Neutron multiplication (M) in the plutonium and uranium as a result of neutrons created by the first two sources. The spontaneous fission yield per gram is independent of thickness, whereas, the above sources 2) and 3) are very dependent on the thickness of the deposit. As the effective thickness of the deposit becomes thin relative to the alpha particle range, the (α,n) reactions and neutrons from multiplication (M) approach zero. In any glove-box, there will always be two primary modes of holdup accumulation, namely direct powder contact and non-contact by air dispersal. These regimes correspond to surfaces in the glove-box that have come into direct contact with the process MOX powder versus surface areas that have not had direct contact with the powder. The air dispersal of PuO{sub 2} particles has been studied for several decades by health physicists, because the primary health hazard of plutonium is breathing the airborne particles. The air dispersal mechanism results from the smaller particles in the top layer of powder that are lifted into the air by the electrostatic charge buildup from the alpha decay process, and the air convection carries the particles to new more distant locations. If there is open plutonium powder in a glove-box, the surfaces at more distant locations will become contaminated over time. The range of an alpha particle in a solid or powder is a function of the particle energy, the material density, and the atomic number A of the material. The average energy of a plutonium alpha particle is ∼5.2 MeV and the range in air is ∼37 mm. The range in other materials can be estimated via the Bragg-Kleenman equation. For plutonium, A is 94, and the typical density for a single particle is ∼11.5 g/cm{sup 3}, but for a powder, the density would be less because of the air packing fraction. The significance of the small diameter is that the range of the alpha particle is ∼50 μm for powder density 2.5 and significantly less for a single particle with density 11.5, so the thin deposit of separate small particles will have a greatly reduced (α,n) yield. The average alpha transit length to the surface in the isolated MOX particle would be < 2.5 μm; whereas, the range of the alpha particle is much longer. Thus, most of the alpha particles would escape from the MOX particle and be absorbed by the walls and air. The air dispersal particles will have access to a large surface area that includes the walls, whereas, the powder contact surface area will be orders of magnitude smaller. Thus, the vast majority of the glove-box surface area does not produce the full (α,n) reaction neutron yield, even from the O{sub 2} in the PuO{sub 2} as well as any impurity contamination such as H{sub 2}O. To obtain a more quantitative estimate of the neutron (α,n) yields as a function of holdup deposit thickness, we have used MCNPX calculations to estimate the absorption of alpha particles in PuO{sub 2} holdup deposits. The powder thickness was varied from 0.1 μm to 5000 μm and the alpha particle escape probability was calculated. As would be expected, as the thickness approaches zero, the escape probability approaches 1.0, and as the thickness gets much greater than the alpha particle range (∼50 μm), the escape probability becomes small. Typically, the neutron holdup calibration measurement are performed using sealed containers of thick MOX that has all 3 sources of neutrons [SF, (α,n), and M], and no significant impurities. Thus, the calibration counting rates need to include corrections for M and (α,n) yields that are different for the holdup compared with the calibration samples. If totals neutron counting is used for the holdup measurements, the variability of the (α,n) term needs to be considered.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Research experiences on materials science in space aboard Salyut and Mir

From 1980 through 1991 approximately 500 materials processing experiments were performed aboard the space stations Salyut 6, Salyut 7 and Mir. This includes work on catalysts, polymers, metals and alloys, optical materials, superconductors, electronic crystals, thin film semiconductors, super ionic crystals, ceramics, and protein crystals. Often the resulting materials were surprisingly superior to those prepared on earth. The Soviets were the first to fabricate a laser (CdS) from a crystal grown in space, the first to grow a heterostructure in space, the first super ionic crystal in space, the first crystals of CdTe and its alloys, the first zeolite crystals, the first protein crystals, the first chromium disilicide glass, etc. The results were used to optimize terrestrial materials processing operations in Soviet industry. The characteristics of these three space stations are reviewed, along with the advantages of a space station for materials research, and the problems encountered by the materials scientists who used them. For example, the stations and the materials processing equipment were designed without significant input from the scientific community that would be using them. It is pointed out that successful results have been achieved also by materials processing at high gravity in large centrifuges. This research is also continuing around the world, including at Clarkson University. It is recommended that experiments be conducted in centrifuges in space, in order to investigate the acceleration regime between earth's gravity and the microgravity achieved in orbiting space stations. One cannot expect to understand the influence of gravity on materials processing from only two data points, earth's gravity and microgravity. One must also understand the influence of fluctuations in acceleration on board space stations, the so-called 'g-jitter.' This paper is presented in outline and graphical form.

Regel, Liya L.↗

Analysis of Water Recovery Rate from the Heat Melt Compactor

Human space missions generate trash with a substantial amount of plastic (20% or greater by mass). The trash also contains water trapped in food residue and paper products and other trash items. The Heat Melt Compactor (HMC) under development by NASA Ames Research Center (ARC) compresses the waste, dries it to recover water and melts the plastic to encapsulate the compressed trash. The resulting waste disk or puck represents an approximately ten-fold reduction in the volume of the initial trash loaded into the HMC. In the current design concept being pursued, the trash is compressed by a piston after it is loaded into the trash chamber. The piston face, the side walls of the waste processing chamber and the end surface in contact with the waste can be heated to evaporate the water and to melt the plastic. Water is recovered by the HMC in two phases. The first is a pre-process compaction without heat or with the heaters initially turned on but before the waste heats up. Tests have shown that during this step some liquid water may be expelled from the chamber. This water is believed to be free water (i.e., not bound with or absorbed in other waste constituents) that is present in the trash. This phase is herein termed Phase A of the water recovery process. During HMC operations, it is desired that liquid water recovery in Phase A be eliminated or minimized so that water-vapor processing equipment (e.g., condensers) downstream of the HMC are not fouled by liquid water and its constituents (i.e., suspended or dissolved matter) exiting the HMC. The primary water recovery process takes place next where the trash is further compacted while the heated surfaces reach their set temperatures for this step. This step will be referred to herein as Phase B of the water recovery process. During this step the waste chamber may be exposed to different selected pressures such as ambient, low pressure (e.g., 0.2 atm), or vacuum. The objective for this step is to remove both bound and any remaining free water in the trash by evaporation. The temperature settings of the heated surfaces are usually kept above the saturation temperature of water but below the melting temperature of the plastic in the waste during this step to avoid any encapsulation of wet trash which would reduce the amount of recovered water by blocking the vapor escape. In this paper, we analyze the water recovery rate during Phase B where the trash is heated and water leaves the waste chamber as vapor, for operation of the HMC in reduced gravity. We pursue a quasi-one-dimensional model with and without sidewall heating to determine the water recovery rate and the trash drying time. The influences of the trash thermal properties, the amount of water loading, and the distribution of the water in the trash on the water recovery rates are determined.

Heat Melt Compactor↗