Advanced electrochemical technology Semiannual report, 1 Jul. - 31 Dec. 1967
Gas diffusion advanced fuel cell and related electrochemical systems
Chen, P. C.↗
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Status of Diffused Junction p(+)n InP Solar Cells for Space Applications
Recently, we have succeeded in fabricating diffused junction p(+)n(Cd,S) InP solar cells with measured AMO, 25 C open circuit voltage (V(sub OC)) of 887.6 mV, which, to the best of our knowledge, is higher than previously reported V(sub OC) values for any InP homojunction solar cells. The experiment-based projected achievable efficiency of these cells using LEC grown substrates is 21.3%. The maximum AMO, 25 C efficiency recorded to date on bare cells is, however, only 13.2%. This is because of large external and internal losses due to non-optimized front grid design, antireflection (AR) coating and emitter thickness. This paper summarizes recent advances in the technology of fabrication of p(+)n InP diffused structures and solar cells, resulted from a study undertaken in an effort to increase the cell efficiency. The topics discussed in this paper include advances in: 1) the formation of thin p(+) InP:Cd emitter layers, 2) electroplated front contacts, 3) surface passivation and 4) the design of a new native oxide/AI203/MgF2 three layer AR coating using a chemically-grown P-rich passivating oxide as a first layer. Based on the high radiation resistance and the excellent post-irradiation annealing and recovery demonstrated in the early tests done to date, as well as the projected high efficiency and low-cost high-volume fabricability, these cells show a very good potential for space photovoltaic applications.
Faur, Mircea↗
The role of native defects and their diffusivity in CdTe
CdTe is a leading thin-film technology for solar-cell applications. Basic features such as the optimum band gap of 1.5 eV and simple manufacturing process have been driving the research on improving the current record efficiency of 22% for CdTe solar cells toward the theoretical limit of 32%. Low p-type doping and short carrier lifetimes in the CdTe absorber have been suggested as the main limiting factors and attributed to defect compensation and carrier recombination. Understanding the role of point defects and impurities in CdTe is crucial to solving these problems. Despite many years of research, the sources of compensation and the microscopic recombination mechanisms are still unclear. By using hybrid density functional calculations with spin-orbit coupling and large supercells, we investigate the electronic properties, the formation energies, and the diffusivities of the native defects in CdTe. As possible sources of compensation for p-type conductivity, we discuss the structural and electronic properties of Cd interstitial, Te vacancies, and TeCd antisites. The stability of each defect is discussed in terms of both the defect formation energy and the migration barrier. We also address possible mechanisms that lead to non-radiative recombination.
14 SOLAR ENERGY↗
Observation of shock-front separation in multi-ion-species collisional plasma shocks
We observe shock-front separation and species-dependent shock widths in multi-ion-species collisional plasma shocks, which are produced by obliquely merging plasma jets of a He/Ar mixture (97% He and 3% Ar by initial number density) on the plasma liner experiment. Visible plasma emission near the He-I 587.6-nm and Ar-II 476.5–514.5-nm lines is simultaneously recorded by splitting a single visible image of the shock into two different fast-framing cameras with different narrow bandpass filters (589 ± 5 nm for observing the He-I line and 500 ± 25 nm for the Ar-II lines). For conditions in these experiments (pre-shock ion and electron densities ≈5×10 14 cm –3 , ion and electron temperatures of ≈2.2 eV, and relative plasma-merging speed of 22 km/s), the observationally inferred magnitude of He/Ar shock-front separation and the shock widths themselves are <1 cm, which correspond to ~50 post-shock thermal ion–ion mean free paths. These experimental length scales are in reasonable qualitative and quantitative agreement with results from 1D multi-fluid simulations using the CHICAGO code. However, we note there are differences between the experimentally inferred and simulation-predicted ionization states and line emission intensities, particularly in the post-shock region. Overall, the experimental and simulation results are consistent with theoretical predictions that the lighter He ions diffuse farther ahead within the overall shock front than the heavier Ar ions.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Advanced supersonic transport propulsion and configuration technology improvements
This paper presents the results of recent Douglas Aircraft Company integration studies for an advanced supersonic transport. The studies include technology improvements such as superplastic formed and diffusion-bonded titanium sandwich primary structure, composite secondary structure, bicone engine inlet, improved mechanical suppressors based on flight test data, improved aerodynamic efficiency based on wind tunnel test data, and updated performance for both variable-cycle and low-bypass-ratio engines. Technology development requirements for an economically viable and environmentally acceptable advanced supersonic transport are defined through these studies. A new Douglas Aircraft Company baseline supersonic transport designed to carry 350 passengers is defined for cost comparisons.
Rowe, W. T.↗
Study of controlled diffusion stator blading. 1. Aerodynamic and mechanical design report
Pratt & Whitney Aircraft is conducting a test program for NASA in order to demonstrate that a controlled-diffusion stator provides low losses at high loadings and Mach numbers. The technology has shown great promise in wind tunnel tests. Details of the design of the controlled diffusion stator vanes and the multiple-circular-arc rotor blades are presented. The stage, including stator and rotor, was designed to be suitable for the first-stage of an advanced multistage, high-pressure compressor.
Canal, E.↗
2D Ni 0.25 Mn 0.75 O 2 : A high-performance cathode for multivalent ion batteries
Although Li-ion batteries have driven portable energy storage in recent decades, there is increasing concern about their safety, cost, and abundance of constituents. Multivalent ion batteries (MVIBs) have the potential to remedy these issues, but they are limited by the currently known MVIB cathodes, which fail to deliver unanimously favorable voltage, energy density, and diffusion kinetics. Here we used density functional theory (DFT) to model the performance of Li, Na, Mg, Ca, and Al ions when paired with 2D Ni 0.25 Mn 0.75 O 2 , a novel cathode that uses increased layer separation to improve on the kinetics of its 3D analog. Our calculations yielded maximum voltages of 3.38 V for Na and 2.7 V for Ca, outperforming 2D Na x MnO 2 and Na x NiO 2 . Diffusion barriers for Li, Na, and Ca are below 300 meV, comparable to existing battery technology and the endpoint 2D cathodes; meanwhile, Mg and Al have prohibitively high diffusion barriers, implying their incompatibility with this cathode. Lastly, density of states calculations and Bader charge analysis show that the cathode becomes conducting following ion adsorption, which is necessary for high-rate performance. 2D Ni 0.25 Mn 0.75 O 2 maintains performance seen with other 2D transition metal oxides while increasing cathode conductivity, indicating that it is a promising candidate for experimental investigation with Li, Na, and Ca ions.
25 ENERGY STORAGE↗
Rapid Patterning and Advanced Device Structures for Low Cost Manufacturable Crystalline Si IBC Cells
Recent record efficiency Si cells have had an interdigitated back contact (IBC) design where both positive and negative contacts are fabricated on the back side of the Si wafer. Many industry groups have investigated IBC cells but used photolithography to pattern the rear contacts although it is considered impractical for low cost, high volume manufacturing. Alternative patterning methods using lasers and mechanical masking have been utilized in fabrication of patterned regions in IBC Si solar cells to replace photolithography. Another exciting advance in Si solar cell technology has been replacing the high temperature diffusion of doped regions inside the crystalline Si wafer with low temperature deposition of very thin layers of doped amorphous hydrogenated Si (a-Si:H) on the Si wafer. This is called a Si heterojunction (HJ) device. The a-Si:H provides excellent passivation of surface defects and has produced the highest open circuit voltages (VOC) of any Si solar cell device structure. The Institute of Energy Conversion (IEC) demonstrated the first IBC-HJ solar cell combining these two strategies in 2007 and has fabricated IBC-HJ cells with 20% efficiency using three photolithography steps. Despite the demonstrated efficiency potential of this device by industry groups (>26%) there is no commercial production because of the challenges of patterning and processing the structure in an industrial environment. Our work sought to address that challenge. The objective of this 3 year project was to develop the processing for the IBC-HJ Si solar cell using lasers for patterning and contact formation instead of photolithography. Laser patterning enables rapid, contactless manufacturing of patterned regions. We intensively studied laser fired contacts, laser patterning of the a-Si multi-layer stacks and metal layers and the use of plasma shadow masks. After an exhaustive focus in the first year on the laser fired emitter (LFE) and contact (LFC), we were unable to achieve VOC greater than 660 mV, compared to the 720 mV required to meet our milestones. We discovered that an additional issue with our original IBC structure was the presence of an inversion layer at the back surface connecting the p and n regions which reduced the VOC and fill factor (FF). We developed innovative methods for characterizing the inversion layer. These two limitations in the original design lead to development of a new IBC-HJ process sequence and device structure which we called Plasma Masked Laser Processed (PMLP). It retained the original high efficiency features including manufacturability. The LFC was replaced with a standard n-type a-Si HJ contact. The inversion layer was eliminated by replacing the previous p-type stack in the gap with an n-type or SiN stack. The PMLP used laser ablation of a multi-layer a-Si stack followed by chemical etching to open the n-contact. It required deposition of a patterned stack through a mask in the plasma deposition chamber. This turned out to be a source of significant problems due to inevitable unwanted deposition ‘leakage’ under the mask. This formed a blocking contact on the emitter which significantly reduced Voc and FF. Several iterations in PMLP device structure and chemical etching steps resulted in a large improvements, e.g. the efficiency increasing from 3 to 15% and Voc from 450 to 660 mV but they were unable to completely eliminate it. The best IBC-HJ device we fabricated had only 15% efficiency. For perspective, our standard FHJ devices had 20% efficiency.
14 SOLAR ENERGY↗
Future long-range transports: Prospects for improved fuel efficiency
A status report is provided on current thinking concerning potential improvements in fuel efficiency and possible alternate fuels. Topics reviewed are: (1) historical trends in airplane efficiency; (2) technological opportunities including supercritical aerodynamics, (3) vortex diffusers, (4) composite materials, (5) propulsion systems, (6) active controls, and terminal-area operations; (7) unconventional design concepts, and (8) hydrogen-fueled airplane.
Nagel, A. L.↗
Impact of a Bluff Body on a Pressurized Oxy-fuel Flame
Designing an effective burner is vital for the development of pressurized oxy-fuel combustion technologies. In the present work, turbulent jet diffusion burners are adopted for a pressurized oxy-combustor, with a bluff-body employed to create a recirculation zone, thereby stabilizing the flame in such a combustor. The objective of this numerical study is to perform a systematic analysis of the characteristics of such a pressurized non-premixed flame. Specifically, a 15-bar pressurized oxy-fuel combustor of power 100 kWth is modeled by means of the Ansys FLUENT commercial platform, using the Reynolds-averaged Navier-Stokes (RANS) approach. The present work focuses on identifying the aerothermodynamic features of the pressurized oxy-fuel burner with a disk-shape bluff-body. It is shown that the fuel-to-oxidizer stream momentum ratio has a great impact on the temperature profile of the down-fired, co-axial, pressurized oxy-coal, diffusion flame. A parametric study of the blockage ratio of the burner identifies an optimal range for this pressurized burner.
Li, Lei↗
About Small Streams and Shiny Rocks: Macromolecular Crystal Growth in Microfluidics
We are developing a novel technique with which we have grown diffraction quality protein crystals in very small volumes, utilizing chip-based, microfluidic ("LabChip") technology. With this technology volumes smaller than achievable with any laboratory pipette can be dispensed with high accuracy. We have performed a feasibility study in which we crystallized several proteins with the aid of a LabChip device. The protein crystals are of excellent quality as shown by X-ray diffraction. The advantages of this new technology include improved accuracy of dispensing for small volumes, complete mixing of solution constituents without bubble formation, highly repeatable recipe and growth condition replication, and easy automation of the method. We have designed a first LabChip device specifically for protein crystallization in batch mode and can reliably dispense and mix from a range of solution constituents. We are currently testing this design. Upon completion additional crystallization techniques, such as vapor diffusion and liquid-liquid diffusion will be accommodated. Macromolecular crystallization using microfluidic technology is envisioned as a fully automated system, which will use the 'tele-science' concept of remote operation and will be developed into a research facility aboard the International Space Station.
vanderWoerd, Mark↗
Program for transfer research and impact studies
Research activities conducted under the Program for Transfer Research and Impact Studies (TRIS) during 1972 included: (1) preparation of 10,196 TSP requests for TRIS application analysis; (2) interviews with over 500 individuals concerning the technical, economic, and social impacts of NASA-generated technology; (3) preparation of 38 new technology transfer example files and 101 new transfer cases; and (4) maintenance of a technology transfer library containing more than 2,900 titles. Six different modes of technology utilization are used to illustrate the pervasiveness of the transfer and diffusion of aerospace innovations. These modes also provide a basis for distinguishing the unique characteristics of the NASA Technology Utilization Program. An examination is reported of the ways in which NASA-generated technology is contributing to beneficial social change in five major areas of human concern: health, environment, safety, transportation, and communication.
Rusnak, J. J.↗
Charge-state independent anomalous transport for a wide range of different impurity species observed at Wendelstein 7-X
Here, the plasma volume averaged impurity confinement of selected charge states and impurity species has been characterized for the Stellarator Wendelstein 7-X (W7-X), covering a wide range of atomic charges (Z = 12–44) and atomic masses (M = 28–184). A comparison of the experimental findings to theoretical neoclassical and turbulent transport expectations suggests, aside from/in addition to the neoclassical transport, an additional significant anomalous transport mechanism, which is not inconsistent with the predictions of a turbulence dominated impurity transport and is in agreement with the experimental results from recent transport studies based on the direct measurements of impurity diffusion profiles, performed at W7-X.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Better vacuum by removal of diffusion-pump-oil contaminants
The complex problem of why large space simulation chambers do not realize true ultimate vacuum was investigated. Some contaminating factors affecting diffusion pump performance were identified, and some advances in vacuum distillation-fractionation technology were achieved which resulted in a two-decade-or-more lower ultimate pressure. Data are presented to show the overall or individual contaminating effects of commonly used phthalate ester plasticizers of 390 to 530 molecular weight on diffusion pump performance. Methods for removing contaminants from diffusion pump silicone oil during operation and for reclaiming contaminated oil by high-vacuum molecular distillation are described. Conceptual self-cleansing designs and operating procedures are proposed for modifying large diffusion pumps into high-efficiency distillation devices. The potential exists for application of these technological advancements to other disciplines, such as medicine, biomedical materials, metallurgy, refining, and chemical (diffusion-enrichment) processing.
Buggele, A. E.↗
Macromolecular Crystal Growth by Means of Microfluidics
We have performed a feasibility study in which we show that chip-based, microfluidic (LabChip(TM)) technology is suitable for protein crystal growth. This technology allows for accurate and reliable dispensing and mixing of very small volumes while minimizing bubble formation in the crystallization mixture. The amount of (protein) solution remaining after completion of an experiment is minimal, which makes this technique efficient and attractive for use with proteins, which are difficult or expensive to obtain. The nature of LabChip(TM) technology renders it highly amenable to automation. Protein crystals obtained in our initial feasibility studies were of excellent quality as determined by X-ray diffraction. Subsequent to the feasibility study, we designed and produced the first LabChip(TM) device specifically for protein crystallization in batch mode. It can reliably dispense and mix from a range of solution constituents into two independent growth wells. We are currently testing this design to prove its efficacy for protein crystallization optimization experiments. In the near future we will expand our design to incorporate up to 10 growth wells per LabChip(TM) device. Upon completion, additional crystallization techniques such as vapor diffusion and liquid-liquid diffusion will be accommodated. Macromolecular crystallization using microfluidic technology is envisioned as a fully automated system, which will use the 'tele-science' concept of remote operation and will be developed into a research facility for the International Space Station as well as on the ground.
vanderWoerd, Mark↗
Status of diffused junction p+n InP solar cells for space applications
Recently, we have succeeded in fabricating diffused junction p(sup +)n(Cd,S) InP solar cells with measured AMO, 25 C open circuit voltage (V(sub OC)) of 887.6 mV, which, to the best of our knowledge, is higher than previously reported V(sub OC) values for any InP homojunction solar cells. The experiment-based projected achievable efficiency of these cells using LEC grown substrates is 21.3 percent. The maximum AMO, 25 C internal losses due to date on bare cells is, however, only 13.2 percent. This is because of large external and internal losses due to non-optimized front grid design, antireflection (AR) coating and emitter thickness. This paper summarizes recent advances in the technology of fabrication of p(sup +)n InP diffused structures and solar cells, resulted from a study undertaken in an effort to increase the cell efficiency. The topics discussed in this paper include advances in: (1) the formation on thin p(sup +) InP:Cd emitter layers, (2) electroplated front contacts, (3) surface passivation and (4) the design of a new native oxide/Al2O3/MgF2 tree layer AR coating using a chemically-grown P-rich passivating oxide as a first layer. Based on the high radiation resistance and the excellent post-irradiation annealing and recovery demonstrated in the early tests done to date, as well as the projected high efficiency and low-cost high-volume fabricability, these cells show a very good potential for space photovoltaic applications.
Faur, Mircea↗
Virtual Volumetric Additive Manufacturing (VirtualVAM)
Abstract Tomographic volumetric additive manufacturing (VAM) produces arbitrary 3D geometries by exposure of a rotating volume of photopolymer resin to tomographically‐patterned illumination. This enables high speed, layer‐less printing of parts from a wide range of photopolymers not amenable to layer‐by‐layer processes. Since the entire geometry is produced at once over the course of a few seconds to minutes, molecular diffusion length scales become significant to the printing process. Understanding these molecular reaction and diffusion processes is imperative for advancing VAM to a usable technology. These processes are experimentally very difficult to monitor and measure. Herein, VirtualVAM ‐ a simulation framework for modeling the tomographic VAM process, is developed and experimentally validated. VirtualVAM simulates reaction, diffusion, and heat generation processes over the course of a print with single‐voxel resolution. From a few experimentally‐determined input parameters and a set of images for projection, VirtualVAM is able to generate a large spatio‐temporal data set for any given tomographic VAM print. Using VirtualVAM, a number of experimentally‐unattainable aspects of the VAM process are investigated such as single‐voxel conversion profiles, effect of molecular oxygen, and stopping time determination. VirtualVAM also enables the optimization of exposure patterns to further improve contrast between in‐part and out‐of‐part delivered dose.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Influence of strong Coulomb coupling on diffusion in atmospheric pressure plasmas
Ion diffusion in atmospheric pressure plasmas is examined and particular attention is paid to the fact that ion–ion interactions can be influenced by strong Coulomb coupling. Three regimes are identified. At low ionization fractions (x i ≲ 10 —6 ), standard weakly correlated ion-neutral interactions set the diffusion rate. At moderate ionization fractions (10 —6 ≲ x i ≲ 10 —2 ) there is a transition from ion-neutral to ion–ion collisions setting the diffusion rate. In this regime, the effect of strong Coulomb coupling in ion–ion collisions is accounted for by applying the mean force kinetic theory. Since both ion-neutral and ion–ion interactions contribute a comparable amount to the total diffusion rate, models (such as particle-in-cell or fluid) must account for both contributions. At high ionization fractions (x i ≳ 10 —2 ), strongly correlated ion–ion collisions dominate and the plasma is heated substantially by a disorder-induced heating (DIH) process associated with strong correlations. The temperature increase due to DIH strongly influences the ion diffusion rate. This effect becomes even more important, and occurs at lower ionization fractions, as the pressure increases above atmospheric pressure. In addition to ion diffusion, DIH affects the neutral gas temperature, therefore influencing the neutral diffusion rate. Model predictions are tested using molecular dynamics simulations, which included a Monte Carlo collision routine to simulate the effect of ion-neutral collisions at the lowest ionization fractions. The model and simulations show good agreement over a broad range of ionization fractions. Importantly, the results provide a model for ion diffusion, on a wide range of ionization fractions and pressures, solely considering the elastic contribution to the diffusion coefficient—as an illustration of how strong Coulomb coupling influences diffusion processes in general.
fast neutral gas heating↗