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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 NTRS2019

Standardizing Microprocessor and GPU Radiation Test Approaches

Microprocessor, Graphics Processing Units (GPUs) and DDRx memory devices have emerged as promising next-generation technologies that enables both high performance processing and acceleration of complex algorithms for the latest challenges in human spaceflight, autonomous vehicles and artificial intelligence (AI). The feature sets of these devices offer exponential increases to throughput, calculation capability and system autonomy when compared to legacy flight systems. NASA's Electronic Part and Packaging (NEPP) Program has conducted an investigation into the radiation susceptibility of leading edge devices and process technologies by establishing standardized test approaches. Unlike most discrete devices, these require state of the art test systems to induce specific hardware activity similar to application software, thus allowing the characterization of failure modes within the system. To best characterize the tested part, NEPP eliminates variables that may impact device performance under radiation. Simplification of remaining system-level variables leads to an improved understanding of complex computational devices and their intended applications. The failure modes and error signatures that are recorded during testing are used to determine radiation sensitivity of the semiconductor process and the microcode architecture of the design. This presentation will discuss the test methodology that NASA Electronic Parts and Packaging (NEPP) is working to establish for its microprocessor, GPU and DDRx memory test programs to provide guidance on these devices and their underlying technology, in regards to their potential usage in future space flight systems.

GPU↗
NASA NTRS1992

An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

Sampson, Paul G.↗
NASA NTRS2002

Using the Process and Excitement of Science and Technology to Empower Teachers and Engage their Students

Students United with NASA Becoming Enthusiastic About Math and Science (SUNBEAMS) is a Partnership between NASA Goddard Space Flight Center (GSFC) and the District of Columbia Public Schools (DCPS). It empowers teachers and inspires students with the process and excitement of science and technology. SUNBEAMS is being developed as a model urban intervention program for sixth grade teachers and their students. The teachers come to Goddard for five weeks during the summer. They partner with Goddard mentors and work much the same way that summer students do. In addition, the teachers are responsible for developing lesson plans that they pilot at their schools and post on the SUNBEAMS web site. During the school year, each teacher brings one class to Goddard for a full week of total immersion in math and science.

Crannell, Carol Jo↗
NASA NTRS1981

USAF solar thermal applications overview

Process heat applications were compared to solar thermal technologies. The generic process heat applications were analyzed for solar thermal technology utilization, using SERI's PROSYS/ECONOMAT model in an end use matching analysis and a separate analysis was made for solar ponds. Solar technologies appear attractive in a large number of applications. Low temperature applications at sites with high insolation and high fuel costs were found to be most attractive. No one solar thermal technology emerges as a clearly universal or preferred technology, however,, solar ponds offer a potential high payoff in a few, selected applications. It was shown that troughs and flat plate systems are cost effective in a large number of applications.

Hauger, J. S.↗
NASA NTRS1975

Solar concentrators for space processing applications

A study on the technological feasibility of using solar concentrators for crystal growth and zone refining in space has been performed. Previous studies related to the many aspects of the problem are reviewed. It was concluded from this effort that the technology for fabricating, orbiting, and deploying large solar concentrators has been developed. It was also concluded that the technological feasibility of space processing materials in the focal region of a solar concentrator depends primarily on two factors: (1) the ability of a solar concentrator to provide sufficient thermal energy for the process and (2) the ability of a solar concentrator to provide a thermal environment that is conducive to the processes of interest. The study indicates that solar concentrators of reasonable dimensions can satisfactorily provide both of these factors. This study also indicates that solar concentrators are attractive for space processing from the viewpoint of system specific power and system flexibility.

Mcdermit, J. H.↗
DOE OSTI2021

Techno-economic analysis of roll-to-roll production of perovskite modules using radiation thermal processes

Perovskite solar technology can produce economically viable photovoltaic devices due to low cost of materials and scalable manufacturing. Solution phase deposition of all active layers lends itself to roll-to-roll fabrication methods which are well-established and have production rates of several hundred square meters per minute. In this techno-economic analysis, the opportunity to scale at this production throughput is considered with manufacturing rates exceeding one gigawatt per year in a single plant. Intense pulsed light is used for the post deposition process to minimize costs associated with the footprint, equipment, and operation. The analysis is limited to the operation of a roll-to-roll manufacturing facility producing a perovskite solar film that can be incorporated into photovoltaic modules. Costs associated with materials, labor, and equipment are considered along with utilities determined from the fundamental engineering calculations. Furthermore, the results show that at very large-scale operations of several gigawatts, the costs to produce the solar films range between $0.04-$0.10 per watt.

14 SOLAR ENERGY↗
DOE OSTI2017

Apodization of spurs in radar receivers using multi-channel processing

The various technologies presented herein relate to identification and mitigation of spurious energies or signals (aka "spurs") in radar imaging. Spurious energy in received radar data can be a consequence of non-ideal component and circuit behavior. Such behavior can result from I/Q imbalance, nonlinear component behavior, additive interference (e.g. cross-talk, etc.), etc. The manifestation of the spurious energy in a radar image (e.g., a range-Doppler map) can be influenced by appropriate pulse-to-pulse phase modulation. Comparing multiple images which have been processed using the same data but of different signal paths and modulations enables identification of undesired spurs, with subsequent cropping or apodization of the undesired spurs from a radar image. Spurs can be identified by comparison with a threshold energy. Removal of an undesired spur enables enhanced identification of true targets in a radar image.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Apodization of spurs in radar receivers using multi-channel processing

The various technologies presented herein relate to identification and mitigation of spurious energies or signals (aka “spurs”) in radar imaging. Spurious energy in received radar data can be a consequence of non-ideal component and circuit behavior. Such behavior can result from I/Q imbalance, nonlinear component behavior, additive interference (e.g. cross-talk, etc.), etc. The manifestation of the spurious energy in a radar image (e.g., a range-Doppler map) can be influenced by appropriate pulse-to-pulse phase modulation. Comparing multiple images which have been processed using the same data but of different signal paths and modulations enables identification of undesired spurs, with subsequent cropping or apodization of the undesired spurs from a radar image. Spurs can be identified by comparison with a threshold energy. Removal of an undesired spur enables enhanced identification of true targets in a radar image.

42 ENGINEERING↗
DOE OSTI2019

Predicting surface deformation during mechanical attrition of metallic alloys

Extensive efforts have been devoted in both the engineering and scientific domains to seek new designs and processing techniques capable of making stronger and tougher materials. One such method for enhancing such damage-tolerance in metallic alloys is a surface nano-crystallization technology that involves the use of hundreds of small hard balls which are vibrated using high-power ultrasound so that they impact onto the surface of a material at high speed (termed Surface Mechanical Attrition Treatment or SMAT). However, few studies have been devoted to the precise underlying mechanical mechanisms associated with this technology and the effect of processing parameters. As SMAT is dynamic plastic deformation process, here we use random impact deformation as a means to investigate the relationship between impact deformation and the parameters involved in the processing, specifically ball size, impact velocity, ball density and kinetic energy. Using analytical and numerical solutions, we examine the size of the indents and the depths of the associated plastic zones induced by random impacts, with results verified by experiment in austenitic stainless steels. In addition, global random impact and local impact frequency models are developed to analyze the statistical characteristics of random impact coverage, together with a description of the effect of random multiple impacts, which are more reflective of SMAT. We believe that these models will serve as a necessary foundation for further, and more energy-efficient, development of such surface nano-crystalline processing technologies for the strengthening of metallic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Treatment of Produced Water from Carbon Sequestration Sites for Water Reuse and Mineral Recovery

Southern Research along with Advanced Resources International, Inc. (ARI), Heartland Technology Partners, LLC (Heartland), New Logic Research, Inc. (New Logic), and Mr. Michael N. DiFilippo, Consultant developed a concept for an on-site strategy and design for management of produced water from CO 2 sequestration sites for maximum water reuse. When CO 2 is injected into deep saline aquifers, it may be necessary to produce water from the reservoir to reduce reservoir pressure. The New Logic Research, vibratory shear enhanced process (VSEP) membrane technology, and Heartland Technology Partners, low momentum-high turbulence (LM-HT) evaporation technology was selected for evaluation for treating this produced water from a 530 MW natural gas combined cycle (NGCC) power plant by utilizing waste heat from the plant to drive the evaporation process. The technology was also evaluated for application to a coal-fired power plant in lieu of the NGCC power plant. The results from the project show that the application of the proposed technology to the 530 MW NGCC power plant scenario could be feasible. The results indicate that formation water TDS has a very large impact on the technical and economic feasibility of the process. One advantage of formations with low TDS water is that the VSEP membrane can be utilized to pre-concentrate the produced water upstream of the LM-HT. The results indicate that a significant portion of the exhaust gas from the NGCC power plant will have to be utilized to provide waste heat for the LM-HT evaporator; however, less will be required with low-TDS formation water. The CAPEX costs for LM-HT for all three formations (97.8USD to 122.7USD MM/year) and VSEP plus LM-HT (106.6USD MM/year) for the Keg River formation is high in cost but lower than all technology compared including crystallization, VSEP plus crystallization, FO plus LM-HT, VCE plus LM-HT, and VCE plus crystallization. The OPEX for the LM-HT for all three formations (6.33USD to 7.97USD MM/year) and VSEP plus LM-HT (13.29USD MM/year) for the Keg River formation is lower than crystallization, VSEP plus crystallization, FO plus LM-HT, and FO plus crystallization. Only VCE plus LM-HT and VCE plus crystallization have a comparable OPEX costs to LM-HT for all three formation and VSEP plus LM-HT for the Keg River formation. The coal-fired power plant comparison showed that it is not feasible to apply the technology to that type of fossil fuel plant.

04 OIL SHALES AND TAR SANDS↗
NASA NTRS1990

Quantitative computer representation of propellant processing

With the technology currently available for the manufacture of propellants, it is possible to control the variance of the total specific impulse obtained from the rocket boosters to within approximately five percent. Though at first inspection this may appear to be a reasonable amount of control, when it is considered that any uncertainty in the total kinetic energy delivered to the spacecraft translates into a design with less total usable payload, even this degree of uncertainty becomes unacceptable. There is strong motivation to control the variance in the specific impulse of the shuttle's solid boosters. Any small gains in the predictability and reliability of the booster would lead to a very substantial payoff in earth-to-orbit payload. The purpose of this study is to examine one aspect of the manufacture of solid propellants, namely, the mixing process. The traditional approach of computational fluid mechanics is notoriously complex and time consuming. Certain simplifications are made, yet certain fundamental aspects of the mixing process are investigated as a whole. It is possible to consider a mixing process in a mathematical sense as an operator, F, which maps a domain back upon itself. An operator which demonstrates good mixing should be able to spread any subset of the domain completely and evenly throughout the whole domain by successive applications of the mixing operator, F. Two and three dimensional models are developed and graphical visualization two and three dimensional mixing processes are presented.

Hicks, M. D.↗
NASA NTRS1982

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.↗
NASA NTRS1995

Superconductivity devices: Commercial use of space

The work described in this report covers various aspects of the Rainbow solid-state actuator technology. It is presented in six parts dealing with materials, processing, fabrication, properties and associated phenomena. The Rainbow actuator technology is a relatively new materials development which had its inception in 1992. It consists of a new processing technology for preparing piezoelectric and electrostrictive ceramic materials. It involves a high temperature chemical reduction process which leads to an internal pre-stressing of the oxide wafer, thus the name Rainbow, an acronym for Reduced And INternally Biased Oxide Wafer. Ceramics fabricated by this method produce bending-mode actuator devices which possess several times more displacement and load bearing capacity than present-day benders (unimorphs, bimorphs). It is anticipated that these solid-state, electromechanical actuators which can be used in a number of applications in space such as cryopump motors, anti-vibration active structures, autoleveling platforms, telescope mirror correctors and autofocusing devices. When considering any of these applications, the key to the development of a successful device is the successful development of a ceramic material which can produce maximum displacement per volt input; hence, this initiative involving a solid-state means for achieving unusually high electromechanical displacement can be significant and far reaching. An additional benefit obtained from employing the piezoelectric effect in these actuator devices is the ability to also utilize them as sensors; and, indeed, they can be used as both motor (actuator) and generator (sensor) in multifunction devices.

Haertling, Gene↗
NASA NTRS2002

Aeronautical Satellite-Assisted Process for Information Exchange Through Network Technologies (Aero-SAPIENT) Conducted

Broadband satellite communications for aeronautics marries communication and network technologies to address NASA's goals in information technology base research and development, thereby serving the safety and capacity needs of the National Airspace System. This marriage of technology increases the interactivity between airborne vehicles and ground systems. It improves decision-making and efficiency, reduces operation costs, and improves the safety and capacity of the National Airspace System. To this end, a collaborative project called the Aeronautical Satellite Assisted Process for Information Exchange through Network Technologies, or Aero-SAPIENT, was conducted out of Tinker AFB, Oklahoma, during November and December 2000.

Zernic, Michael J.↗
DOE OSTI2022

A Process with Decoupled Absorber Kinetics and Solvent Regeneration through Membrane Dewatering and In-Column Heat Transfer (Final Report)

This report summarizes the work conducted on project DE-FE0031604 where University of Kentucky Center for Applied Energy (UK CAER) has validated its intensified CO 2 capture process through substantial enhancements to the kinetics of the absorption process and energy reductions by absorber temperature profile modification, dewatering and heat integration technologies for achieving significant capital and operating cost reductions. To address DOE’s objective of improving post-combustion CO 2 capture technology and reducing associated cost, UK CAER employed an intensified process which combined three key aspects targeted at overcoming inherent limitations or barriers in the conventional CO 2 capture and desorption process. The process designed to be independent of the type of solvent used, included (1) the use of 3-D printed two-channel structured packing material to control the temperature profile and increase the CO 2 absorption rate in the absorber, (2) a zeolite membrane dewatering unit for dewatering of the carbon-rich solvent to decouple solvent concentration needs for CO 2 absorption and desorption, and (3) a rich-split feed with two-phase flow heat transfer prior to the stripper that provided a secondary point of vapor generation to provide energy savings in steam extraction and solvent regeneration. The project was executed over two budget periods. This involved testing of individual process components which included the advanced heat transfer packing and the dewatering membrane on UK CAER’s 30 liter per minute (L/min) CO 2 (3” Column) capture bench unit with simulated flue gas in the first budget period. Subsequent scaled-up testing of these components together with the split-feed configuration were also tested in UK CAER’s 0.1 MWth CO 2 capture unit with coal-derived flue gas in the second-budget period. Long term studies were done during this period to assess process and solvent performance over extended duration. Project partners Lawrence Livermore National Laboratory (LLNL) and Media & Process Technology (MPT) led the development efforts for the advanced packing material and dewatering membrane respectively. Data from the long term testing was used as input for an environmental, health and safety (EH&S) assessment for the process and scaled technology performed by ALL4 LLC. Trimeric Corporation also completed a techno-economic analysis (TEA) for the UK CAER technology which was compared to the DOE reference Case B12B. Tests on the 3” column capture unit showed that the advanced heat transfer packing could be used to lower the bulge temperature in the absorber, and this was also proven in the scaled testing in the 0.1 MWth CO 2 capture unit. The bulge temperature could be lowered by >10 °C, changing the temperature profile in the absorber, and showed potential to enhance absorption with the ability to tailor the profile to provide conditions suitable for a solvent’s properties and kinetics. Conditions for short term evaluation of a 19” zeolite dewatering membrane on the 3” column capture unit yielded desirable fluxes and sustained rejection rates of >80%. However, for the scaled testing of six membrane modules consisting of 21 parts of 31-inch-long membrane tubes in each bundle (surface area 0.3 m 2 ), over a more extended duration, similar rejection rates could not be achieved. With the split-feed of the rich stream to the stripper, improved heat recovery minimized waste heat exiting the top of the stripper. The stripper exhaust temperatures could be reduced by >10 °C; reducing the amount of water vaporization contributed to lowering the regeneration energy by ~ 15%. The energy benefit could be sustained from the long term monitoring of the solvent performance. The solvent properties were not significantly impacted over the long-term operations. The benefits of the UK CAER process demonstrated experimentally were mostly validated from the TEA comparing a commercial scale application of the technology to DOE reference Case B12B. The cost of CO 2 capture for the UK CAER technology was estimated to be ~$34.97/tonne of CO 2 captured; a reduction of 23% compared to Case B12B. The increase in cost of electricity was also shown to be 16% lower than that of Case B12B. The total parasitic demand was also shown to be 11% lower. The key drivers for the benefits are a result of the process intensification approaches employed in the UK CAER technology for enhanced solvent performance, effective heat recovery and improved energy performance. The EH&S assessment did not find any major environmental concerns or barriers to the full scale implementation of the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗
DOE OSTI2018

Bottom-Up Copper Filling of Large Scale Through Silicon Vias for MEMS Technology

An electrodeposition process for void-free bottom-up filling of sub-millimeter scale through silicon vias (TSVs) with Cu is detailed. The 600 μm deep and nominally 125 μm diameter metallized vias were filled with Cu in less than 7 hours under potentiostatic control. The electrolyte is made up of 1.25 mol/L CuSO 4 – 0.25 mol/L CH 3 SO 3 H with polyether and halide additions that selectively suppress metal deposition on the free surface and side walls. A brief qualitative discussion of the procedures used to identify and optimize the bottom-up void-free feature filling is presented.

42 ENGINEERING↗