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At least 1,603 records · Page 89

Examination of cutouts from Nb3Sn coated cavity inner surfaces

The potential for higher operating temperature and higher gradient have motivated SRF cavity researchers to pursue Nb3Sn as an alternative to Nb for nearly fifty years. Far and away the most common embodiment has been a few micron-thick Nb3Sn layer on the cavity interior surface obtained by vapor diffusion coating, with one or another set of parameters. While many cavities have been made and RF tested, reports of dissecting a cavity in detail to examine the coating and relate it to RF measurements are rare. We coated a BCP-treated single cell cavity in a typical process of tin/tin chloride activation at 500 C followed by tin vapor deposition at 1200 C. After RF-testing, we cut and examined sections from several locations to learn composition, thickness topography of the interior surface. The effect of process variables, such as surface preparation, process temperature and duration, and vapor chemistry needs to be explored.

Eremeev, Grigory↗

New Materials for Electric Drive Vehicles - Final CRADA Report

This project was sponsored by the US DOE Global Initiatives for Proliferation Prevention. The object was for Ukrainian and US partners, including Argonne, AETC, and Dontech to develop special carbon materials and factory production equipment with the goal of making better car batteries to achieve DOE's goals for all-electric and plug-in hybrid electric vehicles. Carbon materials are used in designs for lithium-ion batteries and metal-air batteries, both leading contenders for future electric cars. Specifically, the collaborators planned to use the equipment derived from this project to develop a rechargeable battery system that will use the carbon materials produced by the innovative factory process equipment. The final outcome of the project was that the Ukrainian participants consisting of the Kharkov Institute of Physics and Technology (KIPT), the Institute of Gas of National Academy of Sciences of Ukraine and the Materials Research Center, Ltd. designed, built, tested and delivered 14 pieces of processing equipment for pilot scale carbon production lines at the AETC, Arlington Heights facilities. The pilot scale equipment will be used to process materials such as activated carbon, thermally expanded graphite and carbon coated nano-particles. The equipment was shipped from Ukraine to the United States and received by AETC on December 3, 2013. The equipment is on loan from Argonne, control # 6140. Plug-in hybrid electric vehicles (PHEV) and all-electric vehicles have already demostrated success in the U.S. as they begin to share the market with older hybrid electric designs. When the project was conceived, PHEV battery systems provided a ~40 mile driving range (2011 figures). DOE R&D targets increased this to >100 miles at reduced cost less than $250/kWh (2011 figures.) A 2016 Tesla model S has boasted 270 miles. The project object was to develop pilot-production line equipment for advanced hybrid battery system that achieves cycle life of 1000, an energy density of 280 Wh/kg and specific density of 600Wh/l. This project delivers factory equipment to produce these advanced battery materials.

36 MATERIALS SCIENCE↗

Stable Perovskite Core-Shell Nanocrystals as Down-Converting Phosphors for Solid State Lighting

Colloidal perovskite quantum dots (QDs) or nanocrystals (NCs) with structure of CsPbX 3 (X = Cl, Br, I) are promising materials as down-converting phosphors due to their high quantum yield up to >90%, extremely narrow emission band ~15-30 nm, and tunable emission wavelengths of ~410-700 nm via size or composition control. Compared to other QD materials, the optical and electronic properties of perovskite NCs are much more tolerant to defects so highly efficient light-emitting NCs can be easily prepared without carefully removing surface defects. Also, precision size control is not required for obtaining perovskite NCs with narrow emission <30 nm and can greatly enhance the reproducibility and yield rate during mass production. The challenges in using perovskite NCs as LED phosphors are their hygroscopic nature and self-absorption as observed from other QDs. We propose to synthesize core-shell structure perovskite NCs to improve their stability by over-coating a SiO 2 layer, followed by further sol-gel processing into stable micro-sized glass beads. To increase Stokes shift and avoid self-absorption, core/graded-shell/shell structure such as CsSnBr 3 /CsSn 1-x Pb x Br 3 /CsPbBr 3 NCs will be prepared, similar to a concept we demonstrated before in CdSe/Cd 1-x ZnxSe 1-y S y /ZnS structure with significantly separated absorption and emission bands. These NC materials will be integrated into films and used as remote or on-chip downconverters for high efficiency, high CRI and warm white LED. To achieve this goal, PhosphorTech Corporation (PTC) has teamed with Georgia Tech (GT) to develop this unique perovskite system for pcLEDs that offers the promise of high luminous efficacy over a broad temperature and optical flux range.

36 MATERIALS SCIENCE↗

High Quantum Efficiency Uni-Traveling-Carrier Photodiode for Optical to Microwave Transduction

Modern Quantum Information Systems (QIS) employ optical photons for long distance communication, operating at ambient temperature, between microwave cavities, which house microwave photons used in quantum computing and microwave detection. These optical photons, carried by fiber-optic or free-space links, offer a low-cost, uncooled alternative to bulky, expensive microwave coaxial cables, which are lossy, susceptible to EMI, and a significant thermal conductor to the outside ambient environment. To convert between these two types of photons and implement these optical interconnects, it is necessary to develop a high-performance photodetector for optical to microwave transduction. Freedom Photonics and the University of Virginia have a well-established partnership in developing high-performance photodiodes. In this Phase I effort, we collaborated in designing, fabricating, and testing an advanced, high-speed, high quantum efficiency prototype photodiode for transduction from optical to microwave frequencies. These devices have applications not only in quantum computing and axion detection, but also in other optical-cryogenic interconnect applications, in fields such as radio astronomy and quantum cryptography, as well as in quantum metrology and plasmonics. During this Phase I DOE program, we designed, fabricated, and tested prototype PIN GaAs photodiodes which targeted the performance parameters defined by the program. This process involved identifying a new target wavelength, different from that proposed initially, based on conversations with the Oak Ridge National Lab customer. We designed an epitaxial stack, optimized in theory for ≥95% quantum efficiency at 795 nm, ≥5 GHz, per the target objectives of the program. Additionally, we designed a fabrication process and associated mask plates for top-illuminated, AR-coated devices with device diameters ranging from 50 µm to 800 µm. Using these, we fabricated two 3” wafer quarters of devices, and characterized the devices’ dark current, quantum efficiency, and bandwidth for various device diameters. The prototype devices achieved a quantum efficiency of 89% at the target 795 nm detection wavelength. The bandwidth of the devices proved tricky to characterize, but a 50 µm diameter device shows a 3-dB bandwidth of at least 1.6 GHz, possibly a full 5 GHz, depending on the measurement setup. In the future, we plan to characterize the bandwidth of these devices using an impulse response measurement. All tasks for the Phase I were successfully completed, and sample prototype devices were provided to Oak Ridge National Lab Quantum Information Science researchers. The work performed in Phase I has established a strong foundation for future design and fabrication cycles in Phase II, if granted. The early tests at Oak Ridge National Labs will provide guidance for the required photodiode performance in devices to be supplied in Phase II.

42 ENGINEERING↗

Third Harmonic Generator Optics Loop Transportation and Handling

The National Ignition Facility (NIF) uses crystal optics made from Potassium Di-Hydrogen Phosphate (KDP) for frequency conversion, changing the fundamental wavelength of 1053 nm to the third harmonic at 351 nm. The crystal optics are manufactured at a vendor and shipped to Lawrence Livermore National Laboratory (LLNL) where they are measured, mitigated, cleaned, coated, and placed into line replaceable units (LRUs) in the Optics Processing Facility (OPF) clean room and transported to the NIF where they are stored under Nitrogen purge until they are installed in the beamline. The KDP crystal optics are sensitive to humidity and temperature, so they are stored under Nitrogen purge providing a clean and dry environment. The sensitivity to the environment and the brittle nature of the crystals makes transportation and handling (T&H) challenging. Coupled with challenges in holding the crystal optics in the LRU to not distort the optic, there is a balance between T&H and fixturing the optic in the laser system. The purpose of the LRU is to make the optics interchangeable allowing for a relatively quick interchange. Kinematic mounts and ceramic frames aid in making this possible. Optics in the NIF that are frequently changed out have an established recycle loop. The loop for an optic can be complex depending on the amount of processing and rework necessary. Some optics can’t be reconditioned so they are replaced with new optics.

47 OTHER INSTRUMENTATION↗

Bridging Additive Manufacturing and Electronics Printing in the Age of AI

Printing techniques have been instrumental in developing flexible and stretchable electronics, including organic light-emitting diode displays, organic thin film transistor arrays, electronic skins, organic electrochemical transistors for biosensors and neuromorphic computing, as well as flexible solar cells with low-cost processes such as inkjet printing, ultrasonic nozzle, roll-to-roll coating. The rise of additive manufacturing provides even more opportunities to print electronics in automated and customizable ways. In this work, we will review the current technologies of printing electronics (including printed batteries, supercapacitors, fuel cells, and sensors), especially with 3D printing. In this age of ongoing AI revolution, the application of AI algorithms is discussed in terms of combining them with 3D printing and electronics printing for a future with automated optimization, sustainable design, and customizable and scalable manufacturing.

Chemistry↗

The study of excited oxygen molecule gas species production and quenching on thermal protection system materials

The detection of excited oxygen and ozone molecules formed by surface catalyzed oxygen atom recombination and reaction was investigated by laser induced fluorescence (LIF), molecular beam mass spectrometric (MBMS), and field ionization (FI) techniques. The experiment used partially dissociated oxygen flows from a microwave discharge at pressures in the range from 60 to 400 Pa or from an inductively coupled RF discharge at atmospheric pressure. The catalyst materials investigated were nickel and the reaction cured glass coating used for Space Shuttle reusable surface insulation tiles. Nonradiative loss processes for the laser excited states makes LIF detection of O2 difficult such that formation of excited oxygen molecules could not be detected in the flow from the microwave discharge or in the gaseous products of atom loss on nickel. MBMS experiments showed that ozone was a product of heterogeneous O atom loss on nickel and tile surfaces at low temperatures and that ozone is lost on these materials at elevated temperatures. FI was separately investigated as a method by which excited oxygen molecules may be conveniently detected. Partial O2 dissociation decreases the current produced by FI of the gas.

Nordine, Paul C.↗

Mechanisms of degradation and failure in a plasma deposited thermal barrier coating

Failure of a two layer plasma deposited thermal barrier coating is caused by cyclic thermal exposure and occurs by spallation of the outer ceramic layer. Spallation life is quantitatively predictable, based on the severity of cyclic thermal exposure. This paper describes and attempts to explain unusual constitutive behavior observed in the insulative ceramic coating layer, and presents details of the ceramic cracking damage accumulation process which is responsible for spallation failure. Comments also are offered to rationalize the previously documented influence of interfacial oxidation on ceramic damage accumulation and spallation life.

Demasi-Marcin, Jeanine T.↗

Polymer Infiltration Studies

Progress was made on the preparation of carbon fiber composites using advanced polymer resins. Processes reported include powder towpreg process, weaving towpreg made from dry powder prepreg, composite from powder coated towpreg, and toughening of polyimide resin (PMR) composites by semi-interpenetrating networks. Several important areas of polymer infiltration into fiber bundles will be researched. Preparation to towpreg for textile preform weaving and braiding and for automated tow placement is a major goal, as are the continued development of prepregging technology and the various aspects of composite part fabrication.

Marchello, Joseph M.↗

Atomic oxygen durability of solar concentrator materials for Space Station Freedom

The findings are reviewed of atomic oxygen exposure testing of candidate solar concentrator materials containing SiO2 and Al2O3 protective coatings for use on Space Station Freedom solar dynamic power modules. Both continuous and iterative atomic oxygen exposure tests were conducted. Iterative air plasma ashing resulted in larger specular reflectance decreases and solar absorptance increases than continuous ashing to the same fluence, and appears to provide a more severe environment than the continuous atomic oxygen exposure that would occur in the low Earth orbit environment. First generation concentrator fabrication techniques produced surface defects including scratches, macroscopic bumps, dendritic regions, porosity, haziness, and pin hole defects. Several of these defects appear to be preferential sites for atomic oxygen attack leading to erosive undercutting. Extensive undercutting and flaking of reflective and protective coatings were found to be promoted through an undercutting tearing propagation process. Atomic oxygen erosion processes and effects on optical performance is presented.

Degroh, Kim K.↗

Polymer Infiltration Studies

Significant progress has been made on the preparation of carbon fiber composites using advanced polymer resins during the past three months. Current and ongoing research activities reported herein include: (1) Prepregger Hot Sled Operation; (2) Ribbonizing Powder-Impregnated Towpreg; (3) Textile Composites from Powder-Coated Towpreg: Role of Bulk Factor; and (4) Powder Curtain Prepreg Process. During the coming months research will be directed toward further development of the new powder curtain prepregging method and on ways to customize dry powder towpreg for textile and robotic applications in aircraft part fabrication. Studies of multi-tow powder prepregging and ribbon preparation will be conducted in conjunction with continued development of prepegging technology and the various aspects of composite part fabrication using customized towpreg. Also, work will continue on the analysis of the new solution prepegger.

Marchello, Joseph M.↗

Polymer infiltration studies

During the past three months, significant progress has been made on the preparation of carbon fiber composites using advanced polymer resins. The results are set forth in recent reports and publications, and will be presented at forthcoming national and international meetings. Current and ongoing research activities reported herein include: textile composites from powder-coated towpreg - role of surface coating in braiding; prepregger hot sled operation in making tape from powder coated tow; ribbonizing powder-impregnated towpreg; textile composites from powder-coated towpreg - role of bulk factor in consolidation; powder curtain prepreg process improvements in doctoring of powder; and hot/cold shoe for ATP open-section part warpage control.

Marchello, Joseph M.↗

In-situ Frequency Dependent Dielectric Sensing of Cure

With the expanding use of polymeric materials as composite matrices, adhesives, coatings and films, the need to develop low cost, automated fabrication processes to produce consistently high quality parts is critical. Essential to the development of reliable, automated, intelligent processing is the ability to continuously monitor the changing state of the polymeric resin in-situ in the fabrication tool. This final report discusses work done on developing dielectric sensing to monitor polymeric material cure and which provides a fundamental understanding of the underlying science for the use of frequency dependent dielectri sensors to monitor the cure process.

Kranbuehl, David E.↗

Deterrent Concentration Measurement with FTIR and Subsequent Ballistic Performance in Medium Caliber Propellant

To meet ballistic requirements, medium and small caliber propellants use deterrent coatings to obtain burn rate progressivity. The required amount and distribution of deterrent varies between gun systems, propellant types, and often between lots. Micro Fourier Transform Infrared (FTIR) spectroscopy was used to measure deterrent gradients in RP36 propellants coated with methyl centralite (MC) at different deterrent levels and different processing conditions. The aromatic C-C bonds at 1496 cm(exp -1) wavenumber were used to monitor the deterrent profiles through the grain. Deterrent gradients measured with FTIR spectroscopy were then used to estimate burn rate gradients in the deterred grains. Burn rates were calculated from literature models and from closed bomb data of RP36 containing uniform deterrent concentration. Finally, the burn rate gradients were input into an IBHFG2 model of a 200 cc-closed bomb. The early flame spreading portion of the closed bomb ballistic cycle (0 to 0.2 P/Pmax) was roughly modeled by dividing the charge up into five propellant decks and igniting them at different times in the ballistic cycle. Pressure traces and vivacity curves from closed bomb shots were compared to predictions. In addition to the burn rate gradient, the closed bomb pressure trace was heavily dependent on ignition and flame spread. These two phenomena were not readily distinguishable from one another in deterred grains. The same RP-36 propellant was shot in a 25 mm M793TP round which was again modeled with IBHVG2. Peak pressure and muzzle velocity were accurately modeled when erosive burning effects were empirically factored into the model.

Furrow, Keith W.↗

Fast Three-Dimensional Method of Modeling Atomic Oxygen Undercutting of Protected Polymers

A method is presented to model atomic oxygen erosion of protected polymers in low Earth orbit (LEO). Undercutting of protected polymers by atomic oxygen occurs in LEO due to the presence of scratch, crack or pin-window defects in the protective coatings. As a means of providing a better understanding of undercutting processes, a fast method of modeling atomic-oxygen undercutting of protected polymers has been developed. Current simulation methods often rely on computationally expensive ray-tracing procedures to track the surface-to-surface movement of individual "atoms." The method introduced in this paper replaces slow individual particle approaches by substituting a model that utilizes both a geometric configuration-factor technique, which governs the diffuse transport of atoms between surfaces, and an efficient telescoping series algorithm, which rapidly integrates the cumulative effects stemming from the numerous atomic oxygen events occurring at the surfaces of an undercut cavity. This new method facilitates the systematic study of three-dimensional undercutting by allowing rapid simulations to be made over a wide range of erosion parameters.

Snyder, Aaron↗

Inspection Tools

A "NASA Tech Briefs" article describing an inspection tool and technique known as Optically Stimulated Electron Emission (OSEE) led to the formation of Photo Acoustic Technology, Inc. (PAT). PAT produces sensors and scanning systems which assure surface cleanliness prior to bonding, coating, painting, etc. The company's OP1000 series realtime pre-processing detection capability assures 100 percent surface quality testing. The technique involves brief exposure of the inspection surface to ultraviolet radiation. The energy interacts with the surface layer, causing free electrons to be emitted from the surface to be picked up by the detector. When contamination is present, it interferes with the electron flow in proportion to the thickness of the contaminant layer enabling measurement by system signal output. OP1000 systems operate in conventional atmospheres on all types of material and detect both organic and inorganic contamination.

Source record↗

Hypersonic Composites Resist Extreme Heat and Stress

Through research contracts with NASA, Materials and Electrochemical Research Corporation (MER), of Tucson, Arizona, contributed a number of technologies to record-breaking hypersonic flights. Through this research, MER developed a coating that successfully passed testing to simulate Mach 10 conditions, as well as provide several additional carbon-carbon (C-C) composite components for the flights. MER created all of the leading edges for the X-43A test vehicles at Dryden-considered the most critical parts of this experimental craft. In addition to being very heat resistant, the coating had to be very lightweight and thin, as the aircraft was designed to very precise specifications and could not afford to have a bulky coating. MER patented its carbon-carbon (C-C) composite process and then formed a spinoff company, Frontier Materials Corporation (FMC), also based in Tucson. FMC is using the patent in conjunction with low-cost PAN (polyacrylonitrile)-based fibers to introduce these materials to the commercial markets. The C-C composites are very lightweight and exceptionally strong and stiff, even at very high temperatures. The composites have been used in industrial heating applications, the automotive and aerospace industries, as well as in glass manufacturing and on semiconductors. Applications also include transfer components for glass manufacturing and structural members for carrier support in semiconductor processing.

Source record↗

Cleaning Processes across NASA Centers

All significant surfaces of the hardware must be pre-cleaned to remove dirt, grit, scale, corrosion, grease, oil and other foreign matter prior to any final precision cleaning process. Metallic parts shall be surface treated (cleaned, passivated, pickled and/or coated) as necessary to prevent latent corrosion and contamination.

Hammond, John M.↗