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Abrasive jet technique, producing prototype conductor networks for thick-film hybrid microcircuits, does not require screening and fixing procedures. Pantograph engraver is used to perform abrasive cutting of the conductor network.
A new membrane composite material that combines an organosilica proton conductor with perfluorinated Nafion material to achieve good proton conductivity and high-temperature performance for membranes used for fuel cells in stationary, transportation, and portable applications has been developed. To achieve high proton conductivities of the order of 10(exp -1)S/cm over a wide range of temperatures, a composite membrane based on a new class of mesoporous, proton-conducting, hydrogen-bonded organosilica, used with Nafion, will allow for water retention and high proton conductivity over a wider range of temperatures than currently offered by Nafion alone. At the time of this reporting, this innovation is at the concept level. Some of the materials and processes investigated have shown good proton conductivity, but membranes have not yet been prepared and demonstrated.
This presentation provides the background information on NASA-GRC high voltage (HV) materials team research efforts towards electrified propulsion systems since 2016 . Additionally, it covers polymer and ceramic filler materials development for HV electrical insulation composites, copper/ carbon nanotube hybrid conductors, modeling efforts, HV test capabilities, and future material processing capabilities.
Topics covered inclde: Deployable Wireless Camera Penetrators; Hand-Held Units for Short-Range Wireless Biotelemetry; Wearable Wireless Telemetry System for Implantable BioMEMS Sensors; Electronic Escape Trails for Firefighters; Architecture for a High-to-Medium-Voltage Power Converter; 24-Way Radial Power Combiner/Divider for 31 to 36 GHz; Three-Stage InP Submillimeter-Wave MMIC Amplifier; Fast Electromechanical Switches Based on Carbon Nanotubes; Solid-State High-Temperature Power Cells; Fast Offset Laser Phase-Locking System; Fabricating High-Resolution X-Ray Collimators; Embossed Teflon AF Laminate Membrane Microfluidic Diaphragm Valves; Flipperons for Improved Aerodynamic Performance; System Estimates Radius of Curvature of a Segmented Mirror; Refractory Ceramic Foams for Novel Applications; Self-Deploying Trusses Containing Shape-Memory Polymers; Fuel-Cell Electrolytes Based on Organosilica Hybrid Proton Conductors; Molecules for Fluorescence Detection of Specific Chemicals; Cell-Detection Technique for Automated Patch Clamping; Redesigned Human Metabolic Simulator; Compact, Highly Stable Ion Atomic Clock; LiGa(OTf)(sub 4) as an Electrolyte Salt for Li-Ion Cells; Compact Dielectric-Rod White-Light Delay Lines; Single-Mode WGM Resonators Fabricated by Diamond Turning; Mitigating Photon Jitter in Optical PPM Communication; MACOS Version 3.31; Fiber-Optic Determination of N2, O2, and Fuel Vapor in the Ullage of Liquid-Fuel Tanks; Spiking Neurons for Analysis of Patterns; Symmetric Phase-Only Filtering in Particle-Image Velocimetry; Efficient Coupler for a Bessel Beam Dispersive Element; and Attitude and Translation Control of a Solar Sail Vehicle.
The program was undertaken to characterize the performance of small diameter aluminum wire ultrasonically bonded to conductors commonly encountered in hybrid assemblies, and to recommend guidelines for improving this performance. Wire, 25.4, 38.1 and 50.8 um (1, 1.5 and 2 mil), was used with bonding metallization consisting of thick film gold, thin film gold and aluminum as well as conventional aluminum pads on semiconductor chips. The chief tool for evaluating the performance was the double bond pull test in conjunction with a 72 hour - 150 C heat soak and -65 C to +150 C thermal cycling. In practice the thermal cycling was found to have relatively little effect compared to the heat soak. Pull strength will decrease after heat soak as a result of annealing of the aluminum wire; when bonded to thick film gold, the pull strength decreased by about 50% (weakening of the bond interface was the major cause of the reduction). Bonds to thin film gold lost about 30 - 40% of their initial pull strenth; weakening of the wire itself at the bond heel was the predominant cause. Bonds to aluminum substrate metallization lost only about 22%. Bonds between thick and thin film gold substrate metallization and semiconductor chips substantiated the previous conclusions but also showed that in about 20 to 25% of the cases, bond interface failure occurred at the semiconductor chip.
This presentation gives an overview of recent materials research activities carried out at NASA Glenn Research Center. The background and motivation for the development of thermally conductive electrical insulation for a high voltage (HV) turboelectric aircraft concept is briefly discussed. A summary of the challenges and technology gap associated with HV aerospace electrical systems is also covered as well as the development of electrical insulation and engineered ceramic fillers and HV test capabilities. The research has expanded to include the development of a lightweight copper/ carbon nanotube composite conductor. Applications for these materials include hybrid electric aircraft, all electric aircraft, spacecraft, electric propulsion systems, and future power transmission systems for Lunar and Martian destinations.
NASA Goddard Space Flight Center has a need for current leads used in an adiabatic demagnetization refrigerator (ADR) for space applications. These leads must comply with stringent requirements such as a heat leak of approximately 100 W or less while conducting up to 10 A of electric current, from more than 90 K down to 10 K. Additionally, a length constraint of < 300 mm length and < 50 mm diameter is to be maintained. The need for these current leads was addressed by developing a superconducting hybrid lead. This hybrid lead comprises two different high-temperature superconducting (HTS) conductors bonded together at a thermally and electrically determined optimum point along the length of the current lead. By taking advantage of material properties of each conductor type, employing advanced fabrication techniques, and taking advantage of novel insulation materials, the company was able to develop and fabricate the lightweight, low heat-leak leads currently to NASA's specs.
Recent studies have shown that the benefits gained by using graphite-epoxy composite structures may not be realized without some risk. The graphite fibers are very good electrical conductors and fibers released into the environment during a fire create a possible hazard to electrical equipment. Several graphite-epoxy hybrids were exposed to a fire and simulated explosion and their graphite fiber retention characteristics were examined. Several low melting-temperature glasses which wet and clump graphite-fibers and a glass/graphite fabric which reduced impact damage were identified as promising hybridizing components to minimize graphite fiber release.
A key technical challenge is to establish a viable concept for a MW-class hybrid gas-electric propulsion system for a commercial transport aircraft. This includes developing aircraft propulsion system conceptual designs, integrating sub-systems, high efficiency/power density electric machines, flight-weight power system and electronics, and enabling materials in high voltage insulation, high frequency soft magnetics, and conductors. The primary benefit of this research is to diversify the current turbofan propulsion options to include hybrid electric propulsion elements that reduce energy usage, emissions, and noise. A reconfigurable powertrain testbed at NASA Glenn Research Center is described including test results from the initial 500 kW powertrain configuration.
A key technical challenge is to establish a viable concept for a MW-class hybrid gas-electric propulsion system for a commercial transport aircraft. This includes developing aircraft propulsion system conceptual designs, integrating sub-systems, high efficiency/power density electric machines, flight-weight power system and electronics, and enabling materials in high voltage insulation, high frequency soft magnetics, and conductors. The primary benefit of this research is to diversify the current turbofan propulsion options to include hybrid electric propulsion elements that reduce energy usage, emissions, and noise.
Conductive particles unexpectedly present in hermetically sealed hybrid microcircuit packages pose a high risk of shorting the closely spaced planar conductors within the package, causing failure of the device. The present work evaluates commercially available organic coating materials and determines the most promising ones for protection of complex microcircuits against entrapped particulate contaminants. The candidate materials were exposed to a series of physical and electrical screening tests, the results of which were used as a basis for the final coating selection. Silicones and high-purity epoxies are found to not only display excellent compatibility with microcircuits but to improve the performance of microcircuits as to voltage breakdown between adjacent conductors.
Rise in demand for wearable consumer electronics products has given an impetus to the development of flexible electronics technology encompassing flexible substrates and compatible circuitry. Also, additive manufacturing of flexible electronics is emerging rapidly via several techniques such as Inkjet and Aerosol Jet Printing (AJP). The basic component of all flexible circuits to be printed by these technologies is conductible ink, which is generally silver ink. Few studies exist on the printing of copper conductible ink and not many copper ink formulations are available in the market as that of silver inks. This study aims to develop a process development study for deposition of copper conductible lines on flexible substrates using the aerosol jet printing technology. The process development study includes investigation of photosintering parameters for obtaining desirable electrical resistance and shear load to failure values for the printed line. Different pre-drying techniques such as oven pre-drying and platen pre-drying have been used for improving the electrical and mechanical properties of the conductive traces. Techniques such as optical microscopy and white light interferometry have been used for the characterization of print quality of the conductible lines.
A digital computer code CAVE (Conduction Analysis Via Eigenvalues), which finds application in the analysis of two dimensional transient heating of hypersonic vehicles is described. The CAVE is written in FORTRAN 4 and is operational on both IBM 360-67 and CDC 6600 computers. The method of solution is a hybrid analytical numerical technique that is inherently stable permitting large time steps even with the best of conductors having the finest of mesh size. The aerodynamic heating boundary conditions are calculated by the code based on the input flight trajectory or can optionally be calculated external to the code and then entered as input data. The code computes the network conduction and convection links, as well as capacitance values, given basic geometrical and mesh sizes, for four generations (leading edges, cooled panels, X-24C structure and slabs). Input and output formats are presented and explained. Sample problems are included. A brief summary of the hybrid analytical-numerical technique, which utilizes eigenvalues (thermal frequencies) and eigenvectors (thermal mode vectors) is given along with aerodynamic heating equations that have been incorporated in the code and flow charts.
The method of solution is a hybrid analytical numerical technique which utilizes eigenvalues and eigenvectors. The method is inherently stable, permitting large time steps even with the best of conductors with the finest of mesh sizes which can provide a factor of five reduction in machine time compared to conventional explicit finite difference methods when structures with small time constants are analyzed over long time periods. This code will find utility in analyzing hypersonic missile and aircraft structures which fall naturally into this class. The code is a completely general one in that problems involving any geometry, boundary conditions and materials can be analyzed. This is made possible by requiring the user to establish the thermal network conductances between nodes. Dynamic storage allocation is used to minimize core storage requirements. This report is primarily a user's manual for CAVE3 code. Input and output formats are presented and explained. Sample problems are included which illustrate the usage of the code as well as establish the validity and accuracy of the method.
Since the discovery of High-Temperature-Superconductors (HTS) in 1986, a diversity of HTS-based microwave components has been demonstrated. Because of their low conductor losses, HTS-based components are very attractive for integration into microwave circuits for space communication systems. Recent advancements have made deposition of ferroelectric thin films onto HTS thin films possible. Due to the sensitivity of the ferroelectric's dielectric constant (epsilon(sub r)) to an externally applied electric field (E), ferroelectric/superconducting structures could be used in the fabrication of low loss, tunable microwave components. In this paper, we report on our study of Ba(0.5)Sr(0.5)TiO3/YBa2Cu3O(7-delta) and Ba(0.08)Sr(0.92)TiO3/YBa2Cu3O(7-delta) ferroelectric/superconducting thin films on lanthanum aluminate (LaAlO3) substrates. For the (Ba:Sr, 0.50:0.50) epitaxial sample, a epsilon(sub r) of 425 and a loss tangent (tan delta) of 0.040 were measured at 298 K, 1.0 MHz, and zero applied E. For the same sample, a epsilon(sub r) of 360 and tan delta of 0.036 were obtained at 77 K, 1.0 MHz, and zero applied E. Variations in epsilon(sub r) from 180 to 360 were observed over an applied E range of 0V/cm less than or equal to E less than or equal to 5.62 x 10(exp 4) V/cm with little change in tan delta. However, the range of epsilon(sub r) variation for the polycrystalline (Ba:Sr, 0.08:0.92) sample over 0V/cm less than or equal to E less than or equal to 4.00 x 10(exp 4) V/cm was only 3.6 percent while tan delta increased markedly. These results indicate that a lack of epitaxy between the ferroelectric and superconducting layers decreases tuning and increases microwave losses.
Plug-in flat packs and flat conductor cable (FCC) can be used to make compact, lightweight, external monitoring system requiring minimum of hard wiring. Microelectronic monitoring panel includes replaceable integrated or hybrid circuit flat packs and FCC.
An integrating IR detector array for imaging is provided in a hybrid circuit with InSb mesa diodes in a linear array, a single J-FET preamplifier for readout, and a silicon integrated circuit multiplexer. Thin film conductors in a fan out pattern deposited on an Al2O3 substrate connect the diodes to the multiplexer, and thick film conductors also connect the reset switch and preamplifier to the multiplexer. Two phase clock pulses are applied with a logic return signal to the multiplexer through triax comprised of three thin film conductors deposited between layers. A lens focuses a scanned image onto the diode array for horizontal read out while a scanning mirror provides vertical scan.
The electrical and electrochemical properties of V-5 and V-7 vanadium oxides were investigated. The effects of pressure, temperature and moisture on the bulk resistivity of the oxides in powder, sintered, and crystalline form were determined, and the static and dynamic volt-ampere characteristics were obtained. Sintered samples tested showed better electrical stability than the compressed powder samples. Two types of commercially available vanadium pentoxide were heat-treated to obtain various crystalline oxide forms which were mounted on alumina substrates and terminated by thick-film conductors for making electrical connections. Indications are that these materials could have applications as sensors, critical-temperature resistors, high-speed switches, and temperature-compensation elements in hybrid microelectronic circuits.