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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 19 records

Thin-Film Organic-Based Solar Cells for Space Power

Recent advances in dye-sensitized and organic polymer solar cells have lead NASA to investigate the potential of these devices for space power generation. Dye-sensitaized solar cells were exposed to simulated low-earth orbit conditions and their performance evaluated. All cells were characterized under simulated air mass zero (AM0) illumination. Complete cells were exposed to pressures less than 1 x 10 (exp -7)torr for over a month, with no sign of sealant failure or electrolyte leakage. Cells from Solaronix SA were rapid thermal cycled under simulated low-earth orbit conditions. The cells were cycled 100 times from -80 C to 80 C, which is equivalent to 6 days in orbit. The best cell had a 4.6% loss in efficiency as a result of the thermal cycling. In a separate project, novel -Bridge-Donor-Bridge-Acceptor- (-BDBA-) type conjugated block copolymer systems have been synthesized and characterized by photoluminescence (PL). In comparison to pristine donor or acceptor, the PL emissions of final -B-D-B-A- block copolymer films were quenched over 99%. Effective and efficient photo induced electron transfer and charge separation occurs due to the interfaces of micro phase separated donor and acceptor blocks. The system is very promising for a variety high efficiency light harvesting applications. Under an SBIR contract, fullerene-doped polymer-based photovoltaic devices were fabricated and characterized. The best devices showed overall power efficiencies of approximately 0.14% under white light. Devices fabricated from 2% solids content solutions in chlorobenzene gave the best results. Presently, device lifetimes are too short to be practical for space applications.

Bailey, Sheila G.

Thin-film Organic-based Solar Cells for Space Power

Recent advances in dye-sensitized and organic polymer solar cells have lead NASA to investigate the potential of these devices for space power generation. Dye-sensitized solar cells were exposed to simulated low-earth orbit conditions and their performance evaluated. All cells were characterized under simulated air mass zero (AM0) illumination. Complete cells were exposed to pressures less than 1 x 10(exp -7) torr for over a month, with no sign of sealant failure or electrolyte leakage. Cells from Solaronix SA were rapid thermal cycled under simulated low-earth orbit conditions. The cells were cycled 100 times from -80 C to 80 C, which is equivalent to 6 days in orbit. The best cell had a 4.6 percent loss in efficiency as a result of the thermal cycling. In a separate project, novel -Bridge-Donor-Bridge- Acceptor- (-BDBA-) type conjugated block copolymer systems have been synthesized and characterized by photoluminescence (PL). In comparison to pristine donor or acceptor, the PL emissions of final -B-D-B-A- block copolymer films were quenched over 99 percent. Effective and efficient photo induced electron transfer and charge separation occurs due to the interfaces of micro phase separated donor and acceptor blocks. The system is very promising for a variety high efficiency light harvesting applications. Under an SBIR contract, fullerene-doped polymer-based photovoltaic devices were fabricated and characterized. The best devices showed overall power efficiencies of approx. 0.14 percent under white light. Devices fabricated from 2 percent solids content solutions in chlorobenzene gave the best results. Presently, device lifetimes are too short to be practical for space applications.

Bailey, Sheila G.

Study of small turbofan engines applicable to single-engine light airplanes

The design, efficiency and cost factors are investigated for application of turbofan propulsion engines to single engine, general aviation light airplanes. A companion study of a hypothetical engine family of a thrust range suitable to such aircraft and having a high degree of commonality of design features and parts is presented. Future turbofan powered light airplanes can have a lower fuel consumption, lower weight, reduced airframe maintenance requirements and improved engine overhaul periods as compared to current piston engined powered airplanes. Achievement of compliance with noise and chemical emission regulations is expected without impairing performance, operating cost or safety.

Merrill, G. L.

Structural efficiency of long lightly loaded truss and isogrid columns for space applications

The general mass characteristics of long lightly loaded columns for space applications are investigated by studying four column concepts. The first is a simple tubular column, the second is a three longeron truss column constructed of tubular members, the third is a three longeron truss column constructed of solid rod members, and the fourth is an open grid work isogrid wall tubular column. Design procedures, which include an initial imperfection in the straightness of the column, are developed for the different concepts and demonstrated numerically. A new set of structural efficiency parameters are developed for lightly loaded columns and are used to show a comparison of the masses of the four column concepts investigated.

Mikulas, M. M., Jr.

Novel High Efficient Organic Photovoltaic Materials

Solar energy is a renewable, nonpolluting, and most abundant energy source for human exploration of a remote site or outer space. In order to generate appreciable electrical power in space or on the earth, it is necessary to collect sunlight from large areas and with high efficiency due to the low density of sunlight. Future organic or polymer (plastic) solar cells appear very attractive due to their unique features such as light weight, flexible shape, tunability of energy band-gaps via versatile molecular or supramolecular design, synthesis, processing and device fabrication schemes, and much lower cost on large scale industrial production. It has been predicted that supramolecular and nano-phase separated block copolymer systems containing electron rich donor blocks and electron deficient acceptor blocks may facilitate the charge carrier separation and migration due to improved electronic ultrastructure and morphology in comparison to polymer composite system. This presentation will describe our recent progress in the design, synthesis and characterization of a novel block copolymer system containing donor and acceptor blocks covalently attached. Specifically, the donor block contains an electron donating alkyloxy derivatized polyphenylenevinylene (RO-PPV), the acceptor block contains an electron withdrawing alkyl-sulfone derivatized polyphenylenevinylene (SF-PPV). The key synthetic strategy includes the synthesis of each individual block first, then couple the blocks together. While the donor block has a strong PL emission at around 560 nm, and acceptor block has a strong PL emission at around 520 nm, the PL emissions of final block copolymers are severely quenched. This verifies the expected electron transfer and charge separation due to interfaces of donor and acceptor nano phase separated blocks. The system therefore has potential for variety light harvesting applications, including high efficient photovoltaic applications.

Sun, Sam

Crystal growth of ZnSe and related ternary compound semiconductors by physical vapor transport

The materials to be investigated are ZnSe and related ternary semiconducting alloys (e.g., ZnS(x)Se(1-x), ZnTe(x)Se(1-x), and Zn(1-x)Cd(x)Se). These materials are useful for opto-electronic applications such as high efficient light emitting diodes and low power threshold and high temperature lasers in the blue-green region of the visible spectrum. The recent demonstration of its optical bistable properties also makes ZnSe a possible candidate material for digital optical computers. The investigation consists of an extensive ground-based study followed by flight experimentation, and involves both experimental and theoretical work. The objectives of the ground-based work are to establish the characteristics of the crystals grown on Earth as a basis for subsequent comparative evaluations of the crystals grown in a low gravity environment and to obtain the experimental data and perform the analyses required to define the optimum parameters for the flight experiments. During the six months of the Preliminary Definition Phase, the research efforts were concentrated on the binary compound ZnSe - the purification of starting materials of Se by zone refining, the synthesis of ZnSe starting materials, the heat treatments of the starting materials, the vapor transport rate measurements, the vapor partial pressure measurements of ZnSe, the crystal growth of ZnSe by physical vapor transport, and various characterization on the grown ZnSe crystals.

Su, Ching-Hua

Project Profile: Hydrogen Fuel Cell Mobile Lighting Tower (HFCML)

NASA is committed to finding innovative solutions that improve the operational performance of ground support equipment while providing environment and cost benefits, as well. Through the Hydrogen Fuel Cell Mobile Lighting Tower (HFCML) project, NASA gained operational exposure to a novel application of high efficiency technologies. Traditionally, outdoor lighting and auxiliary power at security gates, launch viewing sites, fallback areas, outage support, and special events is provided by diesel generators with metal halide lights. Diesel generators inherently contribute to C02, NOx, particulate emissions, and are very noisy. In 2010, engineers from NASA's Technology Evaluation for Environmental Risk Mitigation Principal Center (TEERM) introduced KSC operations to a novel technology for outdoor lighting needs. Developed by a team led by Sandia National Laboratory (SNL), the technology pairs a 5kW hydrogen fuel cell with robust high efficiency plasma lights in a towable trailer. Increased efficiency, in both the fuel cell power source and lighting load, yields longer run times between fueling operations while providing greater auxiliary power. Because of the unit's quiet operation and no exhaust fumes, it is capable of being used indoors and in emergency situations, and meets the needs of all other operational roles for metal halide/diesel generators. The only discharge is some water and warm air. Environmental benefits include elimination of diesel particulate emissions and estimated 73% greenhouse gas emissions savings when the hydrogen source is natural gas (per GREET model). As the technology matures the costs could become competitive for the fuel cell units which are approximately 5 times diesel units. Initial operational . concerns included the hydrogen storage tanks and valves, lightning safety/grounding, and required operating and refueling procedures. TEERM facilitated technical information exchange (design drawings, technical standards, and operations manuals) necessary for KSC hydrogen system experts to approve use of the HFCML unit, including initiating the environmental checklist (i.e. exterior lighting waiver due to sea turtles), and development of operations and maintenance instructions. TEERM worked with SNL to establish a bailment agreement for KSC to utilize a Beta unit as part of normal Center Operations for a period of twelve months.

McLaughlin, Russell

1.54 micron Emission from Erbium implanted GaN for Photonic Applications

The development of efficient and compact light sources operating at 1.54 micron is of enormous importance for the advancement of new optical communication systems. Erbium (1%) doped fiber amplifiers (EDFA's) or semiconductor lasers are currently being employed as near infrared light sources. Both devices, however, have inherent limitations due to their mode of operation. EDFA's employ an elaborate optical pumping scheme, whereas diode lasers have a strongly temperature dependent lasing wavelength. Novel light emitters based on erbium doped III-V semiconductors could overcome these limitations. Er doped semiconductors combine the convenience of electrical excitation with the excellent luminescence properties of Er(3+) ions. Electrically pumped, compact, and temperature stable optoelectronic devices are envisioned from this new class of luminescent materials. In this paper we discuss the potential of Er doped GaN for optoelectronic applications based on temperature dependent photoluminescence excitation studies.

Thaik, Myo

Sol-Gel Glass Holographic Light-Shaping Diffusers

Holographic glass light-shaping diffusers (GLSDs) are optical components for use in special-purpose illumination systems (see figure). When properly positioned with respect to lamps and areas to be illuminated, holographic GLSDs efficiently channel light from the lamps onto specified areas with specified distributions of illumination for example, uniform or nearly uniform irradiance can be concentrated with intensity confined to a peak a few degrees wide about normal incidence, over a circular or elliptical area. Holographic light diffusers were developed during the 1990s. The development of the present holographic GLSDs extends the prior development to incorporate sol-gel optical glass. To fabricate a holographic GLSD, one records a hologram on a sol-gel silica film formulated specially for this purpose. The hologram is a quasi-random, micro-sculpted pattern of smoothly varying changes in the index of refraction of the glass. The structures in this pattern act as an array of numerous miniature lenses that refract light passing through the GLSD, such that the transmitted light beam exhibits a precisely tailored energy distribution. In comparison with other light diffusers, holographic GLSDs function with remarkably high efficiency: they typically transmit 90 percent or more of the incident lamp light onto the designated areas. In addition, they can withstand temperatures in excess of 1,000 C. These characteristics make holographic GLSDs attractive for use in diverse lighting applications that involve high temperatures and/or requirements for high transmission efficiency for ultraviolet, visible, and near-infrared light. Examples include projectors, automobile headlights, aircraft landing lights, high-power laser illuminators, and industrial and scientific illuminators.

Yu, Kevin

GaAs shallow-homojunction solar cells

The feasibility of fabricating space resistant, high efficiency, light weight, low cost GaAs shallow homojunction solar cells for space application is investigated. The material preparation of ultrathin GaAs single crystal layers, and the fabrication of efficient GaAs solar cells on bulk GaAs substrates are discussed. Considerable progress was made in both areas, and conversion efficiency about 16% AMO was obtained using anodic oxide as a single layer antireflection coating. A computer design shows that even better cells can be obtained with double layer antireflection coating. Ultrathin, high efficiency solar cells were obtained from GaAs films prepared by the CLEFT process, with conversion efficiency as high as 17% at AMI from a 10 micrometers thick GaAs film. A organometallic CVD was designed and constructed.

Fan, J. C. C.

Efficient IR Transmission Diffraction Grating for Circularly Polarized Light

Numerical methods, using rigorous coupled wave theory, are used to design rectangular relief diffraction gratings for an infrared application which requires comparable first order efficiencies in the TE and TM polarization states. The depth, period, and fill factor of the grating are varied to identify optimal two level binary lamellar grating profiles which predict efficiencies for individual TM and TE polarizations above 75 percent, while keeping the difference between the two efficiencies within 10 percent. The application at hand is a rotating, transmissive diffractive scanner for space-based coherent lidar. The operating wavelength is 2.0 microns. A collimated, circularly polarized beam is incident on the diffractive scanner at the Bragg angle; 30 and 45 degree beam deflection angles being studied. Fused silica is the substrate material of choice. Selected designs are fabricated on 3 inch fused silica substrates using lithographic methods. The performance of the test pieces is measured and compared to theoretical predictions.

Cole, Helen

Progress toward a 30 percent-efficient, monolithic, three-junction, two-terminal concentrator solar cell for space applications

Component efficiencies of 0.2/sq cm cells at approximately 100x AMO light concentration and 80 C temperatures are not at 15.3 percent for a 1.9 eV AlGaAs top cell, 9.9 percent for a 1.4 eV GaAs middle cell under a 1.9 eV AlGaAs filter, and 2.4 percent for a bottom 1.0 eV InGaAs cell under a GaAs substrate. The goal is to continue improvement in these performance levels and to sequentially grow these devices on a single substrate to give 30 percent efficient, monolithic, two-terminal, three-junction space concentrator cells. The broad objective is a 30 percent efficient monolithic two-terminal cell that can operate under 25 to 100x AMO light concentrations and at 75 to 100 C cell temperatures. Detailed modeling predicts that this requires three junctions. Two options are being pursued, and both use a 1.9 eV AlGaAs top junction and a 1.4 eV GaAs middle junction grown by a 1 atm OMVPE on a lattice matched substrate. Option 1 uses a low-doped GaAs substrate with a lattice mismatched 1.0 eV InGaAs cell formed on the back of the substrate. Option 2 uses a Ge substrate to which the AlGaAs and GaAs top junctions are lattice matched, with a bottom 0.7 eV Ge junction formed near the substrate interface with the GaAs growth. The projected efficiency contributions are near 16, 11, and 3 percent, respectively, from the top, middle, and bottom junctions.

Partain, L. D.

Recent progress in the development of antimonide-based mid-ir interband cascade lasers

Antimonide-based type-II interband cascade lasers are promising in becoming efficient and compact mid-infrared light sources for many applications such as gas sensing and environmental monitoring. Significant progress toward such a goal has recently been made in terms of achieving low threshold current densities, high temperature operation, and continuous wave operation of single-mode distributed feedback lasers. We review the recent progress of Sb-based mid-IR IC lasers and address the requirements for further improvements in their performance.

semiconductor superlattices

Recent progress in development of mid-IR interband cascade lasers

Type-II interband cascade lasers are promising in becoming efficient and compact mid-infrared light sources for many applications. Significant progress toward such a goal has recently been made in terms of lowering their threshold current densities and raising operation temperature. Also, continuous wave operation of single-mode distributed feedback interband cascade lasers has been demonstrated. We review the recent progress of the Sb-based mid-IR interband cascade lasers and present some latest results.

lasers

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing