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NASA NTRS2010

Calibration Designs for Non-Monolithic Wind Tunnel Force Balances

This research paper investigates current experimental designs and regression models for calibrating internal wind tunnel force balances of non-monolithic design. Such calibration methods are necessary for this class of balance because it has an electrical response that is dependent upon the sign of the applied forces and moments. This dependency gives rise to discontinuities in the response surfaces that are not easily modeled using traditional response surface methodologies. An analysis of current recommended calibration models is shown to lead to correlated response model terms. Alternative modeling methods are explored which feature orthogonal or near-orthogonal terms.

Wind tunnel models↗

NASA NTRS2011

Development of Meandering Winding Magnetometer (MWM (Register Trademark)) Eddy Current Sensors for the Health Monitoring, Modeling and Damage Detection of High Temperature Composite Materials

The increased use of high-temperature composite materials in modern and next generation aircraft and spacecraft have led to the need for improved nondestructive evaluation and health monitoring techniques. Such technologies are desirable to improve quality control, damage detection, stress evaluation and temperature measurement capabilities. Novel eddy current sensors and sensor arrays, such as Meandering Winding Magnetometers (MWMs) have provided alternate or complimentary techniques to ultrasound and thermography for both nondestructive evaluation (NDE) and structural health monitoring (SHM). This includes imaging of composite material quality, damage detection and .the monitoring of fiber temperatures and multidirectional stresses. Historically, implementation of MWM technology for the inspection of the Space Shuttle Orbiter Reinforced Carbon-Carbon Composite (RCC) leading edge panels was developed by JENTEK Sensors and was subsequently transitioned by NASA as an operational pre and post flight in-situ inspection at the Kennedy Space Center. A manual scanner, which conformed'automatically to the curvature of the RCC panels was developed and used as a secondary technique if a defect was found during an infrared thermography screening, During a recent proof of concept study on composite overwrapped pressure vessels (COPV's), three different MWM sensors were tested at three orientations to demonstrate the ability of the technology to measure stresses at various fiber orientations and depths. These results showed excellent correlation with actual surface strain gage measurements. Recent advancements of this technology have been made applying MWM sensor technology for scanning COPVs for mechanical damage. This presentation will outline the recent advance~ in the MWM.technology and the development of MWM techniques for NDE and SHM of carbon wra~ped composite overwrapped pressure vessels (COPVs) including the measurement of internal stresses via a surface mounted sensor array. In addition, this paper will outline recent efforts to produce sensors capable of making real-time measurements at temperatures up to 850 C, and discuss previous results demonstrating capability to monitor carbon fiber temperature changes within a composite material.

Russell, Richard↗

NASA NTRS2013

The Behavior of Environmentally Friendly Corrosion Preventative Compounds in an Aggressive Coastal Marine Environment

The shift to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. The CPCs, while a temporary protective coating, must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different soft film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. The CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing . The initial results for the fifteen CPC systems are reported : Key words: corrosion preventive compound, CPC, spaceport, environmentally friendly, atmospheric exposure, marine, carbon steel, aluminum alloy, galvanic corrosion, wire on bolt.

Montgomery, Eliza L.↗

NASA NTRS2013

Environmentally Friendly Corrosion Preventative Compounds for Ground Support Structures

The need to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. CPCs are used as temporary protective coatings and must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different oily film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing. The results for the fifteen CPC systems are presented in this paper.

Montgomery Eliza L.↗

NASA NTRSDate not supplied

New VIIRS DNB Stray Light Correction Method

The Day/Night Band (DNB) broadband (500-900nm) imager is one of the sensors in the Visible Infrared Imaging Radiometer Suite (VIIRS) on-board the Suomi National Polar-orbiting Partnership (SNPP) and the NOAA-20 satellites, which are polar-orbiting and fly at about 830km above the surface of the Earth. Depending on the satellite location and the sensor viewing geometry, for a short period just before (or after) the satellite enters into (or emerges from) the shadow of the Earth, unwanted stray light, seemingly caused by the reflection of solar beam on the slightly exposed inner side of the leading (or trailing) nadir door, can enter the instrument and impose noticeable impacts to a narrow portion of DNB satellite images in every orbit. The impacted images can be modified to look normal, and the current DNB stray light correction algorithm empirically assigns corrections. There is also an alternative approach using image-processing techniques. Both methods rely mainly on the stray light impacted measurements. To simplify the approach and for better correction results, the new method presented in this paper incorporates the observed asymptotic nature of measurements surrounding the stray light impacted region by fitting to the drop off in sun light from day to night. The new method can be applied to the raw measurements in real-time, and it can help to advance our understanding of this special type of DNB stray light that happens over the polar regions

VIIRS↗

NASA NTRSDate not supplied

Predicting Maximum Thermal Response in a Li-ion Cell as a Thermal Runaway Predictor for a UAV Fight

As the energy storage devices continue to "pack" more energy in a small space, any damage, battery component failure, manufacturing defect, or electrically abusing the battery can lead to catastrophic thermal runaway events. A catastrophic thermal event in a cell leads to high temperature, in some instances to spewing of battery materials due to gas development from side reactions initiated due to high internal temperatures. Moreover, a thermal runaway can propagate from a single "failed" cell to a whole battery pack, resulting in a more serious event. The commercial and automotive sectors need to mitigate thermal runaway events. An electric aircraft (or air taxi) has no alternative in the event of a failure, so preventing such events is paramount. Currently, battery prognostics algorithms only predict the state-of-charge (SOC) and end-of-life (EOL) of a Li-ion battery in a UAV (unmanned air vehicle), but do not predict the maximum temperature during a flight or the likelihood of thermal runaway. Our current work focuses on adding the thermal model (based on Birkl's OCV model, in Ref. [1]) to the existing hybrid electrochemical model (single-particle model with lumped parameters as in Ref. [2]) to determine end-of-discharge, end-of-life, and maximum temperature during discharge.

Thermal runaway↗

NASA NTRSDate not supplied

Ground Test Stand Development for One-step Electrochemical Production of High-Pressure Oxygen

NASA designed a test rig, High-Pressure Oxygen Generation Assembly (HPOGA) to test a novel method of electrolysis as an alternative technology to the state-of-the-art Oxygen Generation Assembly (OGA) currently on the International Space Station (ISS). This approach involves utilizing a specialized electrolysis cell stack designed to both generate and compress high-pressure oxygen up to 3600 PSIG. The design eliminates the need for an external compressor and hydrogen separator, streamlining the oxygen generation process. HPOGA tests the viability of an electrolysis cell stack for extended life usage. Within the system, there are several key subsystems: nitrogen, high/low pressure oxygen, hydrogen, water recirculation, and water injection. The water injection subsystem supplies deionized (DI) water to a centralized reservoir for consumption. Subsequently, a water recirculation loop transfers the DI water across the cathode side of the electrolysis cell stack with constant flow rate. The result is a supply of hydrogen in the water loop and oxygen accumulation on the anode side of the cell stack. Hydrogen is evaporated out as part of the hydrogen sub-system which also measures hydrogen/oxygen concentration for safety. The oxygen subsystem is responsible for managing high pressure oxygen, O2 exhaust, and conducting hydrogen/oxygen concentration measurements. The nitrogen subsystem serves dual functions, purging the hydrogen/oxygen subsystems, and regulating pressure in both high/low-pressure O2 sections via pneumatic back pressure regulators. Various sensors monitor pressure, temperature, humidity, gas concentration and flow rate in each subsystem. This paper presents the design and testing of a comprehensive test stand, which serves to operate and functionally verify the performance of the electrolysis cell while offering valuable lessons learned.

electrolysis↗

NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic composites

Thermoplastics↗

NASA NTRSDate not supplied

Evaluating Crystallinity in Thermoplastic Composites for Aerospace Applications

Polymer matrix composites (PMCs) offer many benefits for the aerospace industry due to their potential for weight reduction when compared to metal or ceramic based materials. Most PMCs currently in flight use thermoset matrices, however, thermoplastic resins are being explored as alternatives due to their ability to be remelted, which is of particular interest due to the potential for in-situ repair and faster production. Most thermoplastic resins are semicrystalline polymers. The properties of semicrystalline thermoplastics are directly influenced by their crystallinity, which can vary due to many factors including thermal treatments, environmental conditions, and mechanical deformation. Within thermoplastic PMC parts, crystallinity gradients can arise due to variations in part geometry, across part thicknesses, and along bonded joints. Monitoring the crystallinity of thermoplastic composites is key to ensuring these materials meet the high demands required for aerospace. Several different analytical techniques exist that can be used to characterize the bulk crystallinity of thermoplastic materials. However, many existing methods lack the specificity required to identify the subtle variations in crystallinity that may play a significant role in the performance and durability of PMC parts. Because of this, a significant amount of work is still required to fully characterize and understand the crystallinity profiles of thermoplastic PMCs and the resulting impact to material properties. This talk discusses the use of multiple techniques such as Differential Scanning Calorimetry, Polarized Light Optical Microscopy, and Fourier-Transform Infrared Spectroscopy to characterize the crystallinity in carbon fiber/thermoplastic composites. Samples of different crystallinity profiles were manufactured using various cooling procedures. This work aims to provide the fundamental data necessary to understand the effects of crystallinity on thermoplastic PMCs, which is key to advancing their use in aerospace applications.

Thermoplastics↗

DOE OSTI2012

Interpretation of the effects of electron cyclotron power absorption in pre-disruptive tokamak discharges in ASDEX Upgrade

Tokamak disruptions are events of fatal collapse of the magnetohydrodynamic (MHD) confinement configuration, which cause a rapid loss of the plasma thermal energy and the impulsive release of magnetic energy and heat on the tokamak first wall components. The physics of the disruptions is very complex and non-linear, strictly associated with the dynamics of magnetic tearing perturbations. The crucial problem of the response to the effects of localized heat deposition and current driven by external (rf) sources to avoid or quench the MHD tearing instabilities has been investigated both experimentally and theoretically on the ASDEX Upgrade tokamak. The analysis of the conditions under which a disruption can be prevented by injection of electron cyclotron (EC) rf power, or, alternatively, may be caused by it, shows that the local EC heating can be more significant than EC current drive in ensuring neoclassical tearing modes (NTMs) stability, due to two main reasons: first, the drop of temperature associated with the island thermal short circuit tends to reduce the neoclassical character of the instability and to limit the EC current drive generation; second, the different effects on the mode evolution of both the location of the power deposition relative to the island separatrix and the island shape deformation lead to less strict requirements of precise power deposition focussing. A contribution to the validation of theoretical models of the events associated with NTM is given and can be used to develop concepts for their control, relevant also for ITER-like scenarios.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Bifurcations of the magnetic axis and the alternating-hyperbolic sawtooth

Here we present a sawtooth model that explains observations where the central safety factor, q 0 , stays well below one, which is irreconcilable with current models that predict a reset to q 0 = 1 after the crash. We identify the structure of the field around the magnetic axis with elements of the Lie group $\mathrm{SL}(2,\ \mathbb{R})$ and find a transition to an alternating-hyperbolic geometry when q 0 = 2/3. This transition is driven by an ideal MHD instability and leads to a chaotic magnetic field near the axis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1978

Forward-bias capacitance and current measurements for determining lifetimes and band narrowing in p-n junction solar cells

A new method is described and illustrated for determining the minority-carrier diffusion length and lifetime in the base region of p-n junction solar cells. The method requires only capacitance measurements at the device terminals and its accuracy is estimated to be + or - 5%. It is applied to a set of silicon p-n junction devices and the values of the diffusion lengths agree with those obtained using the current response to X-ray excitation but disagree with those obtained by the OCVD method. The reasons for the relative inaccuracy of OCVD applied to silicon devices are discussed. The capacitance method includes corrections for a two-dimensional fringing effects which occur in small area devices. For a device having highly-doped base region and surface (emitter) layer, the method can be extended to enable the determination of material properties of the degenerately doped surface layer. These material properties include the phenomenological emitter lifetime and a measure of the energy band-gap narrowing in the emitter. An alternate method for determining the energy band-gap narrowing from temperature dependence of emitter current is discussed and demonstrated.

Neugroschel, A.↗

DOE OSTI2013

High Rate Laser Pitting Technique for Solar Cell Texturing

Efficiency of crystalline silicon solar cells can be improved by creating a texture on the surface to increase optical absorption. Different techniques have been developed for texturing, with the current state-of-the-art (SOA) being wet chemical etching. The process has poor optical performance, produces surfaces that are difficult to passivate or contact and is relatively expensive due to the use of hazardous chemicals. This project shall develop an alternative process for texturing mc-Si using laser micromachining. It will have the following features compared to the current SOA texturing process: (1) Superior optical surfaces for reduced front-surface reflection and enhanced optical absorption in thin mc-Si substrates (2) Improved surface passivation (3) More easily integrated into advanced back-contact cell concepts (4) Reduced use of hazardous chemicals and waste treatment (5) Similar or lower cost. The process is based on laser pitting. The objective is to develop and demonstrate a high rate laser pitting process which will exceed the rate of former laser texturing processes by a factor of ten. The laser and scanning technologies will be demonstrated on a laboratory scale, but will use inherently technologies that can easily be scaled to production rates. The drastic increase in process velocity is required for the process to be implemented as an in-line process in PV manufacturing. The project includes laser process development, development of advanced optical systems for beam manipulation and cell reflectivity and efficiency testing. An improvement of over 0.5% absolute in efficiency is anticipated after laser-based texturing. The surface textures will be characterized optically, and solar cells will be fabricated with the new laser texturing to ensure that the new process is compatible with high-efficiency cell processing. The result will be demonstration of a prototype process that is suitable for scale-up to a production tool and process. The developed technique will have an reducing impact on product pricing. As efficiency has a substantial impact on the economics of solar cell production due to the high material cost content; in essence, improved efficiency through cost-effective texturing reduces the material cost component since the product is priced in terms of $/W. The project is a collaboration between Fraunhofer USA, Inc. and a c-Si PV manufacturer.

14 SOLAR ENERGY↗

DOE OSTI2019

Perspectives on Low-Temperature Electrolysis and Potential for Renewable Hydrogen at Scale

Hydrogen is an important part of any discussion on sustainability and reduction in emissions across major energy sectors. In addition to being a feedstock and process gas for many industrial processes, hydrogen is emerging as a fuel alternative for transportation applications. Renewable sources of hydrogen are therefore required to increase in capacity. Low-temperature electrolysis of water is currently the most mature method for carbon-free hydrogen generation and is reaching relevant scales to impact the energy landscape. However, costs still need to be reduced to be economical with traditional hydrogen sources. Operating cost reductions are enabled by the recent availability of low-cost sources of renewable energy, and the potential exists for a large reduction in capital cost withmaterial and manufacturing optimization. This article focuses on the current status and development needs by component for the low-temperature electrolysis options.

08 HYDROGEN↗

DOE OSTI2025

Harnessing Machine Learning for Agnostic Biodetection

The United States’ current list-based approach to biodefense is limited because it considers only known biological agents. Alternatively, developing and adopting a system based on agent-agnostic signatures would enable detection and characterization of both known and novel agents, thereby engendering greater adaptability in the face of an evolving threat landscape. Machine learning (ML) could aid in such a transition, as it can recognize and encode highly complex patterns from multiple input data modalities and has already demonstrated success in many healthcare and defense applications. Functionalizing ML for environmental biodetection requires understanding current technical capabilities. In this article, we provide a systematic review of existing ML platforms and discuss anticipated development efforts needed to achieve effective ML-enabled, agnostic biodetection.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2017

Direct production of 99m Tc using a small medical cyclotron

This project describes an investigation towards the production of 99m Tc with a small medical cyclotron. This endeavor addresses the current urgent problem of availability of 99m Tc due to the ongoing production reactor failures and the upcoming Canadian reactor shut down. Currently, 99m Tc is produced via nuclear fission using highly enriched uranium which is a concern due to nuclear proliferation risks. In addition to this, the United States is dependent solely on currently unreliable foreign sources of this important medical isotope. Clearly, a need exists to probe alternative production routes of 99m Tc. In the first year, this project measured cross-sections and production yields of potential pathways to 99m Tc and associated radionuclidic impurities produced via these pathways using a small 15 MeV medical cyclotron. During the second and third years target systems for the production of 99m Tc via the most promising reaction routes were developed and separation techniques for the isolation of 99m Tc from the irradiated target material will be investigated. Systems for the recycling of the enriched target isotopes as well as automated target processing systems were examined in years four and five. This project has the potential to alleviate some of the current crisis in the medical community by developing a technique to produce 99m Tc on location at a university hospital. This technology will be applicable at many other sites in the United States as many other similar, low energy (<20 MeV) cyclotrons (currently used for a few hours per day for the production of [ 18 F]fluorodeoxyglucose) are available for production of 99m Tc though this method, thus leading to job creation and preservation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2016

Direct production of 99m Tc using a small medical cyclotron

07 ISOTOPE AND RADIATION SOURCES↗

NASA NTRS1999

Study the Effects of Charged Particle Radiation on Gravitational Sensors in Space

Space-flight charging of free floating masses poses an unusual problem-- how can one control charge on the object without exerting a significant force on it? One approach is to make contact to the object with a fine wire. However, for many precision applications no physical contact is permissible, so charge must be conveyed in, a more sophisticated manner. One method has already been developed: Gravitational Probe B (GP-B) uses an ultraviolet photo-emission system described in ref 1. This system meets the experiment requirements, yet poses a number of constraints, including high power dissipation (approximately 10 W peak, approximately 1 W average), low current output (approximately 10(exp -13) A), and potential reliability problems associated with fiber optics system and the UV source. The aim of the current research is to improve this situation and, if possible, develop a more rugged and lower power alternative, usable in a wide range of situations. An potential alternative to the UV electron source is a Spindt-type field emission cathode. These consist of an array of extremely sharp silicon tips mounted in a standard IC package with provision for biasing them relative to the case potential. They are attractive as electron sources for space applications due to their low power consumption (10(exp -5) W), high current levels (10(exp -9) to 10(exp -5) A), and the absence of mechanical switching. Unfortunately, existing cathodes require special handling to avoid contamination and gas absorption. These contaminants can cause severe current fluctuations and eventual destruction of the cathode tips. Another potential drawback is the absence of any data indicating the possibility of bipolar current flow. This capability is needed because of the large uncertainties in the net charge transfer from cosmic rays to a free floating mass in space. More recent devices reduce the current fluctuations and destructive arcing by mounting the tips on a resistive substrate rather than a good conductor. This effectively wires a resistor to each individual tip, providing a current limit and thus greatly reducing the possibility of destructive arcing through an individual tip. An issue with this resistive layer is its range of operating temperatures. From the experience with the GP-B system, we hypothesized about using secondary electron emission for control of net charge transfer to an object. An important goal of the testing described below was to demonstrate the ability to apply both positive and negative charges to the test object from a single emitter.

Lipa, John A.↗

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