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Reliability and Engineering of Thin-Film Photovoltaic Modules. Research forum proceedings

A Research Forum on Reliability and Engineering of Thin Film Photovoltaic Modules, under sponsorship of the Jet Propulsion Laboratory's Flat Plate Solar Array (FSA) Project and the U.S. Department of Energy, was held in Washington, D.C., on March 20, 1985. Reliability attribute investigations of amorphous silicon cells, submodules, and modules were the subjects addressed by most of the Forum presentations. Included among the reliability research investigations reported were: Arrhenius-modeled accelerated stress tests on a Si cells, electrochemical corrosion, light induced effects and their potential effects on stability and reliability measurement methods, laser scribing considerations, and determination of degradation rates and mechanisms from both laboratory and outdoor exposure tests.

Ross, R. G., Jr.↗

G189A modelling of Space Station Freedom's ECLSS

This paper contains a review of the requirements and design of the Environmental Control and Life Support System (ECLSS) for Space Station Freedom; a review of the G189A ECLSS computer program model developed at Boeing for the complete configuration of pressurized elements or volumes; and some significant computed results from this model showing transient performance for subsystems responsible for Temperature and Humidity Control,. Atmosphere Control and Supply, Air Revitalization, and Water Recovery and Management. The computed results presented here are important in assessing the capabilities of the ECLSS equipment in maintaining acceptable levels of temperature, humidity, 02, N2 and (2% in the occupied volumes during crew changeout events. These events involve up to four extra crew members from the Orbiter being located temporarily in the Space Station modules in addition to the normal contingent of four crew members. These additional crew members impose additional demands on the ECLSS equipment, in order to control the levels of the aforementioned quantities. Satisfactory control of all of these quantities was achieved. The maximum computed pp C02 was in the acceptable degraded performance regime. This level is higher than the 3.00 mm Hg upper limit for normal conditions

Environmental Control and Life Support Systems (EC↗

Mir Cooperative Solar Array Project Accelerated Life Thermal Cycling Test

The Mir Cooperative Solar Array (MCSA) project was a joint U.S./Russian effort to build a photovoltaic (PV) solar array and deliver it to the Russian space station Mir. The MCSA will be used to increase the electrical power on Mir and provide PV array performance data in support of Phase 1 of the International Space Station. The MCSA was brought to Mir by space shuttle Atlantis in November 1995. This report describes an accelerated thermal life cycle test which was performed on two samples of the MCSA. In eight months time, two MCSA solar array 'mini' panel test articles were simultaneously put through 24,000 thermal cycles. There was no significant degradation in the structural integrity of the test articles and no electrical degradation, not including one cell damaged early and removed from consideration. The nature of the performance degradation caused by this one cell is briefly discussed. As a result of this test, changes were made to improve some aspects of the solar cell coupon-to-support frame interface on the flight unit. It was concluded from the results that the integration of the U.S. solar cell modules with the Russian support structure would be able to withstand at least 24,000 thermal cycles (4 years on-orbit). This was considered a successful development test.

Hoffman, David J.↗

The Imaging Properties of a Silicon Wafer X-Ray Telescope

Silicon wafers have excellent optical properties --- low microroughness and good medium-scale flatness --- which Make them suitable candidates for inexpensive flat-plate grazing-incidence x-ray mirrors. On short spatial scales (less than 3 mm) the surface quality of silicon wafers rivals that expected of the Advanced X-Ray Astrophysics Facility (AXAF) high-resolution optics. On larger spatial scales, however, performance may be degraded by the departure from flatness of the wafer and by distortions induced by the mounting scheme. In order to investigate such effects, we designed and constructed a prototype silicon-wafer x-ray telescope. The device was then tested in both visible light and x rays. The telescope module consists of 94 150-mm-diameter wafers, densely packed into the first stage of a Kirkpatrick-Baez configuration. X-ray tests at three energies (4.5, 6.4, and 8.0 keV) showed an energy-independent line spread function with full width at half maximum (FWHM) of 150 arcseconds, dominated by deviations from large-scale flatness.

Joy, M. K.↗

Progress of Ongoing NASA Lithium-Ion Cell Verification Testing for Aerospace Applications

A Lithium-ion Verification and Validation Program with the purpose to assess the capabilities of current aerospace lithium-ion (Li-ion) battery cells to perform in a low-earth-orbit (LEO) regime was initiated in 2002. This program involves extensive characterization and LEO life testing at ten different combinations of depth-of-discharge, temperature, and end-of-charge voltage. The test conditions selected for the life tests are defined as part of a statistically designed test matrix developed to determine the effects of operating conditions on performance and life of Li-ion cells. Results will be used to model and predict cell performance and degradation as a function of test operating conditions. Testing is being performed at the Naval Surface Warfare Center/Crane Division in Crane, Indiana. Testing was initiated in September 2004 with 40 Ah cells from Saft and 30 Ah cells from Lithion. The test program has been expanded with the addition of modules composed of 18650 cells from ABSL Power Solutions in April 2006 and the addition of 50 Ah cells from Mine Safety Appliances Co. (MSA) in June 2006. Preliminary results showing the average voltage and average available discharge capacity for the Saft and Lithion packs at the test conditions versus cycles are presented.

McKissock, Barbara I.↗

Effect of detector dead time on the performance of optical direct-detection communication links

Avalanche photodiodes (APDs) operating in the Geiger mode can provide a significantly improved single-photon detection sensitivity over conventional photodiodes. However, the quenching circuit required to remove the excess charge carriers after each photon event can introduce an undesirable dead time into the detection process. The effect of this detector dead time on the performance of a binary pulse-position-modulated (PPM) channel is studied by analyzing the error probability. It is shown that, when background noise is negligible, the performance of the detector with dead time is similar to that of a quantum-limited receiver. For systems with increasing background intensities, the error rate of the receiver starts to degrade rapidly with increasing dead time. The power penalty due to detector dead time is also evaluated and shown to depend critically on badkground intensity as well as dead time. Given the expected background strength in an optical channel, therefore, a constraint must be placed on the bandwidth of the receiver to limit the amount of power penalty due to detector dead time.

Chen, C.-C.↗

Distributed phased array architecture study

Variations in amplifiers and phase shifters can cause degraded antenna performance, depending also on the environmental conditions and antenna array architecture. The implementation of distributed phased array hardware was studied with the aid of the DISTAR computer program as a simulation tool. This simulation provides guidance in hardware simulation. Both hard and soft failures of the amplifiers in the T/R modules are modeled. Hard failures are catastrophic: no power is transmitted to the antenna elements. Noncatastrophic or soft failures are modeled as a modified Gaussian distribution. The resulting amplitude characteristics then determine the array excitation coefficients. The phase characteristics take on a uniform distribution. Pattern characteristics such as antenna gain, half power beamwidth, mainbeam phase errors, sidelobe levels, and beam pointing errors were studied as functions of amplifier and phase shifter variations. General specifications for amplifier and phase shifter tolerances in various architecture configurations for C band and S band were determined.

Bourgeois, Brian↗

AM03-AM121-115 Hard X-Ray Optics Development at MSFC

We have developed the electroformed-nickel replication process to enable us to fabricate light-weight hard-x-ray region. Two projects currently utilizing this technology are the production of over 250 r from 5 to 10 cm, for our HERO balloon payload, and 15- and 23-cm-diameter shells for a prototype module. The challenge for the former is to fabricate, mount, align and fly a large number of high-r constraints of a modest budget. For the latter, the challenge is to maintain high angular resolution shell thicknesses (100 micron) which make the shells extremely sensitive to electroforming stresses process does not degrade the ultra-smooth surface finish (approx. 3 A required for eventual multilayer c on these two programs.

Ramsey, Brian↗

Mast material test program (MAMATEP)

The Mast Material Test Program (MAMATEP) at NASA Lewis is discussed. Objectives include verifying the need for, and evaluating the performance of, various protection techniques for the Solar Array Assembly mast of the Space Station Photovoltaic Power Module. Mast material samples were evaluated in terms of mass and bending modulus, measured before and after environmental exposure. Test environments included atomic oxygen exposure (RF plasma asher), thermal cycling, and mechanical flexing. Protective coatings included CV-1144 silicon, a Ni/Au/InSn eutectic, and an open weave, Al braid. Results indicate that unprotected samples degrade in an atomic oxygen environment at a steady rate. Open weave, Al braid offers little protection for the fiberglass-epoxy sample in an asher environment. Ni/Au/InSn eutectic offers excellent protection in an asher environment prior to thermal cycling and mechanical flexing. Long duration asher results from unprotected samples indicate that, even though the fiberglass-epoxy degrades, a protection technique may not be necessary to ensure structural integrity. However, a protection technique may be desirable to limit or contain the amount of debris generated by the degradation of the fiberglass-epoxy.

Ciancone, Michael L.↗

Effects of Contamination and Cleaning on Parachute Structural Textile Elements

Throughout their lifecycle, parachute textiles come into contact with various other substances. This contact may occur during manufacturing and repair, storage and transportation, packing, or actual use. While this interaction does not always result in negative repercussions, it may cause a loss in material strength. This paper examines the strength degradation due to several contaminants as well as the effects of cleaning agents on common parachute materials. Materials tested were: Kevlar cord and webbing, Nylon broadcloth and webbing, and Vectran cord; all of these constitute the major structural elements for CPAS (Capsule Parachute Assembly System), the parachute system for the NASA Orion Crew Module. Contaminants tested were: sewing machine oil, dried stamping ink, dirt, basting glue, Sergene, and rust. Recommendations for cleaning (or not cleaning) these materials with respect to each of the contaminants are given in this paper, as well as recommendations for future tests.

Mollmann, Catherine↗

End-of-Test Performance and Wear Characterization of NASA's Evolutionary Xenon Thruster (NEXT) Long-Duration Test

The NASA's Evolutionary Xenon Thruster (NEXT) program is developing the next-generation solar electric ion propulsion system with significant enhancements beyond the state-of-the-art NASA Solar Electric Propulsion Technology Application Readiness (NSTAR) ion propulsion system to provide future NASA science missions with enhanced capabilities. A Long-Duration Test (LDT) was initiated in June 2005 to validate the thruster service life modeling and to quantify the thruster propellant throughput capability. Testing was recently completed in February 2014, with the thruster accumulating 51,184 hours of operation, processing 918 kg of xenon propellant, and delivering 35.5 MN-s of total impulse.As part of the test termination procedure, a comprehensive performance characterization was performed across the entire NEXT throttle table. This was performed prior to planned repairs of numerous diagnostics that had become inoperable over the course of the test. After completion of these diagnostic repairs in November 2013, a comprehensive end-of-test performance and wear characterization was performed on the test article prior to exposure to atmosphere. These data have confirmed steady thruster performance with minimal degradation as well as mitigation of numerous life limiting mechanisms encountered in the NSTAR design. Component erosion rates compare favorably to pretest predictions based on semi-empirical models used for the thruster service life assessment. Additional data relating to ion beam density profiles, facility backsputter rates, facility backpressure effects on thruster telemetry, and modulation of the neutralizer keeper current are presented as part of the end-of-test characterization. Presently the test article for the NEXT LDT has been exposed to atmosphere and placed within a clean room environment, with post-test disassembly and inspection underway.

wear tests↗

Compact Hybrid Laser Rod and Laser System

A hybrid fiber rod includes a fiber core and inner and outer cladding layers. The core is doped with an active element. The inner cladding layer surrounds the core, and has a refractive index substantially equal to that of the core. The outer cladding layer surrounds the inner cladding layer, and has a refractive index less than that of the core and inner cladding layer. The core length is about 30 to 2000 times the core diameter. A hybrid fiber rod laser system includes an oscillator laser, modulating device, the rod, and pump laser diode(s) energizing the rod from opposite ends. The rod acts as a waveguide for pump radiation but allows for free-space propagation of laser radiation. The rod may be used in a laser resonator. The core length is less than about twice the Rayleigh range. Degradation from single-mode to multi-mode beam propagation is thus avoided.

Busch, George E.↗

The Apollo Alpha Spectrometer.

Located in the Science Instrument Module of Apollo 15 and 16, the Alpha Particle Spectrometer was designed to detect and measure the energy of alpha particles emitted by the radon isotopes and their daughter products. The spectrometer sensor consisted of an array of totally depleted silicon surface barrier detectors. Biased amplifier and linear gate techniques were utilized to reduce resolution degradation, thereby permitting the use of a single 512 channel PHA. Sensor identification and in-flight radioactive calibration were incorporated to enhance data reduction.

Jagoda, N.↗

Photothermal characterization of encapsulant materials for photovoltaic modules

A photothermal test matrix and a low cost testing apparatus for encapsulant materials of photovoltaic modules were defined. Photothermal studies were conducted to screen and rank existing as well as future encapsulant candidate materials and/or material formulations in terms of their long term physiochemical stability under accelerated photothermal aging conditions. Photothermal characterization of six candidate pottant materials and six candidate outer cover materials were carried out. Principal products of photothermal degradation are identified. Certain critical properties are also monitored as a function of photothermal aging.

Liang, R. H.↗

Concepts for application of 500- to 2500-We Brayton power systems for shuttle-launched missions

A mini-Brayton power system in the power range of 500 to 2500 We utilizing the multihundred Watt isotope heat source was studied for use in shuttle-launched experiments. The system consists of a single closed gas loop containing a single-shaft, gas cooled, compressor-alternator turbine assembly; a heat source heat exchanger assembly; a startup battery package; an electrical control module; a recuperator; a gas radiator; and a multifoil superinsulation system. The basic configuration and major nuclear payloads for shuttle integration are discussed. It is concluded that mini-Brayton systems have low isotope inventories and high electrical output per thermal input, and have the capability of flying all earth orbital and interplanetary missions with little degradation in performance.

Block, H. B.↗

A modified adaptive delta modulator

This paper presents the results of a study in data compression of adaptive delta modulated video signals. The Song mode ADM is first investigated at a sampling rate of 16 Mbits/s and shown not to produce enough redundancy to warrant entropy encoding. A modified adaptive delta modulator algorithm is presented that operates at a sampling rate of 16 Mbits/s and does produce sufficient redundancy to yield a 40-50 percent data compression by using a simple code on 4 bit data blocks. Other techniques such as field interpolation and direct substitution are shown to increase the possible data compression further without noticeable degradation in the two input images used in this investigation. The effects of channel errors in the transmission of packet video over a computer network are considered. A leaky integrator is used to reduce the effects of channel errors in the data bits. It is shown that the effects of channel errors can be reduced by field interpolating those packets that can be shown to contain errors.

Barba, J.↗

Application of MMIC modules in future multiple beam satellite antenna systems

Multiple beam antenna systems for advanced communication satellites operating in the 30/20 GHz frequency bands (30 GHz uplink, 20 GHz downlink) were developed. Up to twenty 0.3 deg HPBW fixed spot beams and six 0.3 deg HPBW scanning spot beams will be required. Array-fed dual reflector antenna systems in which monolithic microwave integrated circuit (MMIC) phase shift and amplifier modules are used with each radiating element of the feed array for beam pointing and power gain were developed. The feasibility of distributed power amplification and beam pointing with MMIC modules in the elements of an array and to develop a data base for future development were demonstrated. The technical discussion centers around the potential advantages of ""monolithic'' antennas for specific applications as compared to systems using high powered TWT's. These include: reduced losses in the beam forming network; advantage of space combining and graceful degradation; dynamic control of beam pointing and illumination contour; and possibilities for cost and weight reduction.

Smetana, J.↗

Oxygen interaction with space-power materials

Data from the space shuttle flights have established that many materials experience relatively rapid degradation when exposed to the low Earth orbit ambient atmosphere, which is predominately atomic oxygen. While much was learned from samples flown on the shuttle, laboratory simulations of the shuttle environment are necessary for a detailed understanding of the various interactions which contribute to the observed degradations. These laboratory experiments are particularly important for predicting the deterioration to be expected for materials aboard orbiting power systems, which will be exposed for long periods of time and could have components operating at very high temperatures. By using a mass spectrometer to synchronously detect molecules emitted from the surface as a result of amplitude modulated oxygen ion bombardment, quantum yields were obtained as a function of ion energy. A technique was developed to obtain preliminary yield data by slowly scanning the mass setting of the mass spectrometer; measurements were extended down to zero modulation frequency; yield data was obtained for the insulating materials (Nomex, Kevlar, and Teflon) used in the construction of electrodynamic tethers; a heated sample holder was constructed to investigate the effect of sample temperature on quantum yields; and the instrumentation was developed to observe the mass spectrometer signal as a function of time during and following bombardment of the sample by a brief (approximately 1 millisecond) pulse of ions.

Eck, T. G.↗