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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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Continuous-feeding machine automatically bonds solar cells to printed-circuit substrate. In completed machine, cells move to test station where electrical characteristics could be checked. If performance of cell is below specifications, that cell is marked and removed. All machine functions are synchronized by electronics located within unit. It may help to lower costs in future solar-cell production.
A major phase of the Federal Wind Energy Program, the Mod-2 wind turbine, a second-generation machine developed by the Boeing Engineering and Construction Co. for the U.S. Department of Energy and the Lewis Research Center of the National Aeronautics and Space Administration, is described. The Mod-2 is a large (2.5-MW power rating) horizontal-axis wind turbine designed for the generation of electrical power on utility networks. Three machines were built and are located in a cluster at Goodnoe Hills, Washington. All technical aspects of the project are described: design approach, significant innovation features, the mechanical system, the electrical power system, the control system, and the safety system.
Standard surface grinder performs precision machining of thin-wall stainless steel tubing by electrical discharge grinding. A related adaptation, a traveling wire electrode fixture, is used for machining slots in thin-walled tubing.
Technique yields joints with average transmissivity of 91.6 percent. Electric arc passed over butted fiber ends to melt them together. Maximum optical transmissivity of joint achieved with optimum choice of discharge current, translation speed, and axial compression of fibers. Practical welding machine enables delicate and tedious joining operation performed routinely.
Service train follows group of mining machines, paying out utility lines as machines progress into coal face. Service train for four mining machines removes gases and coal and provides water and electricity. Flexible, coiling armored carriers protect cables and hoses. High coal production attained by arraying row of machines across face, working side by side.
Methods of producing large areas of silicon sheets were developed by using inside diameter (I.D.) saws to slice silicon ingots. A 16 inch automated I.D. slicing machine was modified to accept programmable electric feed system, a crystal rotating system and a dyna-track blade monitoring and control system. The saw and accessories were used to slice 75 mm diameter single crystal silicon ingots while rotating them. The automated saw automatically recovered the wafers and loaded them into a cassette. The amount of material lost during slicing was reduced by using smaller blades than ones normally used to slice the wafers. Slicing runs on 100 mm diameter silicon is the next goal.
A control concept for a variable-speed wind energy conversion system is proposed, for which a self-exited asynchronous cage generator is used along with a system of thyristor converters. The control loops are the following: (1) regulation of the entrainment speed as function of available mechanical energy by acting on the resistance couple of the asynchronous generator; (2) control of electric power delivered to the asynchronous machine, functioning as a motor, for start-up of the vertical axis wind converter; and (3) limitation of the slip value, and by consequence, of the induction currents in the presence of sudden variations of input parameters.
Friction free bearings at 77 k or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape and postforming machining. The material is hard and abrasive. It's possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feel for LN2 can be used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material can be molded with the internal surfaces shielded by the Meissner effect. It might be thought of as the dc magnetic analogue of the Faraday cage and the inside can be called the Meissner space. It's selective. The ac fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.
'Friction free' bearings at 77 K or higher are possible using the high T(sub c) copper oxide ceramic superconductors. The conventional method for making such bearings is to use a sintered ceramic monolith. This puts great restraints on size, shape, and postforming machining. The material is hard and abrasive. It is possible to grind up ceramic superconductors and suspend the granules in a suitable matrix. Mechanical properties improve and are largely dependent on the binder. The Meissner effect is confined to individual grains containing electron vortices. Tracks, rails, levitation areas, and bearings can be made this way with conventional plastic molding and extruding machines or by painting. The parts are easily machined. The sacrifice is in bulk electrical conductivity. A percolating wick feed for LN2 is used to cool remote superconductors and large areas quite effectively. A hollow spheroid or cylinder of superconductor material is molded with the internal surfaces shielded by the Meissner effect. It can be thought of as the DC magnetic analog of the Faraday cage and the inside is the 'Meissner space'. It is selective. The AC fields are transmitted with minor attenuation. Particle size and distribution have a profound effect on final magnetic and electrical characteristics.
This report describes the development of a high performance, all metal compact heat exchanger. The device is designed for use in a reverse Brayton cryogenic cooler which provides five watts of refrigeration at 70 K. The heat exchanger consists of a stainless steel tube concentrically assembled within a second stainless steel tube. Approximately 300 pairs of slotted copper disks and matching annular slotted copper plates are positioned along the centerline axis of the concentric tubes. Each of the disks and plates has approximately 1200 precise slots machined by means of a special electric discharge process. Positioning of the disk and plate pairs is accomplished by means of dimples in the surface of the tubes. Mechanical and thermal connections between the tubes and plate/disk pairs are made by solder joints. The heat exchanger assembly is 9 cm in diameter by 50 cm in length and has a mass of 10 kg. The predicted thermal effectiveness is greater than 0.985 at design conditions. Pressure loss at design conditions is less than 5 kPa in both fluid passages. Tests were performed on a subassembly of plates integrally soldered to two end headers. The measured thermal effectiveness of the test article exceeded predicted levels. Pressure losses were negligibly higher than predictions.
Several previous annual reports were written and numerous papers published on the topics for this grant. That work is not repeated here in this final report. Only the work completed in the final year of the grant is presented in this final report. This final year effort concentrated on power loss measurements in magnetic bearing rotors. The effect of rotor power losses in magnetic bearings are very important for many applications. In some cases, these losses must be minimized to maximize the length of time the rotating machine can operate on a fixed energy or power supply. Examples include aircraft gas turbine engines, space devices, or energy storage flywheels. In other applications, the heating caused by the magnetic bearing must be removed. Excessive heating can be a significant problem in machines as diverse as large compressors, electric motors, textile spindles, and artificial heart pumps.
The figure depicts a unit that contains a rotary-position or a rotary-speed sensor, plus electronic circuitry necessary for its operation, all enclosed in a single housing with a shaft for coupling to an external rotary machine. This rotation sensor unit is complete: when its shaft is mechanically connected to that of the rotary machine and it is supplied with electric power, it generates an output signal directly indicative of the rotary position or speed, without need for additional processing by other circuitry. The incorporation of all of the necessary excitatory and readout circuitry into the housing (in contradistinction to using externally located excitatory and/or readout circuitry) in a compact arrangement is the major difference between this unit and prior rotation-sensor units. The sensor assembly inside the housing includes excitatory and readout integrated circuits mounted on a circular printed-circuit board. In a typical case in which the angle or speed transducer(s) utilize electromagnetic induction, the assembly also includes another circular printed-circuit board on which the transducer windings are mounted. A sheet of high-magnetic permeability metal ("mu metal") is placed between the winding board and the electronic-circuit board to prevent spurious coupling of excitatory signals from the transducer windings to the readout circuits. The housing and most of the other mechanical hardware can be common to a variety of different sensor designs. Hence, the unit can be configured to generate any of variety of outputs by changing the interior sensor assembly. For example, the sensor assembly could contain an analog tachometer circuit that generates an output proportional (in both magnitude and sign or in magnitude only) to the speed of rotation.
An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is shown to be a promising candidate tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, and is non-magnetic. Despite its high titanium content, 60NiTi is non-galling even under dry sliding. No other bearing alloy, metallic or ceramic, encompasses all of these attributes. Since 60NiTi contains such a high proportion of titanium and possesses many metallic properties, it was expected to exhibit poor tribological performance typical of titanium alloys, namely galling type behavior and rapid lubricant degradation. In this poster-paper, the oil-lubricated behavior of 60NiTi is studied.
An intermetallic nickel-titanium alloy, 60NiTi (60 wt% Ni, 40 wt% Ti), is shown to be a promising candidate tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, and is non-magnetic. Despite its high Ti content, 60NiTi is non-galling even under dry sliding. No other bearing alloy, metallic or ceramic, encompasses all of these attributes. Since 60NiTi contains such a high proportion of Ti and possesses many metallic properties, it was expected to exhibit poor tribological performance typical of Ti alloys, namely galling type behavior and rapid lubricant degradation. In this poster-paper, the oil-lubricated behavior of 60NiTi is presented.
An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.
A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.
A novel mechanism called the vibration ring is being developed to enable energy conversion elements to be incorporated into the driveline of a helicopter or other rotating machines. Unwanted vibration is transduced into electrical energy, which provides a damping effect on the driveline. The generated electrical energy may also be used to power other devices (e.g., health monitoring sensors). PZT (piezoceramic) and PMN-30%PT (single crystal) stacks, as well as a Tb_0.3 Dy_0.7 Fe_1.92 (Terfenol-D) rod with a bias magnet array and a pickup coil, were tested as alternative energy conversion elements to use within the vibration ring. They were tuned for broadband damping using shunt resistors, and dynamic compression testing was conducted in a high-speed load frame. Energy conversion was experimentally optimized at 750Hz by tuning the applied bias stress and resistance values. Dynamic testing was conducted up to 1000Hz to determine the effective compressive modulus, shunt loss factor, internal loss factor, and total loss factor. Some of the trends of modulus and internal loss factor versus frequency were unexplained. The single crystal device exhibited the greatest shunt loss factor whereas the Terfenol-D device had the highest internal and total loss factors. Simulations revealed that internal losses in the Terfenol-D device were elevated by eddy current effects, and an improved magnetic circuit could enhance its shunt damping capabilities. Alternatively, the Terfenol-D device may be simplified to utilize only the eddy current dissipation mechanism (no pickup coil or shunt) to create broadband damping.
This presentation discusses work done to assess the design of a focusing column in a miniaturized Scanning Electron Microscope (SEM) developed at the NASA Marshall Space Flight Center (MSFC) for use in-situ on the Moon-in particular for mineralogical analysis. The MSFC beam column design uses purely electrostatic fields for focusing, because of the severe constraints on mass and electrical power consumption imposed by the goals of lunar exploration and of spaceflight in general. The resolution of an SEM ultimately depends on the size of the focused spot of the scanning beam probe, for which the stated goal here is a diameter of 10 nanometers. Optical aberrations are the main challenge to this performance goal, because they blur the ideal geometrical optical image of the electron source, effectively widening the ideal spot size of the beam probe. In the present work the optical aberrations of the mini SEM focusing column were assessed using direct tracing of non-paraxial rays, as opposed to mathematical estimates of aberrations based on paraxial ray-traces. The geometrical ray-tracing employed here is completely analogous to ray-tracing as conventionally understood in the realm of photon optics, with the major difference being that in electron optics the lens is simply a smoothly varying electric field in vacuum, formed by precisely machined electrodes. Ray-tracing in this context, therefore, relies upon a model of the electrostatic field inside the focusing column to provide the mathematical description of the "lens" being traced. This work relied fundamentally on the boundary element method (BEM) for this electric field model. In carrying out this research the authors discovered that higher accuracy in the field model was essential if aberrations were to be reliably assessed using direct ray-tracing. This led to some work in testing alternative techniques for modeling the electrostatic field. Ultimately, the necessary accuracy was attained using a BEM/Fourier series hybrid approach. The presentation will give background remarks about the MSFC mini Lunar SEM concept and electron optics modeling, followed by a description of the alternate field modeling techniques that were tried, along with their incorporation into a ray-trace simulation. Next, the validation of this simulation against commercially available software will be discussed using an example lens as a test case. Then, the efficacy of aberration assessment using direct ray-tracing will be demonstrated, using this same validation case. The discussion will include practical error checks of the field solution. Finally, the ray-trace assessment of the MSFC mini Lunar SEM concept will be shown and discussed. The authors believe this presentation will be of general interest to practitioners of modeling and simulation, as well as those with a general optics background. Because electron optics and photon optics share many basic concepts (e.g., lenses, images, aberrations, etc.), the appeal of this presentation need not be restricted to just those interested in charged particle optics.