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At least 307 records · Page 17

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NASA NTRS1975

Study of growth of single crystal ribbon in space

The technical feasibility is studied of growing single-crystal silicon ribbon in the space environment. Procedures are described for calculating the electromagnetic fields produced in a silicon ribbon by an rf shaping coil. The forces on the ribbon and the degree of shaping to be expected are determined. The expected steady-state temperature distribution in the ribbon is calculated in the one-dimensional approximation. Calculations on simplified models indicate, that lack of flatness of the shaped ribbon and excessive heating of the melt by the eddy currents induced by the shaping fields may pose problems. An analysis of the relative effects of various kinds of forces other than electromagnetic showed that in the space environment capillarity forces would dominate, and that the shape of the melt is thus principally determined by the shape of any solids with which it comes in contact. This suggests that ribbon may be produced simply by drawing between parallel wires. A concept is developed for a process of off-angle growth, in which the ribbon is pulled at an angle to the solidification front. Such a process promises to offer increased growth rate, better homogeneity, and thinner ribbon.

Wood, V. E.↗

NASA NTRS1976

Space processing in early Shuttle missions

The paper first reviews potential scientific and commercial benefits of space processing, and discusses roles of ground laboratory, sounding rocket, and Shuttle/Spacelab experimentation in carrying out space processing programs. Benefits which have been identified in such processes as containerless melting/solidification, electrophoresis, crystal growing, etc., and using such specific materials as tungsten, isoenzymes, single crystal silicon ribbon are utilized as specific examples in the above discussion. As a result, the paper identifies spectrum of specific objectives and implementation approaches for Shuttle/Spacelab experimentation. The paper then reviews currently planned Shuttle/Spacelab payload accommodations and traffic model. Finally, the paper matches experimentation approaches with Shuttle/Spacelab plans, and derives a possible schedule of missions in the 1979-1982 time frame using configurations with a high degree of automation where crew time for experiment involvement is limited.

Bloom, H. L.↗

NASA NTRS1976

Flexible, FEP-Teflon covered solar cell module development

Techniques and equipment were developed for the large scale, low-cost fabrication of lightweight, roll-up and fold-up, FEP-Teflon encapsulated solar cell modules. Modules were fabricated by interconnecting solderless single-crystal silicon solar cells and heat laminating them at approximately 300 C between layers of optically clear FEP and to a loadbearing Kapton substrate sheet. Modules were fabricated from both conventional and wraparound contact solar cells. A heat seal technique was developed for mechanically interconnecting modules into an array. The electrical interconnections for both roll-up and fold-up arrays were also developed. The use of parallel-gap resistance welding, ultrasonic bonding, and thermocompression bonding processes for attaching interconnects to solar cells were investigated. Parallel-gap welding was found to be best suited for interconnecting the solderless solar cells into modules. Details of the fabrication equipment, fabrication processes, module and interconnect designs, environmental test equipment, and test results are presented.

Rauschenbach, H. S.↗

NASA NTRS1977

Solar photovoltaics - An aerospace technology

Specific problems affecting the development of low-cost silicon solar array power sources are discussed, taking into account the potential of realizing less than $0.50/per peak watt of silicon solar array technology. A utilization of less expensive processes for the manufacture of pure silicon and more economical procedures of silicon crystal and wafer production appear desirable. Attention is given to a sheet growth process example and a concept of pulsed processing for automated cell production.

Goldsmith, J. V.↗

NASA NTRS1977

Satellite power system LEO vs GEO assembly issues

A strawman crystal-silicon 5-GW Satellite Power System (SPS) concept formed the basis of a study of construction concepts for building a complete SPS in low earth orbit (LEO) or geosynchronous orbit (GEO). Construction scenarios were evolved, including factory-in-space concepts and operations. Design implications imposed on the SPS satellite as a consequence of in-orbit assembly operations, and related attitude control requirements during assembly in LEO or GEO environments, were also evaluated. Results are presented indicating that complete assembly of an operational SPS in LEO, followed by transport to GEO, does not appear technically desirable. The best mix, however, of LEO versus GEO construction activity remains to be resolved.

Mockovciak, J., Jr.↗

NASA NTRS1978

Low-cost high purity production

Economical process produces high-purity silicon crystals suitable for use in solar cells. Reaction is strongly exothermic and can be initiated at relatively low temperature, making it potentially suitable for development into low-cost commercial process. Important advantages include exothermic character and comparatively low process temperatures. These could lead to significant savings in equipment and energy costs.

Kapur, V. K.↗

NASA NTRS1978

Solar power satellite system definition study. Part 3: Preferred concept system definition

A concise but complete system description for the preferred concept of the Solar Power Satellite System is presented. Significant selection decisions included the following: (1) single crystal silicon solar cells; (2) glass encapsulated solar cell blankets; (3) concentration ratio 1; (4) graphite composite materials for primary structure; (5) electric propulsion for attitude control; (6) klystron RF amplifier tubes for the transmitter; (7) one kilometer diameter transmitter with a design trans mission link output power of 5,000 megawatts; (8) construction in low earth orbit with self-powered transfer of satellite modules to geosynchronous orbit; and (9) two-stage winged fully reusable rocket vehicle for transportation to low earth orbit.

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NASA NTRS1978

Floating substrate process: Large-area silicon sheet task low-cost solar array project

Supercooling of silicon-tin alloy melts was studied. Values as high as 78 C at 1100 C and 39 C at 1200 C were observed, corresponding to supersaturation parameter values 0.025 and 0.053 at 1050 C and 1150 C, respectively. The interaction of tin with silane gas streams was investigated over the temperature range 1000 to 1200 C. Single-pass conversion efficiencies exceeding 30% were obtained. The growth habit of spontaneously-nucleated surface growth was determined to be consistent with dendritic and web growth from singly-twinned triangular nucleii. Surface growth of interlocking silicon crystals, thin enough to follow the surface of the liquid and with growth velocity as high as 5 mm/min, was obtained. Large area single-crystal growth along the melt surface was not achieved. Small single-crystal surface growth was obtained which did not propagate beyond a few millimeters.

Garfinkel, M.↗

NASA NTRS1978

Solar power satellites - Heat engine or solar cells

A solar power satellite is the energy-converting element of a system that can deliver some 10 GW of power to utilities on the earth's surface. We evaluated heat engines and solar cells for converting sunshine to electric power at the satellite. A potassium Rankine cycle was the best of the heat engines, and 50 microns thick single-crystal silicon cells were the best of the photovoltaic converters. Neither solar cells nor heat engines had a clear advantage when all factors were considered. The potassium-turbine power plant, however, was more difficult to assemble and required a more expensive orbital assembly base. We therefore based our cost analyses on solar-cell energy conversion, concluding that satellite-generated power could be delivered to utilities for around 4 to 5 cents a kWh.

Oman, H.↗

NASA NTRS1977

Space-based solar power conversion and delivery systems study. Volume 2: Engineering analysis

The technical and economic feasibility of Satellite Solar Power Systems was studied with emphasis on the analysis and definition of an integrated strawman configuration concept, from which credible cost data could be estimated. Specifically, system concepts for each of the major subprogram areas were formulated, analyzed, and iterated to the degree necessary for establishing an overall, workable baseline system design. Cost data were estimated for the baseline and used to conduct economic analyses. The baseline concept selected was a 5-GW crystal silicon truss-type photovoltaic configuration, which represented the most mature concept available. The overall results and major findings, and the results of technical analyses performed during the final phase of the study efforts are reported.

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NASA NTRS1978

Solar power satellite

The solar power satellite (SPS) concept, under evaluation by NASA since 1974, is discussed. A typical system providing a total of 10,000 MW of electrical power to the ground receiving stations is considered. Energy conversion systems, including the photovoltaic device category using single-crystal silicon cells, are taken into account, as are the 2.45-GHz microwave power-transmission link and the ground receiver (or rectenna). Concepts involving space construction of the satellite's large structures (5 x 25 km) are described, noting that a process similar to the familiar roll-forming of light sheet metal parts has been adapted to the space environment. Transportation vehicles are discussed, including the Space Shuttle planned to reach 60 flights per year by the mid 1980's. Electrical power forecasts and advanced systems cost projections are analyzed, together with a description of costs estimates. The indirect economics of energy research and development, and the present NASA/DOE SPS program are noted.

Davis, H. P.↗

NASA NTRS1981

Silicon Ingot Casting - Heat Exchanger Method (HEM). Multi-Wire Slicing - Fixed Abrasive Slicing Technique (Fast). Phase 4 Silicon Sheet Growth Development for the Large Area Sheet Task of the Low-Cost Solar Array Project

The crystallinity of large HEM silicon ingots as a function of heat flow conditions is investigated. A balanced heat flow at the bottom of the ingot restricts spurious nucleation to the edge of the melted-back seed in contact with the crucible. Homogeneous resistivity distribution over all the ingot has been achieved. The positioning of diamonds electroplated on wirepacks used to slice silicon crystals is considered. The electroplating of diamonds on only the cutting edge is described and the improved slicing performance of these wires evaluated. An economic analysis of value added costs of HEM ingot casting and band saw sectioning indicates the projected add on cost of HEM is well below the 1986 allocation.

Schmid, F.↗

NASA NTRS1981

Low cost solar array project production process and equipment task. A Module Experimental Process System Development Unit (MEPSDU)

Technical readiness for the production of photovoltaic modules using single crystal silicon dendritic web sheet material is demonstrated by: (1) selection, design and implementation of solar cell and photovoltaic module process sequence in a Module Experimental Process System Development Unit; (2) demonstration runs; (3) passing of acceptance and qualification tests; and (4) achievement of a cost effective module.

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NASA NTRS1981

Evaluation and verification of epitaxial process sequence for silicon solar-cell production

Several process sequences are shown to be of potentially low cost and to perform effectively when applied to the high quality silicon crystals for which they were developed. The extent to which such process sequences can also perform effectively when applied to lower cost thin film solar cells formed by epitaxial deposition of Si on potentially inexpensive substrates of upgraded metallurgical grade Si was investigated.

Redfield, D.↗

NASA NTRS1981

A Module Experimental Process System Development Unit (MEPSDU)

Design work for a photovoltaic module, fabricated using single crystal silicon dendritic web sheet material, resulted in the identification of surface treatment to the module glass superstrate which improved module efficiencies. A final solar module environmental test, a simulated hailstone impact test, was conducted on full size module superstrates to verify that the module's tempered glass superstrate can withstand specified hailstone impacts near the corners and edges of the module. Process sequence design work on the metallization process selective, liquid dopant investigation, dry processing, and antireflective/photoresist application technique tasks, and optimum thickness for Ti/Pd are discussed. A noncontact cleaning method for raw web cleaning was identified and antireflective and photoresist coatings for the dendritic webs were selected. The design of a cell string conveyor, an interconnect feed system, rolling ultrasonic spot bonding heat, and the identification of the optimal commercially available programmable control system are also discussed. An economic analysis to assess cost goals of the process sequence is also given.

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NASA NTRS1982

Bread board float zone experiment system for high purity silicon

A breadboard float zone experimental system has been established at Westech Systems for use by NASA in the float zone experimental area. A used zoner of suitable size and flexibility was acquired and installed with the necessary utilities. Repairs, alignments and modifications were made to provide for dislocation free zoning of silicon. The zoner is capable of studying process parameters used in growing silicon in gravity and is flexible to allow trying of new features that will test concepts of zoning in microgravity. Characterizing the state of the art molten zones of a growing silicon crystal will establish the data base against which improvements of zoning in gravity or growing in microgravity can be compared. 25 mm diameter was chosen as the reference size, since growth in microgravity will be at that diameter or smaller for about the next 6 years. Dislocation free crystals were growtn in the 100 and 111 orientations, using a wide set of growth conditions. The zone shape at one set of conditions was measured, by simultaneously aluminum doping and freezing the zone, lengthwise slabbing and delineating by etching. The whole set of crystals, grown under various conditions, were slabbed, polished and striation etched, revealing the growth interface shape and the periodic and aperiodic natures of the striations.

Kern, E. L.↗

NASA NTRS1982

Microdistribution of oxygen in silicon and its effects on electronic properties

The effects of interstitial oxygen on the electrical characteristics of Czochralski-grown silicon crystals were investigated for the first time on a microscale. It was found that the generation of thermal donors is not a direct function of the oxygen concentration. It was further found that the minority carrier life-time decreases with increasing oxygen concentration, on a microscale in as-grown crystals. It was thus shown, again for the first time, that oxygen in as grown crystals is not electronically inert as generally believed. Preannealing at 1200 C commonly employed in device fabrication, was found to suppress the donor generation at 450 C and to decrease the deep level concentrations.

Gatos, H. C.↗

NASA NTRS1983

Properties of large nearly perfect crystals at very low temperatures

A liquid helium cryostat of a size and construction unavailable commercially, was built for use in measuring the Q of several materials at milli-Kelvin temperatures. The design and testing of the cryostat is described as well as the design of the experiment vacuum chamber and adaptor for the dilution refrigerator insert. Theory, design, and testing are also discussed for the magnetic coils built to levitate the materials so as to isolate them and increase the measured Q. A four point suspension with capacitor end plates as the transducer was used to obtain preliminary Q measurements of 6061 aluminum alloy and single crystal silicon. Results are tabulated.

Davis, W.↗