Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “difficult”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

Combining Information on Multiple Detection Techniques to Estimate the Effect of Patent Foramen Ovale on Susceptibility to Decompression Illness

The assembly and the maintenance of the International Space Station is expected to require hundreds of extravehicular excursions (EVA's) in the next 10 years. During an EVA, in order to allow movement and bending of limbs, spacesuit pressures are reduced to about 4.3 psi. as compared with about 14.7 psi. for normal atmospheric pressure at sea level. However, the exposure of astronauts to reduced pressures in spacesuits, is conducive to fonnation and growth of gas bubbles within venous blood or tissues, which could cause decompression illness (DCI), a pathology best known to occur among deep-sea divers when they return to the surface. To reduce the risk of DCI, astronauts adjust to the reduced pressure in stages for a prolonged time known as a "pre-breathe" period prior to their extravehicular activity. Despite the use of pre-breathe protocols, an increased risk of DCI can arise for about 25% of humans who have a small hole, known as a patent foramen ovale (PFO), between two chambers of the heart. The atrial septum's fossa oval is, an embryological remnant of a flap between the septae primum and secundum allows fetal right atrial blood to pass into the left atrium, and usually closes after birth (Hagen, et al,. 1984). If fusion does not occur, a valve-like opening, the foramen ovale persists between the two atria. It has been suggested that astronauts with PFO's might be at greater risk of stroke or other serious neurological DCI because bubbles from a venous site may traverse a PFO, travel to the aorta and then enter the cerebral circulatory system causing a stroke (Figure 1). Astronauts are not now screened for PFO's, however consideration is being given to doing so. Here, we study three main methods abbreviated here as "ITE", "TCD" and "TEE", for detecting PFO's in living subjects. All involve the introduction of bubbles into a vein, immediately after which a sensory probe attempts to detect the bubbles in systemic circulation. Presence of the injected bubbles in the systemic circulation is indicative of a PFO. More detailed descriptions are given after the explanation of PFO's under Figure I. Even if a true PFO affects the risk of DCI, there remains a question of how effective screening would be if the detection method has errors of omission and/or commission. Of the three methods studied here, TEE is the "gold standard", matching autopsy results with near-perfect sensitivity and specificity (Schneider, et al. , 1996). However TEE is also the most difficult method to implement, requiring an internal esophagal probe, and is therefore not widely used. Currently, the easiest to use and most common PFO detection method is TTE, which uses an external chest probe. This method has a specificity of near 100%, but suffers from a low sensitivity rate (about 30%). More recently, TCD has been developed, which uses ultrasound probes to detect the presence of bubbles in cerebral arteries. Studies indicate that TCD is quite effective, having a sensitivity of about 91% and a specificity of about 93% (Droste, et al., 1999) when applied correctly, however implementation is difficult and requires considerable training.

Feiveson, Alan H.↗
NASA NTRS2010

Can Vertical Profiles of Tropospheric Methane on Titan Be Derived from Radio-Occultation Soundings?

The intensity of the received signal at Earth in the radio occultations of Titan is attenuated both by refractive defocusing and pressure-induced absorption from N2-N2 and CH4-N2 pairs. Because the absorption strength is different for the two sets of pairs, matching the retrieved absorptivity profile can in principle yield the vertical variation in gaseous methane in the troposphere. There are two factors that make this difficult. The first is the propagation of noise in the phase and amplitude of the received signal in the absorption retrieval. The phase data is first inverted to retrieve vertical profiles of refractivity, from which the refractive defocusing is calculated. This is then subtracted from the observed. intensity attenuation of the received signal to generate a profile of atmospheric absorption. The second problem is the uncertainty in the pressure-induced absorption coefficients. Laboratory data at radio wavelengths is only available near room temperature (see, e.g., [1] for N2-N2), and the extrapolation to the low temperatures in Titan's troposphere is not well established. Ab initio calculations by Borysow et al. [2, 3] provide absorption coefficients at low temperatures and long wavelengths, but their accuracy has come into question. We present examples from Cassini radio occultations of Titan to illustrate the difficulties. For methane mole fractions in the lower troposphere comparable to that inferred from the Huygens probe (approximately 0.05), it will be difficult to separate the contributions of N2-N2 collisions from those of N2-CH4, collisions to the retrieved absorption. However, higher concentrations of CH4 and/or a higher signal-to-noise ratio from a future uplink experiment could result in a successful separation of the two components. However, key to this are highly accurate estimates of the absorption from a combination of laboratory measurements at love temperatures and long wavelengths, and possibly improved theoretical calculations.

Flasar, F. Michael↗
NASA NTRS2009

Electromagnetic Cavity Effects from Transmitters Inside a Launch Vehicle Fairing

This paper provides insight into the difficult analytical issue for launch vehicles and spacecraft that has applicability outside of the launch industry. Radiation from spacecraft or launch vehicle antennas located within enclosures in the launch vehicle generates an electromagnetic environment that is difficult to accurately predict. This paper discusses the test results of power levels produced by a transmitter within a representative scaled vehicle fairing model and provides preliminary modeling results at the low end of the frequency test range using a commercial tool. Initially, the walls of the fairing are aluminum and later, layered with materials to simulate acoustic blanketing structures that are typical in payload fairings. The effects of these blanketing materials on the power levels within the fairing are examined.

Trout, Dawn↗
NASA NTRS2011

Proposal for Certifying Expandable Planetary Surface Habitation Structures

A factor-of-safety (FS) of 4.0 is currently used to design habitation structures made from structural soft goods. This approach is inconsistent with using a FS of 2.0 for metallic and polymeric composite pressure vessels as well as soft good structures such as space suits and parachutes. This inconsistency arises by using the FS to improperly account for the unknown effects of a variety of environmental and loading uncertainties. Using a 4.0 FS not only results in additional structural mass, it also makes it difficult to gain insight into the limitations of the material and/or product form and thus, it becomes difficult to make improvements. In order to bring consistency to the design and certification of expandable habitat structures, the approach used by the Federal Aviation Administration (FAA) to certify polymeric composite aircraft structures is used as a model and point of departure. A draft certification plan for Expandable Habitat Structures is developed in this paper and offered as an option for placing habitats made from soft goods on an equal footing with other structural implementations.

Dorsey, John T.↗
NASA NTRS2006

Architecture Adaptive Computing Environment

Architecture Adaptive Computing Environment (aCe) is a software system that includes a language, compiler, and run-time library for parallel computing. aCe was developed to enable programmers to write programs, more easily than was previously possible, for a variety of parallel computing architectures. Heretofore, it has been perceived to be difficult to write parallel programs for parallel computers and more difficult to port the programs to different parallel computing architectures. In contrast, aCe is supportable on all high-performance computing architectures. Currently, it is supported on LINUX clusters. aCe uses parallel programming constructs that facilitate writing of parallel programs. Such constructs were used in single-instruction/multiple-data (SIMD) programming languages of the 1980s, including Parallel Pascal, Parallel Forth, C*, *LISP, and MasPar MPL. In aCe, these constructs are extended and implemented for both SIMD and multiple- instruction/multiple-data (MIMD) architectures. Two new constructs incorporated in aCe are those of (1) scalar and virtual variables and (2) pre-computed paths. The scalar-and-virtual-variables construct increases flexibility in optimizing memory utilization in various architectures. The pre-computed-paths construct enables the compiler to pre-compute part of a communication operation once, rather than computing it every time the communication operation is performed.

Dorband, John E.↗
NASA NTRS2011

Electrostatic Precipitation of Dust in the Martian Atmosphere: Implications for the Utilization of Resources During Future Manned Exploration Missions

Future human missions to Mars will require the utilization of local resources for oxygen, fuel. and water. The In Situ Resource Utilization (ISRU) project is an active research endeavor at NASA to develop technologies that can enable cost effective ways to live off the land. The extraction of oxygen from the Martian atmosphere. composed primarily of carbon dioxide, is one of the most important goals of the Mars ISRU project. The main obstacle is the relatively large amount of dust present in the Martian atmosphere. This dust must be efficiently removed from atmospheric gas intakes for ISRU processing chambers. A common technique to achieve this removal on earth is by electrostatic precipitation, where large electrostatic fields are established in a localized region to precipitate and collect previously charged dust particles. This technique is difficult to adapt to the Martian environment, with an atmospheric pressure of about one-hundredth of the terrestrial atmosphere. At these low pressures. the corona discharges required to implant an electrostatic charge to the particles to be collected is extremely difficult to sustain and the corona easily becomes biopolar. which is unsuitable for particle charging. In this paper, we report on our successful efforts to establish a stable corona under Martian simulated conditions. We also present results on dust collecting efficiencies with an electrostatic precipitator prototype that could be effectively used on a future mission to the red planet

Calle, Carlos I.↗
NASA NTRS2011

Evidence Report, Risk of Inadequate Design of Human and Automation/Robotic Integration

The success of future exploration missions depends, even more than today, on effective integration of humans and technology (automation and robotics). This will not emerge by chance, but by design. Both crew and ground personnel will need to do more demanding tasks in more difficult conditions, amplifying the costs of poor design and the benefits of good design. This report has looked at the importance of good design and the risks from poor design from several perspectives: 1) If the relevant functions needed for a mission are not identified, then designs of technology and its use by humans are unlikely to be effective: critical functions will be missing and irrelevant functions will mislead or drain attention. 2) If functions are not distributed effectively among the (multiple) participating humans and automation/robotic systems, later design choices can do little to repair this: additional unnecessary coordination work may be introduced, workload may be redistributed to create problems, limited human attentional resources may be wasted, and the capabilities of both humans and technology underused. 3) If the design does not promote accurate understanding of the capabilities of the technology, the operators will not use the technology effectively: the system may be switched off in conditions where it would be effective, or used for tasks or in contexts where its effectiveness may be very limited. 4) If an ineffective interaction design is implemented and put into use, a wide range of problems can ensue. Many involve lack of transparency into the system: operators may be unable or find it very difficult to determine a) the current state and changes of state of the automation or robot, b) the current state and changes in state of the system being controlled or acted on, and c) what actions by human or by system had what effects. 5) If the human interfaces for operation and control of robotic agents are not designed to accommodate the unique points of view and operating environments of both the human and the robotic agent, then effective human-robot coordination cannot be achieved.

Zumbado, Jennifer Rochlis↗
NASA NTRS2005

Software Would Largely Automate Design of Kalman Filter

Embedded Navigation Filter Automatic Designer (ENFAD) is a computer program being developed to automate the most difficult tasks in designing embedded software to implement a Kalman filter in a navigation system. The most difficult tasks are selection of error states of the filter and tuning of filter parameters, which are timeconsuming trial-and-error tasks that require expertise and rarely yield optimum results. An optimum selection of error states and filter parameters depends on navigation-sensor and vehicle characteristics, and on filter processing time. ENFAD would include a simulation module that would incorporate all possible error states with respect to a given set of vehicle and sensor characteristics. The first of two iterative optimization loops would vary the selection of error states until the best filter performance was achieved in Monte Carlo simulations. For a fixed selection of error states, the second loop would vary the filter parameter values until an optimal performance value was obtained. Design constraints would be satisfied in the optimization loops. Users would supply vehicle and sensor test data that would be used to refine digital models in ENFAD. Filter processing time and filter accuracy would be computed by ENFAD.

Chuang, Jason C. H.↗
NASA NTRS2005

Fastener Starter

The Fastener Starter is a creative solution to prevent the loss of small fasteners during their installation. This is the only currently available tool that can firmly grip and hold a single screw, bolt, nut, washer, spacer, or any combination of these parts. Other commercially available fastener starters are unable to accommodate a variety of parts simultaneously. The Fastener Starter is a more capable and easier tool to use than prior tools. Its compact size allows it to be used effectively in cramped, difficult-to-see locations. Its design also allows it to be used with or without handles and extenders in other difficult-to-reach locations. It provides better protection against cross threading and loss of fasteners and associated parts. The Fastener Starter is non-magnetic and does not off-gas, thus meeting flight hardware requirements. The Fastener Starter incorporates a combination of features of several commercially available tools, providing an improved means of installing small fasteners. The Fastener Starter includes a custom molded insert that can be removed easily and replaced with a conventional tool bit (e.g., a screwdriver or hex-driver bit). When used with the insert, the Fastener Starter prevents cross threading and damage to internal threaded holes. This is achieved by allowing the fastener to slip within the tool insert when used without a conventional tool bit. Alternatively, without the insert and with a tool bit, the Fastener Starter can torque a fastener. The Fastener Starter has a square recess hole that accepts a conventional square drive handle or extension to accommodate a variety of applications by providing flexibility in handle style and length.

Chandler, Faith↗
NASA NTRS2005

Vibrating Optical Fibers to Make Laser Speckle Disappear

In optical systems in which laser illumination is delivered via multimode optical fibers, laser speckle can be rendered incoherent by a simple but highly effective technique. The need to eliminate speckle arises because speckle can make it difficult to observe edges and other sharp features, thereby making it difficult to perform precision alignment of optical components. The basic ideas of the technique is to vibrate the optical fiber(s) to cause shifting of electromagnetic modes within the fiber(s) and consequent shifting of the speckle pattern in the light emerging from the fiber(s). If the frequency of vibration is high enough, a human eye cannot follow the shifting speckle pattern, so that instead of speckle, a human observer sees a smoothed pattern of light corresponding to a mixture of many electromagnetic modes. If necessary, the optical fiber(s) could be vibrated manually. However, in a typical laboratory situation, it would be more practical to attach a vibrating mechanism to the fiber(s) for routine use as part of the fiber-optic illuminator. In experiments, a commercially available small, gentle, quiet, variable- speed vibratory device was used in this way, with the result that the appearance of speckle was eliminated, as expected. Figures 1 and 2 illustrate the difference.

McGill, Matthew↗
NASA NTRS2011

Supportability for Beyond Low Earth Orbit Missions

Exploration beyond Low Earth Orbit (LEO) presents many unique challenges that will require changes from current Supportability approaches. Currently, the International Space Station (ISS) is supported and maintained through a series of preplanned resupply flights, on which spare parts, including some large, heavy Orbital Replacement Units (ORUs), are delivered to the ISS. The Space Shuttle system provided for a robust capability to return failed components to Earth for detailed examination and potential repair. Additionally, as components fail and spares are not already on-orbit, there is flexibility in the transportation system to deliver those required replacement parts to ISS on a near term basis. A similar concept of operation will not be feasible for beyond LEO exploration. The mass and volume constraints of the transportation system and long envisioned mission durations could make it difficult to manifest necessary spares. The supply of on-demand spare parts for missions beyond LEO will be very limited or even non-existent. In addition, the remote nature of the mission, the design of the spacecraft, and the limitations on crew capabilities will all make it more difficult to maintain the spacecraft. Alternate concepts of operation must be explored in which required spare parts, materials, and tools are made available to make repairs; the locations of the failures are accessible; and the information needed to conduct repairs is available to the crew. In this paper, ISS heritage information is presented along with a summary of the challenges of beyond LEO missions. A number of Supportability issues are discussed in relation to human exploration beyond LEO. In addition, the impacts of various Supportability strategies will be discussed. Any measure that can be incorporated to reduce risk and improve mission success should be evaluated to understand the advantages and disadvantages of implementing those measures. Finally, an effort to model and evaluate Supportability for beyond LEO missions will be described.

Crillo, William M.↗
NASA NTRS2011

Balancing Training Techniques for Flight Controller Certification

Training of ground control teams has been a difficult task in space operations. There are several intangible skills that must be learned to become the steely eyed men and women of mission control who respond to spacecraft failures that can lead to loss of vehicle or crew if handled improperly. And as difficult as training is, it can also be costly. Every day, month or year an operator is in training, is a day that not only they are being trained without direct benefit to the organization, but potentially an instructor or mentor is also being paid for hours spent assisting them. Therefore, optimization of the training flow is highly desired. Recently the Expedition Division (DI) at Johnson Space Flight Center has recreated their training flows for the purpose of both moving to an operator/specialist/instructor hierarchy and to address past inefficiencies in the training flow. This paper will discuss the types of training DI is utilizing in their new flows, and the balance that has been struck between the ideal learning environments and realistic constraints. Specifically, the past training flow for the ISS Attitude Determination and Control Officer will be presented, including drawbacks that were encountered. Then the new training flow will be discussed and how a new approach utilizes more training methods and teaching techniques. We will look at how DI has integrated classes, workshops, checkouts, module reviews, scenarios, OJT, paper sims, Mini Sims, and finally Integrated Sims to balance the cost and timing of training a new flight controller.

Gosling, Christina↗
NASA NTRS2003

Using Diffusion Bonding in Making Piezoelectric Actuators

A technique for the fabrication of piezoelectric actuators that generate acceptably large forces and deflections at relatively low applied voltages involves the stacking and diffusion bonding of multiple thin piezoelectric layers coated with film electrodes. The present technique stands in contrast to an older technique in which the layers are bonded chemically, by use of urethane or epoxy agents. The older chemical-bonding technique entails several disadvantages, including the following: It is difficult to apply the bonding agents to the piezoelectric layers. It is difficult to position the layers accurately and without making mistakes. There is a problem of disposal of hazardous urethane and epoxy wastes. The urethane and epoxy agents are nonpiezoelectric materials. As such, they contribute to the thickness of a piezoelectric laminate without contributing to its performance; conversely, for a given total thickness, the performance of the laminate is below that of a unitary piezoelectric plate of the same thickness. The figure depicts some aspects of the fabrication of a laminated piezoelectric actuator by the present diffusion- bonding technique. First, stock sheets of the piezoelectric material are inspected and tested. Next, the hole pattern shown in the figure is punched into the sheets. Alternatively, if the piezoelectric material is not a polymer, then the holes are punched in thermoplastic films. Then both faces of each punched piezoelectric sheet or thermoplastic film are coated with a silver-ink electrode material by use of a silkscreen printer. The electrode and hole patterns are designed for minimal complexity and minimal waste of material. After a final electrical test, all the coated piezoelectric layers (or piezoelectric layers and coated thermoplastic films) are stacked in an alignment jig, which, in turn, is placed in a curved press for the diffusion-bonding process. In this process, the stack is pressed and heated at a specified curing temperature and pressure for a specified curing time. The pressure, temperature, and time depend on the piezoelectric material selected. At the end of the diffusion-bonding process, the resulting laminated piezoelectric actuator is tested to verify the adequacy of the mechanical output as a function of an applied DC voltage.

Sager, Frank E.↗
NASA NTRS2011

Broadband Achromatic Phase Shifter for a Nulling Interferometer

Nulling interferometry is a technique for imaging exoplanets in which light from the parent star is suppressed using destructive interference. Light from the star is divided into two beams and a phase shift of radians is introduced into one of the beams. When the beams are recombined, they destructively interfere to produce a deep null. For monochromatic light, this is implemented by introducing an optical path difference (OPD) between the two beams equal to lambda/2, where lambda is the wavelength of the light. For broadband light, however, a different phase shift will be introduced at each wavelength and the two beams will not effectively null when recombined. Various techniques have been devised to introduce an achromatic phase shift a phase shift that is uniform across a particular bandwidth. One popular technique is to use a series of dispersive elements to introduce a wavelength-dependent optical path in one or both of the arms of the interferometer. By intelligently choosing the number, material and thickness of a series of glass plates, a nearly uniform, arbitrary phase shift can be introduced between two arms of an interferometer. There are several constraints that make choosing the number, type, and thickness of materials a difficult problem, such as the size of the bandwidth to be nulled. Several solutions have been found for bandwidths on the order of 20 to 30 percent (Delta(lambda)/lambda(sub c)) in the mid-infrared region. However, uniform phase shifts over a larger bandwidth in the visible regime between 480 to 960 nm (67 percent) remain difficult to obtain at the tolerances necessary for exoplanet detection. A configuration of 10 dispersive glass plates was developed to be used as an achromatic phase shifter in nulling interferometry. Five glass plates were placed in each arm of the interferometer and an additional vacuum distance was also included in the second arm of the interferometer. This configuration creates a phase shift of pi radians with an average error of 5.97 x 10(exp -8) radians and standard deviation of 3.07 x 10(exp -4) radians. To reduce ghost reflections and interference effects from neighboring elements, the glass plates are tilted such that the beam does not strike each plate at normal incidence. Reflections will therefore walk out of the system and not contribute to the intensity when the beams are recombined. Tilting the glass plates, however, introduces several other problems that must be mitigated: (1) the polarization of a beam changes when refracted at an interface at non-normal incidence; (2) the beam experiences lateral chromatic spread as it traverses multiple glass plates; (3) at each surface, wavelength- dependent intensity losses will occur due to reflection. For a fixed angle of incidence, each of these effects must be balanced between each arm of the interferometer in order to ensure a deep null. The solution was found using a nonlinear optimization routine that minimized an objective function relating phase shift, intensity difference, chromatic beam spread, and polarization difference to the desired parameters: glass plate material and thickness. In addition to providing a uniform, broadband phase shift, the configuration achieves an average difference in intensity transmission between the two arms of the interferometer of 0.016 percent with a standard deviation of 3.64 x 10(exp -4) percent, an average difference in polarization between the two arms of the interferometer of 5.47 x 10(exp -5) percent with a standard deviation of 1.57 x 10(exp -6) percent, and an average chromatic beam shift between the two arms of the interferometer of -47.53 microns with a wavelength-by-wavelength spread of 0.389 microns.

Bolcar, Matthew R.↗
NASA NTRS2011

Geomagnetic Secular Variation Prediction with Thermal Heterogeneous Boundary Conditions

It has long been conjectured that thermal heterogeneity at the core-mantle boundary (CMB) affects the geodynamo substantially. The observed two pairs of steady and strong magnetic flux lobes near the Polar Regions and the low secular variation in the Pacific over the past 400 years (and perhaps longer) are likely the consequences of this CMB thermal heterogeneity. There are several studies on the impact of the thermal heterogeneity with numerical geodynamo simulations. However, direct correlation between the numerical results and the observations is found very difficult, except qualitative comparisons of certain features in the radial component of the magnetic field at the CMB. This makes it difficult to assess accurately the impact of thermal heterogeneity on the geodynamo and the geomagnetic secular variation. We revisit this problem with our MoSST_DAS system in which geomagnetic data are assimilated with our geodynamo model to predict geomagnetic secular variations. In this study, we implement a heterogeneous heat flux across the CMB that is chosen based on the seismic tomography of the lowermost mantle. The amplitude of the heat flux (relative to the mean heat flux across the CMB) varies in the simulation. With these assimilation studies, we will examine the influences of the heterogeneity on the forecast accuracies, e.g. the accuracies as functions of the heterogeneity amplitude. With these, we could be able to assess the model errors to the true core state, and thus the thermal heterogeneity in geodynamo modeling.

Kuang, Weijia↗
NASA NTRS2012

On the Probability of Occurrence of Extreme Space Weather Events

By virtue of their rarity, extreme space weather events, such as the Carrington event of 1859, are difficult to study, their rates of occurrence are difficult to estimate, and prediction of a specific future event is virtually impossible. Additionally, events may be extreme relative to one parameter but normal relative to others. In this study, we analyze several measures of the severity of space weather events (flare intensity, coronal mass ejection speeds, Dst, and greater than 30 MeV proton fluences as inferred from nitrate records) to estimate the probability of occurrence of extreme events. By showing that the frequency of occurrence scales as an inverse power of the severity of the event, and assuming that this relationship holds at higher magnitudes, we are able to estimate the probability that an event larger than some criteria will occur within a certain interval of time in the future. For example, the probability of another Carrington event (based on Dst less than - 850 nT) occurring within the next decade is approximately 12%. We also identify and address several limitations with this approach. In particular, we assume time stationarity, and thus, the effects of long-term space climate change are not considered. While this technique cannot be used to predict specific events, it may ultimately be useful for probabilistic forecasting.

Riley, Pete↗
NASA NTRS2011

Metallization for Yb14MnSb11-Based Thermoelectric Materials

Thermoelectric materials provide a means for converting heat into electrical power using a fully solid-state device. Power-generating devices (which include individual couples as well as multicouple modules) require the use of ntype and p-type thermoelectric materials, typically comprising highly doped narrow band-gap semiconductors which are connected to a heat collector and electrodes. To achieve greater device efficiency and greater specific power will require using new thermoelectric materials, in more complex combinations. One such material is the p-type compound semiconductor Yb14MnSb11 (YMS), which has been demonstrated to have one of the highest ZT values at 1,000 C, the desired operational temperature of many space-based radioisotope thermoelectric generators (RTGs). Despite the favorable attributes of the bulk YMS material, it must ultimately be incorporated into a power-generating device using a suitable joining technology. Typically, processes such as diffusion bonding and/or brazing are used to join thermoelectric materials to the heat collector and electrodes, with the goal of providing a stable, ohmic contact with high thermal conductivity at the required operating temperature. Since YMS is an inorganic compound featuring chemical bonds with a mixture of covalent and ionic character, simple metallurgical diffusion bonding is difficult to implement. Furthermore, the Sb within YMS readily reacts with most metals to form antimonide compounds with a wide range of stoichiometries. Although choosing metals that react to form high-melting-point antimonides could be employed to form a stable reaction bond, it is difficult to limit the reactivity of Sb in YMS such that the electrode is not completely consumed at an operating temperature of 1,000 C. Previous attempts to form suitable metallization layers resulted in poor bonding, complete consumption of the metallization layer or fracture within the YMS thermoelement (or leg).

Firdosy, Samad↗
NASA NTRS2012

Germanium Lift-Off Masks for Thin Metal Film Patterning

A technique has been developed for patterning thin metallic films that are, in turn, used to fabricate microelectronics circuitry and thin-film sensors. The technique uses germanium thin films as lift-off masks. This requires development of a technique to strip or undercut the germanium chemically without affecting the deposited metal. Unlike in the case of conventional polymeric lift-off masks, the substrate can be exposed to very high temperatures during processing (sputter deposition). The reason why polymeric liftoff masks cannot be exposed to very high temperatures (greater than 100 C) is because (a) they can become cross linked, making lift-off very difficult if not impossible, and (b) they can outgas nitrogen and oxygen, which then can react with the metal being deposited. Consequently, this innovation is expected to find use in the fabrication of transition edge sensors and microwave kinetic inductance detectors, which use thin superconducting films deposited at high temperature as their sensing elements. Transition edge sensors, microwave kinetic inductance detectors, and their circuitry are comprised of superconducting thin films, for example Nb and TiN. Reactive ion etching can be used to pattern these films; however, reactive ion etching also damages the underlying substrate, which is unwanted in many instances. Polymeric lift-off techniques permit thin-film patterning without any substrate damage, but they are difficult to remove and the polymer can outgas during thin-film deposition. The outgassed material can then react with the film with the consequence of altered and non-reproducible materials properties, which, in turn, is deleterious for sensors and their circuitry. The purpose of this innovation was to fabricate a germanium lift-off mask to be used for patterning thin metal films.

Brown, Ari↗