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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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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1978

Silicon solar cells, a manufacturing cost analysis

A detailed cost analysis of solar cell module manufacturing, utilizing process sequences incorporating near-term technology, has been performed. The entire structuring of a factory to manufacture solar cell modules, starting from supplied polycrystalline silicon and other raw materials, was specified. This analysis then formed the basis for a sensitivity analysis of the major cost factors. The results of the cost and sensitivity analyses are presented here.

Grenon, L. A.↗
NASA NTRS1998

Low-Cost Manufacturing of High- Temperature Polymer Composites

Major goals of NASA and the Integrated High Performance Turbine Engine Technology (IHPTET) initiative include improvements in the affordability of propulsion systems, significant increases in the thrust/weight ratio, and increases in the temperature capability of components of gas turbine engines. Members of NASA Lewis Research Center's HITEMP project worked cooperatively with Allison Advanced Development Corporation to develop a manufacturing method to produce low-cost components for gas turbine engines. Affordability for these polymer composites is defined by the savings in acquisition and life-cycle costs associated with engine weight reduction. To lower engine component costs, the Lewis/Allison team focused on chopped graphite fiber/polyimide resin composites. The high-temperature polyimide resin chosen, PMR-II-50, was developed at NASA Lewis.

Sutter, James K.↗
DOE OSTI2023

A framework for hybrid manufacturing cost minimization and preform design

Here, this paper describes preform design optimization in hybrid additive-subtractive manufacturing. In hybrid manufacturing, the question of what form and what geometry the additive preform should take has largely been a matter of intuition and experience, or trial and error. The choice of a more optimal preform depends on the target parameters, such as stiffness, cost, or lead time. We demonstrate a framework for preform optimization using static stiffness, and then the combined cost of additive and subtractive manufacturing, while respecting stable cutting conditions for the tool-part combination. The procedure is illustrated by comparing three preform geometries for a thin wall.

42 ENGINEERING↗
DOE OSTI2024

Updated Manufactured Cost Analysis for Proton Exchange Membrane Water Electrolyzers

Enabling rapid and extensive decarbonization within the electric power and industrial sectors is likely to require high levels of renewable energy deployment, supported by technologies that store and transform renewable electricity into other useful forms. Within hard to decarbonize sectors such as organic chemicals and heavy-duty transportation, the use of low-carbon intensity hydrogen as a fuel and chemical building block is emerging as a near-term alternative to reduce their fossil-fuel dependency. Water splitting electrolysis to produce hydrogen requires only water and electricity as inputs, eliminating the use of natural gas in steam methane reforming, which is the conventional hydrogen production pathway. When powered by low-carbon electricity, electrolysis represents an important pathway towards cross-sectoral decarbonization.

08 HYDROGEN↗
DOE OSTI2020

Rapid Patterning and Advanced Device Structures for Low Cost Manufacturable Crystalline Si IBC Cells

Recent record efficiency Si cells have had an interdigitated back contact (IBC) design where both positive and negative contacts are fabricated on the back side of the Si wafer. Many industry groups have investigated IBC cells but used photolithography to pattern the rear contacts although it is considered impractical for low cost, high volume manufacturing. Alternative patterning methods using lasers and mechanical masking have been utilized in fabrication of patterned regions in IBC Si solar cells to replace photolithography. Another exciting advance in Si solar cell technology has been replacing the high temperature diffusion of doped regions inside the crystalline Si wafer with low temperature deposition of very thin layers of doped amorphous hydrogenated Si (a-Si:H) on the Si wafer. This is called a Si heterojunction (HJ) device. The a-Si:H provides excellent passivation of surface defects and has produced the highest open circuit voltages (VOC) of any Si solar cell device structure. The Institute of Energy Conversion (IEC) demonstrated the first IBC-HJ solar cell combining these two strategies in 2007 and has fabricated IBC-HJ cells with 20% efficiency using three photolithography steps. Despite the demonstrated efficiency potential of this device by industry groups (>26%) there is no commercial production because of the challenges of patterning and processing the structure in an industrial environment. Our work sought to address that challenge. The objective of this 3 year project was to develop the processing for the IBC-HJ Si solar cell using lasers for patterning and contact formation instead of photolithography. Laser patterning enables rapid, contactless manufacturing of patterned regions. We intensively studied laser fired contacts, laser patterning of the a-Si multi-layer stacks and metal layers and the use of plasma shadow masks. After an exhaustive focus in the first year on the laser fired emitter (LFE) and contact (LFC), we were unable to achieve VOC greater than 660 mV, compared to the 720 mV required to meet our milestones. We discovered that an additional issue with our original IBC structure was the presence of an inversion layer at the back surface connecting the p and n regions which reduced the VOC and fill factor (FF). We developed innovative methods for characterizing the inversion layer. These two limitations in the original design lead to development of a new IBC-HJ process sequence and device structure which we called Plasma Masked Laser Processed (PMLP). It retained the original high efficiency features including manufacturability. The LFC was replaced with a standard n-type a-Si HJ contact. The inversion layer was eliminated by replacing the previous p-type stack in the gap with an n-type or SiN stack. The PMLP used laser ablation of a multi-layer a-Si stack followed by chemical etching to open the n-contact. It required deposition of a patterned stack through a mask in the plasma deposition chamber. This turned out to be a source of significant problems due to inevitable unwanted deposition ‘leakage’ under the mask. This formed a blocking contact on the emitter which significantly reduced Voc and FF. Several iterations in PMLP device structure and chemical etching steps resulted in a large improvements, e.g. the efficiency increasing from 3 to 15% and Voc from 450 to 660 mV but they were unable to completely eliminate it. The best IBC-HJ device we fabricated had only 15% efficiency. For perspective, our standard FHJ devices had 20% efficiency.

14 SOLAR ENERGY↗
NASA NTRS1997

Technology Needs for Reduced Design and Manufacturing Cost of Commercial Transport Engines

The objective of the study was to assess the needs in the design and manufacturing processes and identify areas where technology could impact in cost and cycle-time reduction. At the highest level, the team first identified the goals that were in line with long-range needs of the aeropropulsion industry, and to which technology and process improvements would be required to contribute. These goals are to reduce the time and costs in the development cycle of aircraft engines by a factor of two, reduce production cycle time by a factor of four, and to reduce production costs by 25%. Also, it was the intent of the team to identify the highest impact technologies that could be developed and demonstrated in five years.

Rohn, Douglas A.↗
DOE OSTI2022

III-V Solar Cells with Novel Epitaxial Lift-off Architectures for Extended Substrate Reuse for Low-cost Manufacturing

The highest solar cell efficiencies have been achieved with III-V photovoltaics (PV). Still, the use of III-V materials in terrestrial applications has been very limited, mainly because of their high cost. The high cost is primarily due to the expensive Ge or GaAs wafers which could amount up to one-half of the total module cost! A prominent approach to reduce the impact of the high cost of substrates used for III-V PV is through re-use of the wafer substrates by Epitaxial Lift-Off (ELO). Typically, using a sacrificial layer such as AlAs, the device part of the cell is lifted off, leaving behind the substrate for re-use for fabrication of the next device. While conversion efficiency as high as 29.1% has been achieved by ELO method, chemical mechanical polishing (CMP) of the substrate is required which significantly adds to the overall solar cell cost. In this project, we have developed a novel ELO architecture for single junction gallium arsenide (GaAs) solar cells that will not require CMP of the substrate for re-use. Multiple reuses of GaAs wafers have been demonstrated with no CMP, without degradation in solar cell efficiency. Also, the solar cells have been successfully lifted off and transferred to inexpensive substrates with less than 2% change in efficiency. By elimination of the CMP process, which is the highest cost component of III-V solar cells made by conventional ELO method (~$10/W), and decreasing the substrate cost by multiple re-uses, the developed technology could be a leap forward in significantly reducing the cost of III-V photovoltaics.

14 SOLAR ENERGY↗
NASA NTRS1979

DOE/NASA SIMS Prototype Solar System, no. 4. Part 1: Market analysis. Part 2: Modular manufacturing cost estimate

The findings of the IIT Research Institute (IITRI) market study of the SIMS Prototype System 4, a hot water (DHW) system are documented. The feasibility of prepackaging currently available solar heating components into modular subsystems for site assembly is addressed. A documented design and installation procedure and a performance test report were prepared. The potential markets and applications for this particular system in the nonfederal market are profiled by assessing the needs and requirements of potential users and specifiers, by characterizing the nature of the market and the competitive environment, by identifying the barriers to commercial acceptance, and by estimating the size of the potential market.

Source record↗
NASA NTRS2002

Low Cost Manufacturing of Composite Cryotanks

This viewgraph presentation reviews research and development of cryotank manufacturing conducted by Northrup Grumman. The objectives of the research and development included the development and validation of manufacturing processes and technology for fabrication of large scale cryogenic tanks, the establishment of a scale-up and facilitization plan for full scale cryotanks, the development of non-autoclave composite manufacturing processes, the fabrication of subscale tank joints for element tests, the performance of manufacturing risk reduction trials for the subscale tank, and the development of full-scale tank manufacturing concepts.

Meredith, Brent↗
NASA NTRS2019

Advances in Low-Cost Manufacturing and Folding of Solar Sail Membranes

Solar sail membranes must have a high area-to-mass ratio and high solid volume fraction when stowed. In order to meet mission requirements, current solar sail projects, such as NASA’s Near Earth Asteroid Scout, require metallized sail membranes with thicknesses on the order of 2-3 μm. These very thin membranes do not retain creases like thicker membranes, solar panels, or paper models. For Cubesat-class spacecraft, volume, rather than mass, is often the driving requirement for deployable structural elements. These two factors make it both difficult and highly desirable to characterize the practical differences between solar sail membrane packaging methods with laboratory demonstrations. This paper presents lessons gathered from lab work with solar sail membranes at a 10-meter scale.

Stohlman, Olive R.↗
NASA NTRSDate not supplied

Advances in Low-Cost Manufacturing and Folding of Solar Sail Membrane

Solar sail membranes must have a high area-to-mass ratio and high solid volume fraction when stowed. In order to meet mission requirements, current solar sail projects, such as the NASA Near Earth Asteroid Scout and Advanced Composite Solar Sail System, require metallized sail membranes with thicknesses on the order of 2-3 μm. These very thin membranes do not retain creases like thicker membranes, solar panels, or paper models. For CubeSat-class spacecraft, volume, rather than mass, is often the driving requirement for deployable structural elements. These two factors make it both difficult and highly desirable to characterize the practical differences between various membrane designs and packaging methods with laboratory demonstrations. This paper presents lessons gathered from lab work on solar sail membranes at a 9-meter scale. Among other results, laboratory deployment of a full-scale sail quadrant revealed important differences between seaming methods.

Olive R Stohlman↗
DOE OSTI2022

Low-Cost, High Performance Catalyst Coated Membranes for PEM Water Electrolyzers (Final Technical Report)

In this project, the objective was to develop reduced-cost manufacturing techniques capable of producing proton exchange membrane water electrolyzer (PEMWE) catalyst coated membranes (CCMs) with further improved performance relative to then-current 3M CCM technology. Processes to be developed would enable 1) production of 0.5 m wide CCMs (approximately 2x wider than produced by the current laboratory/pilot-scale processes) and 2) 3x higher net-effective linear rates (lineal-meters of CCM produced per cumulative process time) than the baseline CCM process. In combination, the wider width CCM and increased net-effective linear rates would result in a 6-fold decrease in CCM manufacturing cost (defined as cumulative machine and labor time) per m 2 of CCM produced. PEMWE CCMs produced with these optimized processes were targeted to produce 1) 0.25 A/cm 2 or greater at 1.5 V, 2) 2.0 A/cm 2 or greater at 1.75 V and 3) 4 A/cm 2 or greater at 1.95V, 4) with total catalyst platinum-group metal (PGM) loadings of ≤ 0.50 mg/cm 2 , measured in a cell with 50 cm 2 active area (or larger) at 80°C cell temperature and ambient outlet pressures.

08 HYDROGEN↗
NASA NTRS1975

An economic study of an advanced technology supersonic cruise vehicle

A description is given of the methods used and the results of an economic study of an advanced technology supersonic cruise vehicle. This vehicle was designed for a maximum range of 4000 n.mi. at a cruise speed of Mach 2.7 and carrying 292 passengers. The economic study includes the estimation of aircraft unit cost, operating cost, and idealized cash flow and discounted cash flow return on investment. In addition, it includes a sensitivity study on the effects of unit cost, manufacturing cost, production quantity, average trip length, fuel cost, load factor, and fare on the aircraft's economic feasibility.

Smith, C. L.↗
NASA NTRS1991

Welding technology transfer task/laser based weld joint tracking system for compressor girth welds

Sensors to control and monitor welding operations are currently being developed at Marshall Space Flight Center. The laser based weld bead profiler/torch rotation sensor was modified to provide a weld joint tracking system for compressor girth welds. The tracking system features a precision laser based vision sensor, automated two-axis machine motion, and an industrial PC controller. The system benefits are elimination of weld repairs caused by joint tracking errors which reduces manufacturing costs and increases production output, simplification of tooling, and free costly manufacturing floor space.

Looney, Alan↗