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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Stainless Steel Coating Test Report

A process was developed to coat 316L stainless steel pieces having very low levels of fixed contamination on their surface (~100 dpm/100 cm²). The coating process served to significantly decrease the likelihood of any fixed contamination becoming loose contamination due to physical shocks. Prior to coating, the stainless steel was etched with a commercial methane sulfonic acid (MSA) solution in a heated ultrasonic bath, rinsed with deionized water, cleaned with a basic detergent solution, and then rinsed with deionized water. The MSA etched the surface of the stainless-steel pieces, creating a more favorable surface on which the coating could adhere. Due to the short timeline of the project, only commercially available clear coating products were considered. The clear coating had to be wear-resistant, shock resistant, radiation resistant, and have high adhesion to the surface of the stainless steel. Adhesion of coatings to stainless steel is notoriously difficult. A commercial, high molecular weight polymer coating was found that met these requirements. The adhesion properties of this coating to stainless steel are very good, and are significantly improved by the etching process. The etching process results in a higher surface area that is free of debris and other residues, making the surface much more wetable, and at the same time creating a favorable surface topography for adhesion. The polymer in its uncured form is a low viscosity liquid. It can be applied by brush or pipette, and it cures in air alone, but heat is required to speed up curing and attain the highest performance of the cured polymer. As the project progressed, the project team became interested in the composition of the selected commercial polymer coating, and in ways that this polymer coating could be made more wear resistant and potentially more radiation resistant. Nano-particle addition was chosen as the preferred way to achieve higher performance. Therefore, a series of tests were planned and performed. This report summarizes these tests, and presents the results.

36 MATERIALS SCIENCE↗
NASA NTRS2002

Design of a Modular 5-kW Power Processing Unit for the Next-Generation 40-cm Ion Engine

NASA Glenn Research Center is developing a 5/10-kW ion engine for a broad range of mission applications. Simultaneously, a 5-kW breadboard poster processing unit is being designed and fabricated. The design includes a beam supply consisting of four 1.1 kW power modules connected in parallel, equally sharing the output current. A novel phase-shifted/pulse-width-modulated dual full-bridge topology was chosen for its soft-switching characteristics. The proposed modular approach allows scalability to higher powers as well as the possibility of implementing an N+1 redundant beam supply. Efficiencies in excess of 96% were measured during testing of a breadboard beam power module. A specific mass of 3.0 kg/kW is expected for a flight PRO. This represents a 50% reduction from the state of the art NSTAR power processor.

Pinero, Luis R.↗
NASA NTRS1980

Tailored emitter, low-resistivity, ion-implanted silicon solar cells

Open-circuit voltages as high as 0.645 V (AM0, 25 C) have been obtained by a new process developed for low-resistivity silicon. The process utilizes high-dose phosphorus implantation followed by furnace annealing and simultaneous oxide growth. The effect of the thermally grown oxide is a reduction of surface recombination velocity; the oxide also acts as a moderately efficient antireflection (AR) coating. Boron-doped, float-zone silicon with resistivities from 0.1 to 1.0 (omega)(cm) has been processed according to this sequence; results show that the highest open-circuit voltage is obtained with 0.1(omega)(cm) starting material. The effects of Auger recombination and bandgap narrowing caused by high doping concentrations in the n(+)junction region have been investigated by implanting phosphorus over a wide range of dose levels. The effects of emitter-phosphorus concentrations tailored to optimize electric fields in the emitter have also been investigated.

Minnucci, J. A.↗
NASA NTRS2006

Daily Planet Redesign: eZ Publish Web Content Management Implementation

This viewgraph presentation reviews the process of the redesign of the Daily . Planet news letter as a content management implementation project. This is a site that is an internal news site that acts as a communication vehicle for a large volume of content. The Objectives for the site redesign was: (1) Clean visual design, (2) Facilitation of publication processes, (3) More efficient maintenance mode, (4) Automated publishing to internal portal, (5) Better navigation through improved site IA, (6) Archiving and retrieval functionality, (7) Back to basics on fundamental business goals. The CM is a process not a software package

web content management↗
NASA NTRS1979

Automated Array Assembly, Phase 2

The Automated Array Assembly Task, Phase 2 of the Low Cost Silicon Solar Array Project is a process development task. The contract provides for the fabrication of modules from large area tandem junction cells (TJC). During this quarter, effort was focused on the design of a large area, approximately 36 sq cm, TJC and process verification runs. The large area TJC design was optimized for minimum I squared R power losses. In the TJM activity, the cell-module interfaces were defined, module substrates were formed and heat treated and clad metal interconnect strips were fabricated.

Carbajal, B. G.↗
NASA NTRS1989

Ion optics for high power 50-cm-diam ion thrusters

The process used at the NASA-Lewis to fabricate 30 and 50-cm-diameter ion optics is described. The ion extraction capabilities of the 30 and 50-cm diameter ion optics were evaluated on divergent field and ring-cusp discharge chambers and compared. Perveance was found to be sensitive to the effects of the type and power of the discharge chamber and to the accelerator electrode hole diameter. Levels of up to 0.64 N and 20 kW for thrust and input power, respectively, were demonstrated with the divergent-field discharge chamber. Thruster efficiencies and specific impulse values up to 79 percent and 5000 sec., respectively, were achieved with the ring-cusp discharge chamber.

Rawlin, Vincent K.↗
NASA NTRS1980

Silicon solar cells with high open-circuit voltage

Open-circuit voltages as high as 0.645 V (AM0-25 C) have been obtained by a new process developed for low-resistivity silicon. The method utilizes high-dose phosphorus implantation, followed by furnace annealing and simultaneous oxide growth to form high-efficiency, shallow junctions. The effect of the thermally grown oxide is a reduction of surface recombination velocity; the oxide also acts as a moderately efficient AR coating. Boron doped silicon with resistivities from 0.1 to 0.3 ohm-cm has been processed according to this sequence; results show highest open-circuit voltage is attained with 0.1-ohm-cm starting material. The effects of bandgap narrowing, caused by high doping concentrations in the junction, were also investigated by implanting phosphorus over a wide range of dose levels.

Minnucci, J. A.↗
NASA NTRS1989

Ion optics for high power 50-cm-dia ion thrusters

The process used at the NASA Lewis Research Center to fabricate 30 and 50-cm-diameter ion optics is described. The ion extraction capabilities of the 30 and 50-cm diameter ion optics were evaluated on divergent field and ring-cusp discharge chambers and compared. Perveance was found to be sensitive to the effects of the type and power of the discharge chamber and to the accelerator electrode hole diameter. Levels of up to 0.64 N and 20 kW for thrust and input power, respectively, were demonstrated with the divergent-field discharge chamber. Thruster efficiencies and specific-impulse values up to 79 percent and 5000 seconds, respectively, were achieved with the ring-cusp discharge chamber.

Rawlin, Vincent K.↗
DOE OSTI2026

15.3% AM1.5G Efficiency GaAs Solar Cells Fabricated via an Epitaxy-Free Process

Here, we report simple and potentially low-cost techniques for creating high-quality n-type gallium arsenide (GaAs) and GaAs p/n junctions and fabricate GaAs p/n junction solar cells. Detailed-balance modeling suggests that 20% AM1.5G efficiency p/n homojunction devices may be possible if the surface doping concentration can be limited to values less than ∼ 5 × 10 19 cm −3 . Our process exploits an open-tube, vapor-phase, deposition-free, zinc diffusion technique for forming p-type layers in melt-grown n-GaAs substrates that results in sheet resistances less than 1 kΩ/$\square$. In addition, we have improved the minority carrier diffusion lengths of melt-grown GaAs from less than one micron to over five microns using an open-tube, vacuum-free, annealing process which reduces the density of EL2 midgap defects. Finally, we have combined these advances to fabricate epitaxy-free, GaAs solar cells with a validated AM1.5G efficiency of 15.3%.

14 SOLAR ENERGY↗
NASA NTRS1994

Formation of thin sulfide rinds on the CM parent body

Many of the textures that are observed in CM chondrites have been alternately assigned nebular, parent-body, or combined nebular-parent body origins. Since it is very difficult to substantiate the production of complex textures in the nebula, an alternate approach to this problem is to rigorously determine which of the observable textures could have been produced by reasonable aqueous alteration processes on the CM parent body. Potential parent body reactions involving S deserve special attention because S-bearing phase define many important CM textures, such as rims. We have examined the possibility that the thin (about 5 microns) rinds of sulfides observed around some partially dissolved olivines within the chondrules and matrixes of CM chondrites were formed by the preferential precipitation of sulfides at or near dissolving olivine boundaries during parent-body alteration. Our model defines two infinite and parallel planes of olivine that are separated by pure water. Average separation distances between olivine grains in CM chondrites at the time of accretion (about 100-200 microns) were estimated by assuming a closed system fluid/rock ratio of 45% and varying the bimodal grain-size distribution. We restrict our calculations to the case of an isochemical system with sufficient bisulfide in solution to account for precipitation of pyrrhotite at STP. Our model examines the possibility that dissolving olivines with compositions between Fo(sub 0.9) and Fo(sub 0.4) can produce a strong gradient of Fe(2+) at pHs from 7 to 12 such that the precipitation of pyrrhotite will be initiated at the olivine-fluid boundary. Since CM phase equilibria is consistent with highly reducing conditions, Fe released by olivines would largely remain in solution as Fe(2+) until the solubility product of a Fe(2+) bearing phase was exceeded. Our calculations indicate that all examined combinations of olivine composition and pH yield a strong Fe(2+) gradient at the time the pyrrhotite solubility is exceeded near the olivine-fluid boundary. This favors the initiation of sulfide precipitation around dissolving olivines. However, sulfide rinds are not observed around all partially dissolved olivine grains in CM chondrites, which suggests that the availability of aqueous sulfide species limits the production of the thin sulfide rinds.

Browning, L. B.↗
NASA NTRS1979

A continuous silicon-coating facility

Automatic continuous silicon-coating facility is used to process 100 by 10 cm graphite-coated ceramic substrates for silicon solar cells. Process reduces contamination associated with conventional dip-coating processes, improving material service life.

Butter, C.↗
DOE OSTI2025

Surrogate modeling and optimization of the leaching process in a rare earth elements recovery plant

Critical minerals (CMs) and Rare Earth Elements (REEs) play a vital role in crucial infrastructure technologies such as renewable energy generation and batteries. Recovering them from waste materials has recently been found to significantly reduce environmental impact and supply chain costs related to these materials. In this work, we investigate surrogate modeling techniques aimed to simplify the modeling, simulation, and optimization of the leaching processes involved in CM and REE recovery flowsheets. As there is currently a lack of systematic studies on this topic, we perform extensive computational testing to ascertain which surrogate models are easier to construct and offer high predictive accuracy. Further, our results suggest that sparse quadratic models balance predictive accuracy and computational efficiency. Training and using these surrogates for global optimization of the leaching process requires two orders of magnitude fewer measurements and is up to four orders of magnitude faster than optimizing the original simulation using equation-oriented optimization or derivative-free optimization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Meteor over New York City: Brines in a primitive CM asteroid

The CI (Ivuna-type) carbonaceous material returned from asteroids Ryugu and Bennu contain mobilized sodium from the evaporation or freezing of liquid water into brines, shedding light on the internal structure of ice-rich CI-type worlds and the formation of prebiotic organic compounds. The formation of brines has not been demonstrated in CM (Mighei-type) carbonaceous chondrites, which also supplied organic matter to the early Earth. Here, we announce the fall of a primitive meteorite from a daytime fireball over the New York metropolitan area in July 2024. It is a CM2 breccia that contains unique CM1 clasts rich in water and sodium. The meteorite contains abundant amino acids and other products of organic chemistry in brines that reveal subsurface processes on CM-type asteroid parent bodies.

Geosciences↗
DOE OSTI2026

Innovations Driven by Advanced Characterization to Strategize Critical Mineral Production and Beneficial Reuse from Fossil Energy Waste

Critical minerals (CM), such as rare earth elements (REE), cobalt, nickel, and lithium, have important uses in modern electronics and advanced manufacturing, yet are vulnerable to potential supply chain disruptions. Relatively abundant and readily available fossil energy (FE) wastes, such as coal combustion ash, acid mine drainage (AMD) and treatment solids (AMD solids), and Oil and Gas (O&G) drilling wastes (drill cuttings and produced waters) are under consideration as CM feedstocks. The National Energy Technology Laboratory (NETL) has studied CM resources for various FE wastes as part of the U.S. Department of Energy’s mission of bolstering the domestic CM supply, and makes the data available to the public on EDX at sites such as the NEWTS group. Advanced characterization utilizing synchrotron x-ray techniques coupled with laboratory extractions has been performed to identify CM hosting phases in these FE wastes to inform CM recoverability mechanisms. Novel methods to selectively recover CMs while co-producing other valuable byproducts have been developed. Successful examples discussed here include: (1) The identification of REE/Co/Ni/Sc binding and hosting phases in select FE waste (coal combustion ash and AMD solids), resulting in the development of a patented CM step-extraction process, (2) coupled production of functional sorbents from these extraction wastes and for CM recovery. A pilot-scale testing to evaluate the patent’s technical feasibility for extracting REE from coal ash on a barrel scale has been successfully performed. Additionally, (3) evaluation and measurements of brine geochemistry from U.S. O&G produced waters has informed a high Li recovery potential from Marcellus Shale produced water. NETL researchers have been developing tailored pre-treatment processes, an innovative and highly durable lithium sorbent, and geochemical model guided precipitation to accelerate Li production from the Marcellus Shale produced waters. These innovations driven by characterization are integral for maximizing and advancing the potential for CM recovery while offsetting the cost and environmental footprint for FE waste management.

critical mineral processing↗
DOE OSTI2024

Silicon-On-Silicon Carbide Platform for Integrated Photonics

Silicon carbide (SiC)'s nonlinear optical properties and applications to quantum information have recently brought attention to its potential as an integrated photonics platform. However, despite its many excellent material properties, such as large thermal conductivity, wide transparency window, and strong optical nonlinearities, it is generally a difficult material for microfabrication. Here, it is shown that directly bonded silicon-on-silicon carbide can be a high-performing hybrid photonics platform that does not require the need to form SiC membranes or directly pattern in SiC. The optimized bonding method yields defect-free, uniform films with minimal oxide at the silicon–silicon–carbide interface. Ring resonators are patterned into the silicon layer with standard, complimentary metal–oxide–semiconductor (CMOS) compatible (Si) fabrication and measure room-temperature, near-infrared quality factors exceeding 10 5 . The corresponding propagation loss is 5.7 dB cm -1 . The process offers a wafer-scalable pathway to the integration of SiC photonics into CMOS devices.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cooperative Research and Development Agreement among National Energy Technology Laboratory, University of Wyoming, and Energy Capital Economic Development [Abstract]

NETL is partnering with the University of Wyoming (UW) and ECED to mature a promising process for the recovery of rare earth elements (REE) and critical metals (CM) from the Powder River Basin (PRB) in Wyoming. The project will identify promising ash candidates from operating power generation facilities and optimize NETL’s proprietary REE and CM extraction and enrichment process for those materials, ultimately culminating in the creation and start-up of a pilot-scale production facility. This facility will demonstrate process performance and validate project economics, reducing the risk and uncertainty for further scale-up.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Cross sections for charge transfer between mercury ions and other metals

Cross sections for charge transfer between several ions and metals of interest to the NASA electro propulsion program have been measured. Specifically, the ions considered were Hg(+), Xe(+) and Cs(+) and the metals Mo, Fe, Al, Ti, Ta, and C. Measurements were made in the energy regime from 1 to 5,000 eV. In general, the cross sections for charge transfer were found to be less than 10 to the minus 15 power sq cm for most processes over the total energy range. Exceptions are Hg(+) in collision with Ti and Ta. The results obtained for each reaction are given in both graphical and numerical form in the text. For quick reference, the data at several ion velocities are condensed into one table given in the summary.

Vroom, D. A.↗
NASA NTRS1985

Dissociation of metastable O2 as a potential source of atmospheric odd oxygen

An analysis of the possible dissociation of metastable oxygen molecules subject ot constraints imposed by selection rules for molecular transitions, airglow observations, and atmospheric chemistry leads to the following conclusions. Dissociation of O2(b1Sigma g +) must produce a negligible number of oxygen atoms at all altitudes in the earth's atmosphere. However, if the dissociation cross section of O2(a1Delta g) has a maximum value in the range 10 to the -20th to 10 to the -19th/sq cm, then the process O2(a1Delta g) + h(nu) yields O2(C3Delta u) yields O(3P) + O(3P) will constitute a significant, and potentially the major, source of odd oxygen in the uppermost stratosphere and mesosphere.

Frederick, J. E.↗