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At least 613 records · Page 34

Development of a monolithic GaAs integrated optical transmitter

The paper discusses a program designed for the development of a GaAs IOC transmitter consisting of a monolithic surface laser whose output is coupled into patterned channel waveguides. Modulation and switching of the radiation occur in the waveguide circuit and are controlled separately. These structures are to be fabricated monolithically on a single semiconductor chip with each device amenable to integrated low-cost manufacture. The waveguide outputs of the IOC transmitter will be coupled to single mode optical fibers which form a transmission cable. The properties of the semiconductors (Ga,Al)As and (Ga,In)As permit performance of each of the basic functions included in the device considered. The concept of monolithic nondiscrete GaAs diode lasers is examined along with optical stripline channel waveguides and electro-optic channel waveguide modulators and switches.

Blum, F. A.↗

Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS): Robotically Assembled Sustainable Lunar Infrastructure

Introduction: The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project at NASA Ames Research Center is developing autonomous infrastructure, instrumentation, and spacecraft assembly and manufacturing capabilities for next generation exploration and science missions, with a goal to change the cost scaling of these missions relative to mission size and duration. Using a building-block approach with a 'kit of parts' composed of ultra-light, high-performance mechanical metamaterials, simplified robots leverage the period environment to achieve high levels of autonomy and reliability for in-space and surface assembly of large-scale apertures, solar-arrays, towers, habitats, and other infrastructure. Robots and structure break down into a compact form factor for launch. By leveraging economies of scale and achieving high-packing ratios, ARMADAS technology can revolutionize possible space missions by breaking the tyranny of the launch shroud, decreasing development times, decreasing mission costs for transformative science capability, and providing a scalable and versatile space infrastructure strategy. Capabilities: To date, the ARMADAS project has demonstrated autonomous assembly of large numbers of structural modules into a meters-scale structure in an earth gravity environment. The mechanical performance is on par with conventional space structures, at a fraction of the cost. By using highly repeatable manufacturing processes (injection molding carbon fiber reinforced space-rated polymers), the structures are both cost effective and highly precise. The ARAMADAS system carefully designs parts for high-precision assembly–the simple and cost-effective robots build structures much larger and more precise than themselves. While maintaining structural efficiency, the ARMADAS system encompasses many functional module types, including for solar power, comm/power routing, etc., that will enable entire infrastructure systems to be engineered and autonomously assembled with modular parts. With well-defined interfaces, custom instrumentation modules can easily be added to fit many mission objectives. Lunar Infrastructure Vision: At the LSIC spring meeting, ARMADAS will present a vision for a general-purpose lunar construction kit capable of meeting a wide variety of lunar surface infrastructure needs (Figure 1). Investing in an ecosystem of reconfigurable, discretely repairable parts and robots enables systems than can expand their capability, reconfigure to meet emergency or unforeseen needs, self-repair and reduce spare-part needs. With a small set of parts (module types), a wide variety of infrastructure needs can be met. Footing modules will allow infrastructure construction at locations with no surface preparation. Footer, primary structure, and rail modules can create reconfigurable rail systems. These rail systems can be used to reduce cost-of-transport between frequently accessed sites, provide dust mitigation, and convey power and communications. High-performance structure modules combined with power-routing and solar modules can create tall towers for power and communication. Concepts for habitats and garages encompass a structure to support regolith cover for a pre-integrated module to an entirely ARMADAS system-based structure. This system can be leveraged by many in-situ resource utilization (ISRU) technologies to simplify processes and augment capabilities.

C. E. Gregg↗

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗

Packing fraction control during additive manufacturing of powder green bodies

The demand for high performance ceramic and metal components with complex geometry necessitates developments in powder handling and green body shaping. Here, in this study, vibrational powder deposition is adapted to three-dimensional printing with the ability to modulate packing fraction during printing. Boron carbide powder with sub-micron primary particle size is printed over a packing fraction range of 25.0 % to 46.5 % (below the poured density to above the tapped density). Solid metal powders are printed at 67.5 %, which enables novel freestanding, vertical-walled features without binder. These capabilities introduce opportunities for more complex geometries in high-performance materials, e.g. large-scale uniaxial hot-pressing of ceramic ballistic armor components with graded thickness and three-dimensional curved or stepped features (by compensating for displacement differences during compaction). This technology also enables multi-material patterning of additive manufacturing powder beds with reduced feedstock quantity requirements and wastage.

36 MATERIALS SCIENCE↗

Room‐Temperature Mid‐Infrared Detection Using Metasurface‐Absorber‐Integrated Phononic Crystal Oscillator

Mid-infrared (MIR) detectors find extensive applications in chemical sensing, spectroscopy, communications, biomedical diagnosis, and space exploration. Alternative to semiconductor MIR photodiodes and bolometers, mechanical-resonator-based MIR detectors show advantages in higher sensitivity and lower noise at room temperature, especially toward longer wavelength infrared. Here, uncooled room-temperature MIR detectors based on lithium niobate surface acoustic wave phononic crystal (PnC) resonators integrated with wavelength-and-polarization-selective metasurface absorber arrays are demonstrated. The detection is based on the resonant frequency shift induced by the local temperature change due to MIR absorptions. The PnC resonator is configured in an oscillating mode, enabling active readout and low-frequency noise. The 1-GHz oscillator-based MIR detector shows a relative frequency deviation of 5.24 × 10 −10 Hz −1/2 at an integration time of 50 µs, leading to an incident noise equivalent power of 197 pW Hz −1/2 when input 6-µm MIR light is modulated at 1.8 kHz, and a large dynamic range of 10 7 in incident MIR power. The device architecture is compatible with the scalable manufacturing process and can be readily extended to a broader spectral range by tailoring the absorbing wavelengths of metasurface absorbers.

Xi, Zichen [Virginia Polytechnic Inst. and State U↗

SU-F-T-189: Dosimetric Comparison of Spot-Scanning Proton Therapy Techniques for Liver Tumors Close to the Skin Surface

Purpose: Spot-scanning technique has been utilized to achieve conformal dose distribution to large and complicated tumors. This technique generally does not require patient-specific devices such as aperture and compensator. The commercially available spot-scanning proton therapy (SSPT) systems, however, cannot deliver proton beams to the region shallower than 4 g/cm2. Therefore some range compensation device is required to treat superficial tumors with SSPT. This study shows dosimetric comparison of the following treatment techniques: (i) with a tabletop bolus, (ii) with a nozzle-mounted applicator, and (iii) without any devices and using intensity-modulated proton therapy (IMPT) technique. Methods: The applicator composed of a combination of a mini-ridge filter and a range shifter has been manufactured by Hitachi, Ltd., and the tabletop bolus was made by .decimal, Inc. Both devices have been clinically implemented in our facility. Three patients with liver tumors close to the skin surface were examined in this study. Each treatment plan was optimized so that the prescription dose of 76 Gy(RBE) or 66 Gy(RBE) would be delivered to 99% of the clinical target volume in 20 fractions. Three beams were used for tabletop bolus plan and IMPT plan, whereas two beams were used in the applicator plan because the gantry angle available was limited due to potential collision to patient and couch. The normal liver, colon, and skin were considered as organs at risk (OARs). Results: The target heterogeneity index (HI = D{sub 5}/D{sub 95}) was 1.03 on average in each planning technique. The mean dose to the normal liver was considerably less than 20 Gy(RBE) in all cases. The dose to the skin could be reduced by 20 Gy(RBE) on average in the IMPT plan compared to the applicator plan. Conclusion: It has been confirmed that all treatment techniques met the dosimetric criteria for the OARs and could be implemented clinically.

60 APPLIED LIFE SCIENCES↗

Evolutionary space platform concept study. Volume 3: Programmatics for manned space platform concepts

The programmatic data for the reference concept of the Manned Space Platform is presented. Details regarding work breakdown structure (WBS) and dictionary, the facilities and equipment required to produce the modules, the project schedule and logic diagram, a preliminary assessment of environmental impacts and details regarding the estimated costs for the reference concept are included. The proposed WBS which was developed to provide summary and system level segregation of the nonrecurring and recurring portions of the Manned Space Platform project is also included. The accompanying dictionary outlines the function and activities contained within each WBS element. The facility and equipment required to produce the various modules is discussed. Generally, required equipment is within the existing state of the art although the size of some of the items to be manufactured is a consideration. A preliminary manufacturing flow was also provided. The project schedules presented consist of the Master Project Summary Schedule, the Master Project Phasing Chart and the Logic Network.

Source record↗

Final prototype of magnetically suspended flywheel energy storage system

A prototype of a 500 Wh magnetically suspended flywheel energy storage system was designed, built, and tested. The authors present the work done and include the following: (1) a final design of the magnetic bearing, control system, and motor/generator, (2) construction of a prototype system consisting of the magnetic bearing stack, flywheel, motor, container, and display module, and (3) experimental results for the magnetic bearings, motor, and the entire system. The successful completion of the prototype system has achieved: (1) manufacture of tight tolerance bearings, (2) stability and spin above the first critical frequency, (3) use of inside sensors to eliminate runout problems, and (4) integration of the motor and magnetic bearings.

Anand, D. K.↗

High rate lithium/thionyl chloride bipolar battery development

Presented in viewgraph format are results and accomplishments on the development of lithium/thionyl chloride bipolar batteries. Results include the development of manufacturing capability for producing large quantities of uniform cathodes and bipolar plates; the development of assembly, sealing, and activation procedures for fabrication of battery modules containing up to 150 cells in bipolar configuration; and the successful demonstration of a 10.7 kW 150-cell module with constant power pulse discharge, 20 second pulse, and 10 percent duty cycle.

Russell, Philip G.↗

Avancando na Transicao Energetica: Desafios e Estrategias para a Implantacao Sustentavel de FV

As the world embarks on an ambitious journey towards global decarbonization, the spotlight turns to photovoltaic (PV) technology as a cornerstone for sustainable energy solutions. This talk delves into the current status and projections of PV for the World, US and Brasil, and the necessary considerations to do this increase in manufacturing and deployment sustainably. With the projected scale of deployment, the industry faces significant challenges related to material demand and the management of PV modules at their end of life. The principles of the Circular Economy (CE) and its associated R-Actions - Reduce, Reuse, Recycle, among others - present a promising framework to address these challenges by mitigating end-of-life management and material sourcing concerns. However, traditional CE metrics, often focused solely on mass, fall short by excluding vital energy flow considerations. In this talk, we will highlight how various metrics are needed to understand sustainable PV solutions, how continuing the search for increased efficiency can significantly reduce material demands and enhance energy metrics, while strategies around material circularity and module lifetime and reliability improvements will offer substantial reductions in both material and energy demands.

Brasil↗

FINAL REPORT - Development of High Pressure Hydrogen Storage Tank for Storage and Gaseous Truck Delivery

The “Development of High Pressure Hydrogen Storage Tanks for Storage and Gaseous Truck Delivery” project [DE-FG36-08GO18062] was initiated on 01 July 2008. Hexagon Lincoln (then Lincoln Composites) received grant funding from the U.S. Department of Energy to support the design and development of an improved bulk hauling and storage solution for hydrogen in terms of cost, safety, weight and volumetric efficiency. The development of this capability required parallel development and qualification of large all-composites pressure vessels, a custom ISO container to transport and store said tanks, and performance of trade studies to identify optimal operating pressure for the system. Qualification of the 250 bar TITAN® module was completed in 2009 with supervision from the American Bureau of Shipping [ABS], and the equipment has been used internationally for bulk transportation of fuel gases since 2010. Phase 1 of the project was successfully completed in 2012 with the issuance of USDOT SP 14951, the special permit authorizing the manufacture, marking, sale and use of TITAN® Mobile Pipeline® equipment in the United States. The introduction of tube trailers with light weight composite tankage has meant that 2 to 3 times as much gaseous fuel can be transported with each trip. This increased hauling efficiency offers dramatically reduced operating costs and has enabled a profitable business model for over-the-road compressed natural gas delivery. The economic drivers of this business opportunity vary from country to country and region to region, but in many places gas distribution companies have realized profitable operations. Additional testing was performed in 2015 to characterize hydrogen-specific operating protocols for use of TITAN® systems in CHG service at 250 bar. This program demonstrated that existing compression and decompression methodologies can efficiently and safely fill and unload lightweight bulk hauling systems. Hexagon Lincoln and U.S. DOE agreed to continue into Phase 2 of the project without pursuing the development of higher pressure capabilities as originally planned. At 250 bar, development of equipment for hydrogen transport is supported by strong activity in the adjacent natural gas transportation sector. Trade studies performed since 2011 indicate optimization of hauling efficiency and system cost for hydrogen transport at about 350 bar (5076 psi). However, due to reduced efficiency of compression of natural gas above 250 bar, 350 bar operation is not an attractive option for natural gas transportation. The CHG market is not developed at this time, and it is difficult to forecast the arrival of significant revenues. On the investment side, the cost to fully qualify a large tank module at 350 bar is estimated at $3MM to $5MM. There is insufficient CHG market definition to support a stand-alone business case for this investment without near term revenue in the adjacent CNG transportation market. Therefore development of a 350 bar TITAN® system was deferred and not pursued under this project. Hexagon Lincoln continues to support the development of tankage and equipment for operation at 350 bar and above; with 700 bar vehicle tanks and 950 bar tanks for ground storage applications. Phase 2 activities were focused on reducing system cost, increasing system capacity, increasing system safety and characterization of polymer material performance specific to hydrogen pressure vessel usage. With the successful launch of TITAN® modules and trailers in natural gas transportation, over 600 units have been produced through the end of 2016, resulting in improved purchasing power for raw materials and manufactured components. This has allowed Hexagon Lincoln to approach the current project goals for system cost. At $590/kg of compressed hydrogen delivered, the system cost of the baseline TITAN® module is below the project’s 2015 target of $730/kg H2 delivered, and very close to the project’s 2020 target of $575/kg H2 delivered. [Based on product pricing in 1Q2017.] Emphasis was placed on configuration of larger capacity systems within the vehicle weights and dimensions allowed on federal and state highways in the United States and other countries. These activities resulted in the design and development of integrated tube trailer systems that have increased delivery capacities by 45%. The hydrogen delivery capacity of our largest system is 845 kg, exceeding the project’s 2015 target of 700 kg H2 delivered. Emerging technologies offering improvement of the safety systems used on the equipment were investigated, with particular focus on improving the reliability and cost of the emergency venting system for fire protection. Finally, investment in our materials laboratory improved detection and characterization of hydrogen-induced damage in polymer materials, supporting the development of operational protocols to avoid damage to pressure vessel liners and valve components.

08 HYDROGEN↗

Oakland University Cybersecurity Center (Final Scientific/Technical Report)

This report summarizes the outcomes of Award DE-CR0000023, “Oakland University Cybersecurity Center,” a 31-month project funded by the U.S. Department of Energy Office of Cybersecurity, Energy Security, and Emergency Response (CESER). The project addressed cybersecurity risks facing small and medium-sized manufacturers (SMMs) transitioning to Industry 4.0. The project integrated customer discovery, applied research, and cybersecurity training development. A total of 51 cybersecurity assessments identified significant gaps in baseline practices, incident response, and workforce capability. Research efforts produced a scalable mitigation framework tailored to SMM environments, and workforce analysis identified persistent talent gaps. Eight cybersecurity training modules were developed and deployed via Oakland University’s Professional and Continuing Education (PACE) platform. All objectives were completed, with 98.93% federal budget utilization and cost share exceeding requirements. The project establishes a scalable model for strengthening cybersecurity resilience and workforce capacity across U.S. manufacturing supply chains.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Dynamic Electric Field Assisted CO 2 Methanation

Energy-efficient advanced chemical reactions are essential for accelerating the growth of hydrocarbon economy. Sabatier reaction stands out for its potential to effectively transform carbon dioxide into valuable hydrocarbons and is an asset for long-duration Mars missions. This study explores a novel catalytic approach that harnesses electric field-assisted catalysis to substantially enhance the efficiency of the Sabatier reaction. Application of a dynamically perturbed electric field at 1000 Hz resulted in remarkable enhancements, increasing methane formation rates by over 100% at 350 °C and by 74% at 400 °C. Post-reaction catalyst characterization further revealed reduced blockage of active catalytic surface area under the applied electric field, emphasizing improved catalytic longevity and sustained activity. These results underscore the potential of tailored electric field waveforms to dynamically modulate elementary reaction kinetics and surface processes, positioning electric field-assisted catalysis as a transformative strategy for energy-efficient, cost-effective chemical manufacturing and energy conversion technologies.

42 - ENGINEERING↗

Labeling Solar-Cell Modules

Photocopying machine produces durable identification label. Process used for double glass photovoltaic-cell modules. Matrix of cells sandwiched between thin, flexible glass mats and covered above and below by protective sheets of glass. Label contains such information as manufacturer, model number, voltage and power ratings, and serial number. May also contain electrical-shock hazard warning and identification of positive and negative terminals. Method saves expense of procuring and applying conventional labels.

Watson, E. G.↗

Intelligent Agent Technology

Open Sesame! is the first commercial software product that learns user's behavior, and offers automation and coaching suggestions to the user. The neural learning module looks for repetitive patterns that have not been automated; when it finds one, it creates an observation and, upon approval, automates the task. The manufacturer, Charles River Analytics, credits Langley Research Center and Johnson Space Center Small Business Innovation Research grants and the time the president and vice president spent at the two centers in the 1970s as being essential to the development of their product line.

Source record↗

Validating Phasing and Geometry of Large Focal Plane Arrays

The Kepler Mission is designed to survey our region of the Milky Way galaxy to discover hundreds of Earth-sized and smaller planets in or near the habitable zone. The Kepler photometer is an array of 42 CCDs (charge-coupled devices) in the focal plane of a 95-cm Schmidt camera onboard the Kepler spacecraft. Each 50x25-mm CCD has 2,200 x 1,024 pixels. The CCDs accumulate photons and are read out every six seconds to prevent saturation. The data is integrated for 30 minutes, and then the pixel data is transferred to onboard storage. The data is subsequently encoded and transmitted to the ground. During End-to-End Information System (EEIS) testing of the Kepler Mission System (KMS), there was a need to verify that the pixels requested by the science team operationally were correctly collected, encoded, compressed, stored, and transmitted by the FS, and subsequently received, decoded, uncompressed, and displayed by the Ground Segment (GS) without the outputs of any CCD modules being flipped, mirrored, or otherwise corrupted during the extensive FS and GS processing. This would normally be done by projecting an image on the focal plane array (FPA), collecting the data in a flight-like way, and making a comparison between the original data and the data reconstructed by the science data system. Projecting a focused image onto the FPA through the telescope would normally involve using a collimator suspended over the telescope opening. There were several problems with this approach: the collimation equipment is elaborate and expensive; as conceived, it could only illuminate a limited section of the FPA (.25 percent) during a given test; the telescope cover would have to be deployed during testing to allow the image to be projected into the telescope; the equipment was bulky and difficult to situate in temperature-controlled environments; and given all the above, test setup, execution, and repeatability were significant concerns. Instead of using this complicated approach of projecting an optical image on the FPA, the Kepler project developed a method using known defect features in the CCDs to verify proper collection and reassembly of the pixels, thereby avoiding the costs and risks of the optical projection approach. The CCDs composing the Kepler FPA, as all CCDs, had minor defects. At ambient temperature, some pixels look far brighter than they should. These ghot h pixels have a higher rate of charge leakage than the others due to manufacturing variations. They are usually stable over time, and appear at temperatures above 5 oC. The hot pixels on the Kepler FPA were mapped before photometer assembly during module testing. Selected hot pixels were used as target gstars h for the purposes of EEIS testing. gDead h pixels are permanently off, producing a permanently black pixel. These can also be used if there is some illumination of the FPA. During EEIS testing, Dark Current Full Frame Images (FFIs) taken at room temperature were used to create the hot pixel maps for all 84 Kepler photometer CCD channels. Data from two separate nights were used to create two hot pixel maps per channel, which were cross-correlated to remove cosmic ray events which appear to be hot pixels. These hot pixel maps obtained during EEIS testing were compared to the maps made during module testing to verify that the end-to-end data flow was correct.

Standley, Shaun P.↗

Cadmium Telluride Accelerator Consortium (CTAC)

The United States is the leader in cadmium telluride (CdTe) photovoltaic (PV) manufacturing, and CdTe is the second most-deployed solar technology in the world. The CdTe Accelerator Consortium (CTAC) was formed to enhance U.S. technology leadership and competitiveness in CdTe photovoltaics (PV) including increasing cell efficiencies, decreasing module costs, and maintaining or increasing domestic CdTe PV material and module production. Leadership for the 3-year consortium was selected by an NREL team through a competitive solicitation. CTAC was formally announced on August 1st by U.S. Secretary of Energy Jennifer M. Granholm and U.S. Representative Marcy Kaptur at an event held at University of Toledo. We will give an overview of CTAC research directions along with their goals and activities. We can also discuss how CTAC relates to the National Renewable Energy Laboratory (NREL) and to the U.S. Manufacturing of Advanced Cadmium Telluride Photovoltaics Consortium (US-MAC). Visit our poster to find out who leads CTAC and how you can get involved.

costs↗

Elastic light-scattering modulator: A concept

Simple structure can be used as electrically-controlled light valve, to scatter both transmitted and reflected beams. Its operation is based on physical phenomenon called frosting. Device may be of interest to manufacturers of page composers, alphanumeric displays, flat-panel displays, large-screen televisions, and optical input terminals for computers.

Vilkomerson, D. H. R.↗